Em PDF

ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
HR16DE Removal and Installation .........................................18 F
SYMPTOM DIAGNOSIS ............................... 5 SPARK PLUG ................................................... 19

Exploded View .........................................................19
G
NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................19
(NVH) TROUBLESHOOTING ............................. 5
NVH Troubleshooting - Engine Noise ....................... 5 CAMSHAFT VALVE CLEARANCE .................. 21
Use the Chart Below to Help You Find the Cause Inspection and Adjustment ......................................21 H
of the Symptom ......................................................... 6 COMPRESSION PRESSURE ........................... 24
PRECAUTION ............................................... 7 Inspection ................................................................24
I
PRECAUTIONS ................................................... 7 ON-VEHICLE REPAIR ................................. 25
Precaution for Supplemental Restraint System DRIVE BELT IDLER PULLEY .......................... 25
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- J
Exploded View .........................................................25
SIONER" ................................................................... 7
Removal and Installation .........................................25
Precaution for Procedure without Cowl Top Cover...... 7
Precaution Necessary for Steering Wheel Rota- AIR CLEANER AND AIR DUCT ....................... 27 K
tion After Battery Disconnect ..................................... 7 Exploded View .........................................................27
Precaution for Drain Coolant ..................................... 8 Removal and Installation .........................................27
Precaution for Disconnecting Fuel Piping ................. 8 Inspection ................................................................28 L
Precaution for Removal and Disassembly ................ 8
Precaution for Inspection, Repair and Replace- INTAKE MANIFOLD ......................................... 29
ment .......................................................................... 8 Exploded View .........................................................29
Precaution for Assembly and Installation .................. 8 Removal and Installation .........................................29 M
Parts Requiring Angular Tightening .......................... 8
Precaution for Liquid Gasket ..................................... 9 EXHAUST MANIFOLD ...................................... 32
Exploded View .........................................................32 N
PREPARATION ........................................... 11 Removal and Installation .........................................32
PREPARATION ..................................................11 FUEL INJECTOR AND FUEL TUBE ................ 35

Special Service Tools .............................................. 11 Exploded View .........................................................35 O
Commercial Service Tools ...................................... 12 Removal and Installation .........................................35
Inspection ................................................................39
ON-VEHICLE MAINTENANCE .................... 15 P
OIL PAN (LOWER) ........................................... 40
DRIVE BELTS ....................................................15 Exploded View .........................................................40
Checking ................................................................. 15 Removal and Installation .........................................40
Tension Adjustment ................................................ 15 Inspection ................................................................41
Removal and Installation ......................................... 16
OIL PAN (UPPER) AND OIL STRAINER ......... 42
AIR CLEANER FILTER ......................................18 Component ..............................................................42
EM-1
Removal and Installation ........................................ 42 SERVICE DATA AND SPECIFICATIONS
IGNITION COIL, SPARK PLUG AND ROCK- (SDS) ......................................................... 122
ER COVER ......................................................... 47 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 47 (SDS) ................................................................ 122
Removal and Installation ........................................ 47 General Specification ............................................ 122
TIMING CHAIN .................................................. 50 Drive Belts ............................................................. 122
Exploded View ........................................................ 50 Spark Plug ............................................................ 123
Removal and Installation ........................................ 50 Exhaust Manifold .................................................. 123
Camshaft ............................................................... 123
Inspection ............................................................... 57
Cylinder Head ....................................................... 125
CAMSHAFT ....................................................... 59 Cylinder Block ....................................................... 127
Exploded View ........................................................ 59 Connecting Rod Bearing ....................................... 130
Removal and Installation ........................................ 59 Main Bearing ......................................................... 131
Inspection ............................................................... 71 MR18DE
OIL SEAL ........................................................... 77 SYMPTOM DIAGNOSIS ........................... 132
VALVE OIL SEAL ..................................................... 77 NOISE, VIBRATION AND HARSHNESS
VALVE OIL SEAL : Removal and Installation ......... 77 (NVH) TROUBLESHOOTING ........................... 132
NVH Troubleshooting - Engine Noise ................... 132
FRONT OIL SEAL ..................................................... 77
Use the Chart Below to Help You Find the Cause
FRONT OIL SEAL : Removal and Installation ........ 78
of the Symptom ..................................................... 133
REAR OIL SEAL ....................................................... 78
REAR OIL SEAL : Removal and Installation .......... 78 PRECAUTION ........................................... 134
CYLINDER HEAD .............................................. 80 PRECAUTIONS ................................................ 134

Removal and Installation ........................................ 80 Precaution for Supplemental Restraint System
Disassembly and Assembly .................................... 82 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................... 134
REMOVAL AND INSTALLATION ............... 89 Precaution for Procedure without Cowl Top Cover. 134
Precaution Necessary for Steering Wheel Rota-
ENGINE ASSEMBLY ......................................... 89 tion After Battery Disconnect ................................ 134
Exploded View ........................................................ 89 Precaution for Drain Coolant ................................. 135
Removal and Installation ........................................ 89 Precaution for Disconnecting Fuel Piping ............. 135
Inspection ............................................................... 92 Precaution for Removal and Disassembly ............ 135
Precaution for Inspection, Repair and Replace-
DISASSEMBLY AND ASSEMBLY ............. 94 ment ...................................................................... 135
ENGINE STAND SETTING ................................ 94 Precaution for Assembly and Installation .............. 135
Setting .................................................................... 94 Parts Requiring Angular Tightening ...................... 135
Precaution for Liquid Gasket ................................. 136
ENGINE UNIT .................................................... 95
Disassembly ........................................................... 95 PREPARATION ......................................... 138
Assembly ................................................................ 95 PREPARATION ................................................ 138
OIL PAN (UPPER) ............................................. 96 Special Service Tool ............................................. 138
Exploded View ........................................................ 96 Commercial Service Tool ...................................... 140
Removal and Installation ........................................ 96
ON-VEHICLE MAINTENANCE ................. 142
Inspection ............................................................... 99
DRIVE BELTS .................................................. 142
CYLINDER BLOCK ......................................... 100
Component ........................................................... 142
Exploded View .......................................................100
Checking Drive Belts ............................................. 142
Disassembly and Assembly ...................................101
Tension Adjustment .............................................. 142
Inspection ..............................................................108
Removal and Installation ....................................... 142
HOW TO SELECT PISTON AND BEARING ... 117
AIR CLEANER FILTER .................................... 144
Description .............................................................117
Connecting Rod Bearing .......................................117
Main Bearing .........................................................119 SPARK PLUG ................................................... 145
EM-2
Component ............................................................ 145 Inspection After Disassembly ................................ 202
Removal and Installation ....................................... 145 A
REMOVAL AND INSTALLATION ............. 207
CAMSHAFT VALVE CLEARANCE ................. 148
Valve Clearance .................................................... 148 ENGINE ASSEMBLY ...................................... 207
Component ............................................................ 207 EM
COMPRESSION PRESSURE .......................... 151 Removal and Installation ....................................... 207
Checking Compression Pressure .......................... 151
DISASSEMBLY AND ASSEMBLY ............ 211 C
ON-VEHICLE REPAIR ............................... 153
ENGINE UNIT .................................................. 211
DRIVE BELT AUTO TENSIONER ................... 153 Component ............................................................ 211
Component ............................................................ 153 Disassembly and Assembly ................................... 212 D
Removal and Installation of Drive Belt Auto Ten- Inspection After Disassembly ................................ 219
sioner .................................................................... 153
HOW TO SELECT PISTON AND BEARING .. 230 E
AIR CLEANER AND AIR DUCT ...................... 154 How to Select Piston and Bearing ......................... 230
Component ............................................................ 154
Removal and Installation ....................................... 154 SERVICE DATA AND SPECIFICATIONS
(SDS) .......................................................... 238 F
INTAKE MANIFOLD ......................................... 156
Component ............................................................ 156 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ....................................... 156 (SDS) ............................................................... 238 G
Standard and Limit ................................................ 238
EXHAUST MANIFOLD ..................................... 159
Component ............................................................ 159
K9K
Removal and Installation ....................................... 159 H
SYMPTOM DIAGNOSIS ............................ 249
FUEL INJECTOR AND FUEL TUBE ............... 162 NOISE, VIBRATION AND HARSHNESS
Component ............................................................ 162
(NVH) TROUBLESHOOTING ......................... 249 I
NVH Troubleshooting - Engine Noise .................... 249
OIL PAN ........................................................... 166 Use the Chart Below to Help You Find the Cause
Component ............................................................ 166 of the Symptom ..................................................... 250 J
PRECAUTION ............................................ 251
IGNITION COIL ................................................ 172
Component ............................................................ 172
PRECAUTIONS ............................................... 251 K
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
ROCKER COVER ............................................. 173 SIONER" ............................................................... 251 L
Component ............................................................ 173 Precaution for Procedure without Cowl Top Cover.. 251
Removal and Installation ....................................... 173 Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ................................. 251
TIMING CHAIN ................................................. 176 Precaution for Drain Coolant ................................. 252 M
Component ............................................................ 176 Precaution for Disconnecting Fuel Piping .............. 252
Removal and Installation ....................................... 177 Precaution for Removal and Disassembly ............. 252
Precaution for Inspection, Repair and Replace- N
CAMSHAFT ...................................................... 186 ment ....................................................................... 252
Component ............................................................ 186 Precaution for Assembly and Installation .............. 252
Removal and Installation ....................................... 186 Parts Requiring Angular Tightening ....................... 252 O
OIL SEAL ......................................................... 195 Precaution for Liquid Gasket ................................. 253
Precaution for Diesel Equipment ........................... 253
Removal and Installation of Valve Oil Seal ........... 195
Installation of Thread Inserts ................................. 257
Removal and Installation of Front Oil Seal ............ 195 P
Removal and Installation of Rear Oil Seal ............ 196 PREPARATION ......................................... 258
CYLINDER HEAD ............................................ 198 PREPARATION ............................................... 258
Component ............................................................ 198
Special Service Tools ............................................ 258
Commercial Service Tools ..................................... 260
Component ............................................................ 200
Disassembly and Assembly .................................. 200 ON-VEHICLE MAINTENANCE .................. 263
EM-3
DRIVE BELTS .................................................. 263 OIL PAN ............................................................ 284
Exploded View .......................................................263 Exploded View ...................................................... 284
Inspection and Adjustment ....................................263 Removal and Installation ....................................... 284
Removal and Installation .......................................263 Inspection .............................................................. 286
AIR CLEANER FILTER ................................... 265 HIGH PRESSURE SUPPLY PUMP .................. 287
Removal and Installation .......................................265 Exploded View ...................................................... 287
CAMSHAFT VALVE CLEARANCE ................. 266
Inspection and Adjustment ....................................266 ROCKER COVER ............................................. 289
Exploded View ...................................................... 289
COMPRESSION PRESSURE .......................... 267 Removal and Installation ....................................... 289
Inspection ..............................................................267
TIMING BELT ................................................... 291
ON-VEHICLE REPAIR ............................... 268 Exploded View ...................................................... 291
DRIVE BELT AUTO-TENSIONER ................... 268
Exploded View .......................................................268 CAMSHAFT ...................................................... 298
AIR CLEANER AND AIR DUCT ...................... 269 Inspection .............................................................. 300
Exploded View .......................................................269
Removal and Installation .......................................269 REMOVAL AND INSTALLATION ............. 302
CHARGE AIR COOLER .................................. 270 ENGINE ASSEMBLY ....................................... 302
Exploded View .......................................................270 Exploded View ...................................................... 302
Removal and Installation .......................................270 Removal and Installation ....................................... 302
Inspection ..............................................................271 Inspection .............................................................. 304
EGR SYSTEM .................................................. 272 DISASSEMBLY AND ASSEMBLY ........... 305
Exploded View .......................................................272
Removal and Installation .......................................272 ENGINE STAND SETTING .............................. 305
Setting ................................................................... 305
CATALYST ...................................................... 274
Exploded View .......................................................274 CYLINDER HEAD ............................................. 306
Inspection ..............................................................274 Removal and Installation ....................................... 306
Disassembly and Assembly .................................. 307
TURBOCHARGER .......................................... 275 Cleaning ................................................................ 310
Exploded View .......................................................275 Inspection .............................................................. 310
Removal and Installation .......................................275
Inspection ..............................................................276 CYLINDER BLOCK .......................................... 314
Exploded View ...................................................... 314
EXHAUST MANIFOLD .................................... 277 Disassembly and Assembly .................................. 314
Exploded View .......................................................277 Inspection .............................................................. 330
Inspection ..............................................................278 SERVICE DATA AND SPECIFICATIONS
GLOW PLUG ................................................... 279 (SDS) ......................................................... 333
Exploded View .......................................................279 SERVICE DATA AND SPECIFICATIONS
Removal and Installation .......................................279 (SDS) ................................................................ 333
VACUUM PUMP .............................................. 280 General Specification ........................................... 333
Exploded View .......................................................280 Drive Belt .............................................................. 333
Removal and Installation .......................................280 Camshaft ............................................................... 333
Inspection ..............................................................280 Cylinder Head ...................................................... 335
Cylinder Block ...................................................... 337
INJECTION TUBE AND FUEL INJECTOR ..... 281 Turbocharger ........................................................ 339
Exploded View .......................................................281
EM-4
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [HR16DE]
SYMPTOM DIAGNOSIS A
NVH Troubleshooting - Engine Noise INFOID:0000000001381371
EM
PBIC3870E
EM-5
< SYMPTOM DIAGNOSIS > [HR16DE]
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000001381372
1. Locate the area where noise occurs.

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

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-21
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
EM-123
Cylinder Rattle C A — A B C bearing clearance
EM-123
head noise Camshaft runout
Piston to piston pin oil

Slap or Piston pin clearance EM-127
— A — B B —
knock noise Connecting rod small EM-130
end clearance
Piston to cylinder bore
Crank- clearance
EM-127
shaft pul- Piston ring side clear-
Slap or Piston EM-127
ley A — — B B A ance
rap slap noise EM-127
Cylinder Piston ring end gap
EM-130
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod small
Oil pan ing rod end clearance EM-127
Knock A B C B B B
bearing Connecting rod bearing EM-130
noise oil clearance
Main bearing oil clear-
Main bear- EM-131
Knock A B — A B C ance
ing noise EM-127
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-57
Front cov- ticking Timing chain tensioner
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-122
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-21
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related
EM-6
PRECAUTIONS
< PRECAUTION > [HR16DE]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000001527642
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
Precaution for Procedure without Cowl Top Cover INFOID:0000000001527633
When performing the procedure after removing cowl top cover, cover
the lower end of windshield. H
PIIB3706J
K
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000001527634
NOTE: L
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYS-
TEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the M
″LOCK″ position.
• Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work.
If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech- N
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible. O
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE P
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
EM-7
PRECAUTIONS
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-II.
Precaution for Drain Coolant INFOID:0000000001527635
• Drain coolant when engine is cooled.

Precaution for Disconnecting Fuel Piping INFOID:0000000001527636
• 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 leakage.
Precaution for Removal and Disassembly INFOID:0000000001527637
• 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 Inspection, Repair and Replacement INFOID:0000000001527638
• Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and Installation INFOID:0000000001527639
• 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.
• 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 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
leakage.
Parts Requiring Angular Tightening INFOID:0000000001527640
• Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- Camshaft sprocket (INT)
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
Tool number : KV10112100 (BT-8653-A)

• Do not use a torque value for final tightening.
EM-8
PRECAUTIONS
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil. A
Precaution for Liquid Gasket INFOID:0000000001527641
EM
REMOVAL OF LIQUID GASKET SEALING
• After removing the bolts and nuts, separate the mating surface and
remove the sealant using Tool.
C
Tool number : KV10111100 (J-37228)
CAUTION:
Be careful not to damage the mating surfaces. D
• In areas where the cutter is difficult to use, use a plastic hammer to
lightly tap (1) the cutter where the RTV Silicone Sealant is applied.
Use a plastic hammer to slide the cutter (2) by tapping on the side. E
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed WBIA0566E
screwdriver is used, be careful not to damage the mating sur-

faces. F
LIQUID GASKET APPLICATION PROCEDURE

1. Using a scraper, remove the old Silicone RTV Sealant adhering G
to the gasket application surface and the mating surface.
• Remove the sealant completely from the groove of the gasket
application surface, bolts, and bolt holes.
H
2. Thoroughly clean the gasket application surface and the mating
surface and remove adhering moisture, grease and foreign
materials.
I
3. Attach the sealant tube to the tube presser.
Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-27, "Recommended Chemical Products and Sealants".
PBIC0003E J
4. Apply the sealant without breaks to the specified location using

Tool. K
Tool number WS39930000 ( – )

• If there is a groove for the sealant application, apply the seal- L
ant to the groove.
• As for the bolt holes, normally apply the sealant inside the
holes. If specified, it should be applied outside the holes. Make M
sure to read the text of this manual.
• Within five minutes of the sealant application, install the mat-
ing component. WBIA0567E
• If the sealant protrudes, wipe it off immediately. N

• Do not retighten after the installation.
• After 30 minutes or more have passed from the installation, fill
the engine with the specified oil and coolant. Refer to MA-19, O
"Fluids and Lubricants".
SEM159F
CAUTION:
EM-9
PRECAUTIONS
Follow all specific instructions in this manual.
EM-10
PREPARATION
< PREPARATION > [HR16DE]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000001381382
EM
Tool number
Description C
Tool name
KV10111100 Removing oil pan (lower and upper) etc.
Seal cutter
D
E
S-NT046
KV10116200 Disassembling and assembling valve mecha-

Valve spring compressor nism F
1. KV10115900 Part (1) is a component of KV10116200, but
Attachment Part (2) is not so.
2. KV10109220
G
Adapter
PBIC1650E
H
KV10112100 Tightening bolts for bearing cap, cylinder
Angle wrench head, etc. in angle
J
S-NT014
KV10117100 Loosening or tightening heated oxygen sen-

Heated oxygen sensor wrench sor 1
K
For 22 mm (0.87 in) width hexagon nut
NT379
KV10107902 Removing valve oil seal M

Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
N
SZNT605 O
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia. P
b: 13 (0.51) dia. e: 10.7 (0.421)
c: 10.3 (0.406) dia. f: 5 (0.20)
Unit: mm (in)
S-NT603
EM-11
PREPARATION
Tool number
Description
Tool name
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
S-NT044
KV11103000 Removing crankshaft pulley

Pulley puller
NT676
Quick connector release Removing fuel tube quick connectors in en-

gine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
PBIC0198E
1. Press stand: ST13030020 Installing and removing piston pin

2. Center shaft: KV10114120
3. Drift: KV10109730
4. Spring: ST13030030
5. Center cap: KV10110310
PBIC3873E
KV11105210 Fixing drive plate and flywheel

Stopper plate
ZZA0009D
Commercial Service Tools INFOID:0000000001381383
EM-12
PREPARATION
Tool name Description
A
Spark plug wrench Removing and installing spark plug
EM
C
PBIC3874E
Valve seat cutter set Finishing valve seat dimensions
S-NT048
Piston ring expander Removing and installing piston ring F
S-NT030
H
Valve guide drift Removing and installing valve guide
J
PBIC4012E
Valve guide reamer 1: Reaming valve guide inner hole

2: Reaming hole for oversize valve guide K
PBIC4013E
Oxygen sensor thread cleaner Reconditioning the exhaust system threads M

before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
a = 18 mm (0.71 in) dia. for zirconia heated
N
oxygen sensor
b = 12 mm (0.47 in) dia. for titania heated
oxygen sensor
AEM488
O
Acoustic tension gauge Checking drive belt tension
PBIC3881E
EM-13
PREPARATION
Tool name Description
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
Manual lift table caddy Removing and installing engine
ZZA1210D
Tube presser Pressing the tube of liquid gasket
S-NT052
EM-14
DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [HR16DE]
ON-VEHICLE MAINTENANCE A
DRIVE BELTS
Checking INFOID:0000000001381384
EM
• Inspection should be done only when engine is cold or over 30
minutes after the engine is stopped.
C
1 : Generator
2 : Water pump
3 : Crankshaft pulley D
: A/C compressor (with A/C models)
4
: Idler pulley (without A/C models)
5 : Idler pulley E
6 : Drive belt
PBIC3642E
• Visually check belts for wear, damage, and cracks on inside and
F
edges.
• Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the
test.
• When measuring deflection, apply 98 N (10 kg, 22 lb) at the ( ) marked point. G
• Measure the belt tension and frequency with acoustic tension gauge (commercial service tool) at the ( )
marked point.
CAUTION: H
• When the tension and frequency are measured, the acoustic tension gauge should be used.
• When checking immediately after installation, first adjust it to the specified value. Then, after turning
crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection
between pulleys. I
Belt Deflection / Belt Tension and Frequency : Refer to EM-122, "Drive Belts".
J
Tension Adjustment INFOID:0000000001381385
K
Location Location of adjuster and tightening method
Drive belt Adjusting bolt on idler pulley
L
CAUTION:
• When belt is replaced with new one, adjust belt tension to the value for “New belt”, because new belt
will not fully seat in the pulley groove.
• When tension of the belt being used exceeds “Limit”, adjust it to the value for “After adjusted”. M
• When installing a belt, make sure it is correctly engaged with the pulley groove.
• Never allow oil or engine coolant to get on the belt.
• Never twist or bend the belt strongly.
N
1. Loosen the idler pulley lock nut (A) from the tightening position
with the specified torque by 45 degrees.
1 : Generator O
2 : Water pump
3 : Crankshaft pulley
P
4
5 : Idler pulley
6 : Drive belt
PBIC3643E
A : Idler pulley lock nut
B : Adjusting bolt
EM-15
DRIVE BELTS
CAUTION:
• When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjust-
ment cannot be performed. Never loosen it excessively (more than 45 degrees).
• Put a matching mark on the lock nut, and check turning angle with a protractor. Never visually
check the tightening angle.
2. Adjust the belt tension by turning the adjusting bolt.
CAUTION:
• When checking immediately after installation, first adjust it to the specified value. Then, after
turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflec-
tion between pulleys.
• When the tension adjustment is performed, the lock nut should be in the condition at step“2”. If
the tension adjustment is performed when the lock nut is loosened more than the standard, the
idler pulley tilts and the correct tension adjustment cannot be performed.
3. Tighten the idler pulley lock nut.
Idler pulley lock nut : 34.8 N·m (3.5 kg-m, 26 ft-lb)
Removal and Installation INFOID:0000000001381386
REMOVAL
1. Loosen the idler pulley lock nut (A), and then adjust the belt ten-
sion by turning the adjusting bolt (B).
1 : Generator
2 : Water pump
4
5 : Idler pulley
6 : Drive belt PBIC3643E
2. Remove drive belt.

INSTALLATION
1. Pull the idler pulley in the loosening direction, and then tempo-
rarily tighten the idler pulley lock nut (A) to the following torque.
1 : Generator
2 : Water pump
4
5 : Idler pulley
6 : Drive belt
PBIC3643E
B : Adjusting bolt
Idler pulley lock nut : 4.4 N·m (0.45 kg-m, 39 in-lb)

NOTE:
Do not move the lock nut from the tightened position. Proceed to step “2”.
2. Install the drive belt to each pulley.
CAUTION:
• Make sure that there is no oil, grease, or coolant, etc. in pulley grooves.
• Make sure that the belt is securely inside the groove on each pulley.
3. Adjust drive belt tension by turning the adjusting bolt. Refer to EM-15, "Tension Adjustment".
CAUTION:
EM-16
DRIVE BELTS
• Perform the belt tension adjustment with the lock nut temporarily tightened at the step “1” so as
not to tilt the idler pulley. A
• When checking immediately after installation, first adjust it to the specified value. Then, after
turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflec-
tion between pulleys.
EM
4. Tighten the idler pulley lock nut.
Idler pulley lock nut : 34.8 N·m (3.5 kg-m, 26 ft-lb) C

5. Make sure that belt tension of each belt within the standard.
EM-17
AIR CLEANER FILTER
AIR CLEANER FILTER
REMOVAL
1. Push the tabs (A) of both ends of the air cleaner cover (1) into
the inside (B).
2. Pull up the air cleaner cover (1) and remove it (C).
PBIC3557J
3. Remove air cleaner filter (1) and holder (2) assembly from the
air cleaner case.
4. Remove the air cleaner filter (1) from the holder (2).
PBIC3558J
INSPECTION AFTER REMOVAL

It is necessary to clean air cleaner filter or replace it at the recommended intervals, more often under dusty
conditions. Refer to MA-7, "Periodic Maintenance".
• Blow air into the back side of air cleaner filter until no objects spray
out.
SMA384C
INSTALLATION
Installation is in the reverse order of removal.
• Install the air cleaner cover (1) in the direction shown.
2 : Air cleaner filter

3 : Holder
PBIC3559J
EM-18
SPARK PLUG
SPARK PLUG
A
Exploded View INFOID:0000000001381388
EM
G
PBIC3662E
1. Ignition coil 2. Spark plug

H
REMOVAL I
1. Remove intake manifold. Refer to EM-29, "Removal and Installation".
2. Remove ignition coil. Refer to EM-47, "Removal and Installation".
3. Remove spark plug with a spark plug wrench (commercial ser- J
vice tool).
M
PBIC3871E

Use the standard type spark plug for normal condition. N
Spark plug (Standard type): Refer to MA-29, "SPARK PLUG : In-

spection".
O
CAUTION:
EM-19
SPARK PLUG
• Never drop or shock spark plug.
• Never use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used.
Cleaner air Less than 588 kPa (6 kg/cm2, 85 psi)

pressure:
Cleaning time: Less than 20 seconds
SMA773C
• Checking and adjusting plug gap is not required between

change intervals.
JPBIA0031ZZ
INSTALLATION
Installation is the reverse order of removal.
Plug type : Platinum tipped

Make : NGK
Part number : PLZKAR6AP-11
Gap (nominal) : 1.1 mm (0.043 in)
EM-20
CAMSHAFT VALVE CLEARANCE
A
Inspection and Adjustment INFOID:0000000001381391
INSPECTION EM
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-47, "Exploded View". C
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (2) clockwise and align TDC mark D
(without paint mark) (A) to timing indicator (1) on front cover.
B : White paint mark (Not use for service)

E
PBIC3673E G
• At the same time, make sure that both intake and exhaust cam
noses of No. 1 cylinder face outside as shown. H
1 : Camshaft (INT)
2 : Camshaft (EXH) I
: Engine front
• If they do not face outside, rotate crankshaft pulley once more

(360 degrees) and align as shown. J
PBIC3359J
K
b. Use a feeler gauge, measure the clearance between valve lifter
and camshaft.
L
Valve Clearance: Refer to EM-123, "Camshaft".
N
SEM139D
• By referring to the figure, measure the valve clearances at O

locations marked “×” as shown in the table below [locations
indicated with black arrow ( ) shown] with a feeler gauge.
P
A : No. 1 cylinder compression TDC
: Engine front
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
Measurement po- EXH × ×

PBIC3707E
sition INT × ×
EM-21
c. Rotate crankshaft pulley (2) one revolution (360 degrees) and
align TDC mark (without paint mark) (A) to timing indicator (1) on
front cover.
PBIC3673E
• By referring to the figure, measure the valve clearance at loca-

tions marked “×” as shown in the table below [locations indi-
cated with black arrow ( ) shown] with a feeler gauge.
A : No. 4 cylinder compression TDC

: Engine front
Measurement EXH × ×
point INT × × PBIC3708E
3. If out of standard, perform adjustment procedure.

ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-59, "Exploded View".
2. Remove valve lifters at the locations that are out of the standard.
3. Measure the center thickness of the removed valve lifters with a
micrometer (A).
PBIC3195J
4. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1– C2)

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)
Exhaust : 0.33 mm (0.013 in)
EM-22
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder). A
• Stamp mark “300” indicates 3.00 mm (0.118 in) in thickness.
EM
PBIC3196J
D
NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-123, "Camshaft". E
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-59, "Exploded View".
7. Manually rotate crankshaft pulley a few rotations. F
8. Make sure that valve clearances for cold engine are within specifications by referring to the specified val-
ues.
9. Install all removed parts in the reverse order of removal. G
10. Warm up the engine, and check for unusual noise and vibration.
EM-23
COMPRESSION PRESSURE
Inspection INFOID:0000000001381392
1. Warm up engine thoroughly. Then, stop it.

2. Release fuel pressure. Refer to EC-377, "Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD).
3. Remove ignition coil and spark plug from each cylinder. Refer to EM-47, "Exploded View".
4. Connect an engine tachometer (not required in use of CONSULT-III).
5. Install a compression tester (B) with an adapter (commercial
service tool) (A) onto spark plug hole.
PBIC3730E
• Use the adapter whose picking up end inserted to spark plug

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
SBIA0533E
6. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each
cylinder.
Compression Pressure: Refer to EM-122, "General Specification".

CAUTION:
Always use fully a changed battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder
head gasket.
7. After inspection is completed, install removed parts.
8. Start the engine, and confirm that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-469, "Description".
EM-24
DRIVE BELT IDLER PULLEY
< ON-VEHICLE REPAIR > [HR16DE]
ON-VEHICLE REPAIR A
EM
1 : Generator bracket
2 : Center shaft
C
3 : Spacer
4 : Adjusting bolt
D
5 : Washer
6 : Idler pulley
7 : Plate
E
PBIC3644E
I
J
REMOVAL
1. Remove drive belt. Refer to EM-16, "Removal and Installation".
2. Remove the lock nut, and then remove the plate, idler pulley, and washer. K
3. Remove the center shaft together with the spacer with inserting the adjusting bolt.
INSTALLATION
L
EM-25
1. Insert the center shaft (1) into the slide groove of the spacer (2).
Fully screw in the adjusting bolt (3) in the belt loosening direc-
tion ( ).
• At that time, place the flange (a) of the adjusting bolt and the
seat (b) of the center shaft on the spacer.
2. Place each surface (c, d) of the spacer on the generator bracket.
Install the washer, idler pulley, and plate, and then temporarily
tighten the lock nut.
: 4.4 N·m (0.45 kg-m, 39 in-lb)
PBIC3885E
3. Installation is in the reverse order of removal.
EM-26
AIR CLEANER AND AIR DUCT
A
EM
I
PBIC3645E
1. Air cleaner filter 2. Mass air flow sensor 3. O-ring J

4. Holder 5. Air cleaner cover 6. Air duct
7. PCV hose 8. Clip 9. Air duct (Inlet)
10. Grommet 11. Air duct 12. Grommet K
13. Air cleaner case
A. To electronic throttle control actuator B. To rocker cover
L
REMOVAL M
1. Remove the battery. Refer to PG-6, "Removal and Installation".
2. Remove the air duct (inlet).
3. Remove the air cleaner filter from the air cleaner case. Refer to EM-18, "Removal and Installation". N
4. Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.
5. Remove the PCV hose.
6. Remove the air duct (between air cleaner case and electronic throttle control actuator). O
• Add marks as necessary for easier installation.
7. Disconnect harness connector from mass air flow sensor.
8. Remove air cleaner case. P
9. Remove the mass air flow sensor from the air cleaner case, if necessary.
CAUTION:
• Handle mass air flow sensor carefully and avoid impacts.
• Never touch sensor part.
INSTALLATION
EM-27
• Align marks. Attach each joint. Screw clamps firmly.

Inspect air ducts and air cleaner assembly for crack or tear.
• If anything found, replace air ducts and air cleaner assembly as necessary.
EM-28
INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
I
PBIC4737E
1. EVAP hose 2. Vacuum tank 3. EVAP hose J

EVAP canister purge volume control
4. O-ring 5. 6. Electric throttle control actuator
solenoid valve
7. Water hose (Northern Europe models) 8. Water hose (Northern Europe models) 9. Gasket
K
10. Intake manifold support (rear) 11. Intake manifold 12. Intake manifold support (front)
13. Intake manifold support (center) 14. Cylinder head 15. Vacuum hose
16. Gasket L
A. To centralized under-floor piping B. To brake booster C. To water outlet

M
REMOVAL
1. Remove the air duct (inlet) and air duct (between air cleaner case and electronic throttle control actuator).
Refer to EM-27, "Exploded View". N
2. Remove the reservoir tank. Refer to CO-16, "Component".
3. Remove the oil level gauge.
O
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
4. Remove electronic throttle control actuator and position aside.
CAUTION: P
• Handle electric throttle control actuator carefully and avoid impacts.
• Never disassemble or adjust electric throttle control actuator.
5. Disconnect the harness connector and EVAP hose from the EVAP canister purge volume control solenoid
valve.
6. Disconnect vacuum hose for brake booster from intake manifold.
EM-29
INTAKE MANIFOLD
7. Remove intake manifold support front (1) and bolt from rear (2).
• Bracket (2) is not removed. Remove bolt from intake manifold.
JPBIA0278ZZ
8. Remove intake manifold.

• Loosen bolts in the reverse of the order shown.
: Engine front
PBIC3652E
9. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
CAUTION:
Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.
10. Remove intake manifold support (center) from cylinder head, if necessary.
NOTE:
The intake manifold support (center) functions as the guide when the intake manifold is installed.
INSTALLATION
Intake Manifold
1. Install the gasket to the intake manifold.
• Align the protrusion (A) of gasket to the groove of intake mani-
fold.
PBIC3651E
2. Place the intake manifold into the installation position.

CAUTION:
Make sure that the oil level gauge guide is not disconnected from the fixing clip of water inlet due
to interference with intake manifold.
EM-30
INTAKE MANIFOLD
3. Tighten bolts in the numerical order shown.
A
: Engine front
EM
PBIC3652E
D
4. Install intake manifold support (front and rear).
Electronic Throttle Control Actuator
• Tighten bolts of electronic throttle control actuator equally and diagonally in several steps. E
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec-
tric throttle control actuator. Refer to EC-27, "THROTTLE VALVE CLOSED POSITION LEARNING :
Description" (EURO-OBD), EC-390, "THROTTLE VALVE CLOSED POSITION LEARNING : Description" F
(WITHOUT EURO-OBD).
• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing
electric throttle control actuator. Refer to EC-27, "THROTTLE VALVE CLOSED POSITION LEARNING :
Description" (EURO-OBD), EC-390, "THROTTLE VALVE CLOSED POSITION LEARNING : Description" G
(WITHOUT EURO-OBD), EC-27, "IDLE AIR VOLUME LEARNING : Description" (EURO-OBD), EC-390,
"IDLE AIR VOLUME LEARNING : Description" (WITHOUT EURO-OBD).
H
EM-31
EXHAUST MANIFOLD
EXHAUST MANIFOLD
PBIC4750E
1. Exhaust manifold cover 2. Exhaust manifold cover 3. Harness bracket

4. Heated oxygen sensor 1 5. Exhaust manifold stay 6. Exhaust manifold
7. Gasket 8. Stud bolt 9. Heat insulator
: Engine front
REMOVAL
1. Remove the cowl. Refer to EXT-20, "Removal and Installation".
2. Remove the engine room cover.
3. Remove exhaust front tube. Refer to EX-5, "Component".
4. Remove the harness bracket of heated oxygen sensor 1 from the cylinder head.
5. Remove exhaust manifold cover.
6. Remove the heated oxygen sensor 1.
EM-32
EXHAUST MANIFOLD
• Using heated oxygen sensor wrench [SST: KV10117100] (A),
remove heated oxygen sensor 1. A
CAUTION:
Handle heated oxygen sensor 1 carefully and avoid
impacts.
EM
NOTE:
The exhaust manifold can be removed and installed without
removing the heated oxygen sensor 1 (Disassembly of harness
connector is necessary). C
PBIC3654E
D
7. Remove exhaust manifold side mounting bolt of exhaust manifold stay.
8. Remove exhaust manifold.
• Loosen nuts in the reverse of the order shown. E
: Engine front
F
PBIC3774E H
9. Remove gasket.
CAUTION:
I
Cover engine openings to avoid entry of foreign materials.
10. Remove exhaust manifold cover from back of exhaust manifold.
INSPECTION AFTER REMOVAL J
Mounting Surface Distortion
• Use suitable tools (A) and (B) to check distortion of exhaust mani-
fold mounting surface as shown. K
Limit : 0.3 mm (0.012 in)

• Replace exhaust manifold if outside the limit. L
PBIC3530J
N
INSTALLATION
Exhaust Manifold O
EM-33
EXHAUST MANIFOLD
1. Tighten nuts in numerical order shown.
: Engine front
2. Tighten to the specified torque again.
PBIC3774E
EM-34
FUEL INJECTOR AND FUEL TUBE
A
EM
I
PBIC3663E
1. Quick connector cap 2. Fuel feed hose 3. Fuel tube J

4. Fuel tube protector 5. O-ring (black) 6. Clip
7. Fuel injector 8. O-ring (green)
CAUTION: K
Never remove or disassemble parts unless instructed as shown.
L
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. M
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
REMOVAL
N
1. Release the fuel pressure. Refer to EC-377, "Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD).
2. Remove intake manifold. Refer to EM-29, "Exploded View". O
EM-35
3. Disconnect quick connector with the following procedure. Dis-
connect fuel feed hose from fuel tube.
1 : Quick connector cap

NOTE:
There is no fuel return path.
PBIC3771E
a. Remove quick connector cap (1) from quick connector connec-

tion.
b. Disconnect fuel feed hose from hose clamp.
PBIC3664E
c. With the sleeve side of quick connector release (SST) facing quick connector, install quick connector
release onto fuel tube.
d. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
e. Draw and pull out quick connector straight from fuel tube.
CAUTION:
• Pull quick connector holding “A” position.
• Never pull with lateral force applied. O-ring inside quick KBIA0702E
connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed hose during installation/
removal.
• To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
PBIC2205E
4. Disconnect harness connector from fuel injector.
EM-36
5. Remove fuel tube protector.
• Loosen bolts in the reverse of the order shown. A
: Engine front
EM
PBIC3665E D
6. Remove the fuel injector and fuel tube assembly.

• Loosen bolts in the reverse of the order shown. E
: Engine front
CAUTION: F
• When removing, be careful to avoid any interference with
fuel injector.
• Use a shop cloth to absorb any fuel leaks from fuel tube.
G
PBIC3666E H
7. Remove the fuel injector (3) from the fuel tube (1) with the fol-
lowing procedure.
I
a. Open and remove the clip (2).
b. Remove fuel injector from the fuel tube by pulling straight.
CAUTION:
• Be careful about fuel leakage remaining in fuel tube. J
• Be careful not to damage the nozzle of fuel injector.
• Never subject fuel injector to impact by dropping or hit-
ting. K
• Never disassemble.
PBIC3667E
INSTALLATION L
1. Install new the O-ring to the fuel injector, paying attention to the following.
CAUTION:
• The upper and lower O-rings are different. Be careful not to confuse them. M
Fuel tube side : Black

Nozzle side : Green N
• Handle O-ring with bare hands. (Never wear gloves.)
• Lubricate O-ring with engine oil.
• Never clean O-ring with solvent. O
• Make sure that the O-ring and its mating part are free of foreign material.
• Be careful not to scratch O-ring with tool or fingernails when installing it. Also be careful not to
twist or stretch O-ring. If O-ring is stretched while installing, never insert it into fuel tube immedi-
ately. P
• Insert O-ring straight into fuel tube. Never decenter or twist it.
EM-37
2. Install the fuel injector (4) onto the fuel tube (1) with the following
procedure:
3 : O-ring (Black)
5 : O-ring (Green)
a. Insert the clips (2) into the clip mounting grooves on the fuel
injector.
• Insert clip cut-out (D) into fuel injector protrusion (F).
CAUTION:
• Always replace clip with new one.
• Make sure that the clip does not interfere with the O-
ring. If interference occurs, replace the O-ring.
b. Insert the fuel injector into the fuel tube with clip attached.
• Make sure that the axis is lined up when inserting.
• Insert clip cut-out (C) into fuel tube protrusion (B).
• Make sure that the flange (A) on the fuel tube fits securely in
the clip flange fixing groove (E).
c. Make sure that installation is complete by checking that fuel
injector does not rotate or come off.
PBIC3668E
3. Install fuel tube and injector assembly onto cylinder head.

• Tighten bolts in the numerical order shown.
: Engine front
CAUTION:
Be careful not to let tip of injector nozzle interfere with
other parts.
PBIC3666E
4. Install fuel tube protector.

• Tighten bolts in the numerical order shown.
: Engine front
PBIC3665E
5. Connect harness connector to fuel injector.

6. Connect fuel feed hose with the following procedure.
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
EM-38
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector to fuel tube until the top spool on fuel A
tube is inserted completely and the 2nd level spool is posi-
tioned slightly below quick connector bottom end.
CAUTION:
EM
• Hold “A” position 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. C
• Insert until you hear a “click” sound and actually feel
the engagement.
KBIA0272E
• To avoid misidentification of engagement with a similar D
sound, be sure to perform the next step.
d. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding “A” position.
Make sure it is completely engaged (connected) so that it does not come out from fuel tube.
E
e. Install quick connector cap (1) to quick connector connection.
• Install quick connector cap with the side arrow facing quick
connector side (fuel feed hose side).
CAUTION: F
• Make sure that the quick connector and fuel tube are
securely engaged with the quick connector cap mount-
ing groove. G
• Quick connector may not be connected correctly if
quick connector cap cannot be installed easily. Remove
the quick connector cap, and then check the connection
of quick connector again. H
PBIC3664E
f. Install fuel feed hose to hose clamp.

I
7. Installation is in the reverse order of removal, for the remaining parts.
J
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
K
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, make sure
there are no fuel leaks at connection points.
NOTE:
Use mirrors for checking at points out of clear sight. L
2. Start the engine. With engine speed increased, make sure again that there are no fuel leaks at connection
points.
CAUTION: M
Never touch the engine immediately after stopped, as the engine becomes extremely hot.
EM-39
OIL PAN (LOWER)
OIL PAN (LOWER)
JPBIA0553GB
1. Rear oil seal 2. O-ring 3. Oil pan (upper)

4. Chain tensioner 5. Oil pump drive chain 6. Crankshaft sprocket
7. Oil pump sprocket 8. Oil pan drain plug 9. Washer
10. Oil pan (lower) 11. Oil filter stud bolt 12. Oil filter
13. Oil level sensor
A. Refer to EM-50 B. Refer to LU-9 C. Oil pan side
REMOVAL
1. Drain engine oil. Refer to LU-7, "Draining".
2. Remove the oil pan (lower) with the following procedure.
a. Loosen bolts in the reverse of the order shown.
: Engine front
b. Insert the seal cutter [SST: KV10111100] between oil pan

(upper) and oil pan (lower).
CAUTION:
• Be careful not to damage the mating surface.
• A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off
using a flat- bladed screwdriver, etc.
PBIC4345E
EM-40
OIL PAN (LOWER)
INSTALLATION
1. Install oil pan (lower) with the following procedure. A
a. Use scraper to remove old liquid gasket from mating surfaces.
• Also remove the old liquid gasket from mating surface of oil pan (upper).
• Remove old liquid gasket from the bolt holes and threads. EM
CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Apply a continuous bead of liquid gasket (A) with the tube C
presser (commercial service tool) to areas shown.
: Engine out side D

Use Genuine Liquid Gasket or equivalent.
CAUTION:
Attaching should be done within 5 minutes after coating. E
PBIC5006E
c. Tighten bolts in the numerical order shown in the figure. J
: Engine front
K
PBIC4345E
M
2. Install oil pan drain plug.

• For installation direction of washer. Refer to EM-40, "Exploded View". N
3. Install in the reverse order of removal, for the rest of parts.
CAUTION:
Pour engine oil at least 30 minutes after oil pan is installed. O
INSPECTION AFTER INSTALLATION P
1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection".
2. Start engine, and check there is no leak of engine oil.
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-6, "Inspection".
EM-41
OIL PAN (UPPER) AND OIL STRAINER
Component INFOID:0000000001532078
JPBIA0553GB

NOTE:
The oil strainer and oil pump are included in the oil pan (upper). Individual disassembly is prohibited.
REMOVAL
NOTE:
When removing oil pan (lower) only, steps “2” and “3” are not necessary. Perform step “5” after completing
step “4”.
1. Remove engine undercover using power tool.
2. Remove engine and transaxle assembly from the vehicle, and then separate engine and transaxle. Refer
to EM-89, "Removal and Installation".
3. Install engine assembly to widely use engine stand. Refer to EM-94, "Setting".
5. Remove the oil pan (lower) using the following procedure.
EM-42
A
: Engine front
b. Insert the seal cutter (SST: KV10111100) between oil pan EM

(upper) and oil pan (lower).
CAUTION:
• A more adhesive liquid gasket is applied compared to pre- C
using a flat- bladed screwdriver, etc. PBIC4345E
D
6. Remove oil level gauge.
7. Remove front cover and timing chain. Refer to EM-50, "Removal and Installation".
8. Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain. Refer to EM-50, E
"Exploded View".
9. Remove oil pan (upper) using the following procedure.
a. Loosen oil pan (upper) mounting bolts in the reverse of the order F
shown.
: Engine front G
MBIB1374E I
b. Insert a flat-bladed offset screwdriver into the arrow ( ) in the

figure and open up a crack between the oil pan (upper) cylinder J
block.
: Engine front K
c. Insert the seal cutter (SST: KV10111100) between remove the
oil pan (upper) and cylinder block.Slide seal cutter by tapping on
the side of tool with a hammer. L
CAUTION:
• Be careful not to damage the mating surface. MBIB1375E
• A more adhesive liquid gasket is applied compared to pre- M
vious types when shipped, so it should not be forced off using a screwdriver, etc. outside the
indicated location.
• Do not remove oil pump and oil strainer from oil pan (upper).
10. Remove rear oil seal from crankshaft. N
INSTALLATION
1. Install the oil pan (upper) in the following procedure. O
• Also remove the old liquid gasket from mating surface of cylinder block.
• Remove old liquid gasket from the bolt holes and threads. P
CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Install O-ring to the cylinder block.
EM-43
c. Apply a continuous bead of liquid gasket (C) with the tube
presser (SST: WS39930000) to areas shown.
A : 2 mm (0.07 in) protruded to outside

B : 2 mm (0.07 in) protruded to rear oil seal mounting side
: Engine front
: Engine out side
CAUTION:
Installation should be done within 5 minutes after coating.
PBIC4344E
d. Tighten bolts in the numerical order shown.
: Engine front
CAUTION:
Install avoiding misalignment of both oil pan gasket and O-
ring.
• The bolts are different according to the installation position.
Follow the numbers shown.
M8 × 179 mm (7.09 in) : No. 9, 10 MBIB1374E
M8 × 25 mm (0.98 in) : No. 4, 7, 8

M8 × 90 mm (3.54 in) : No. 1, 2, 3, 5, 6
2. Install rear oil seal with the following procedure:

CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Do not touch oil seal lip.
a. Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a spatula.
b. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
c. Press-fit the rear oil seal using a drift with outer diameter 113
mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial
service tool) (A).
PBIC3660E
EM-44
• Press-fit to the dimensions specified.
A
1. Rear oil seal
A. Rear end surface of cylinder block
CAUTION: EM
• Do not touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part
of oil pan (upper) and cylinder block or the crankshaft. C
• Install straight to make sure that oil seal does not curl or
tilt.
PBIC3761E
d. After press-fitting the rear oil seal, completely wipe off any liquid D
gasket protruding to rear end surface side.
3. Install crankshaft sprocket, oil pump sprocket, oil pump drive chain, and chain tensioner. Refer to EM-50,
"Exploded View".
E
4. Install timing chain and related parts. Refer to EM-50, "Removal and Installation".
5. Install front cover and related parts. Refer to EM-50, "Removal and Installation".
6. Install oil pan (lower) with the following procedure. F
• Also remove the old liquid gasket from mating surface of oil pan (upper).
• Remove old liquid gasket from the bolt holes and threads. G
CAUTION:
Do not scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Apply a continuous bead of liquid gasket (A) with the tube
presser (SST: WS39930000) to areas shown in the figure. H
: Engine out side

I
CAUTION:
Installation should be done within 5 minutes after coating.
J
N
PBIC5006E
c. Tighten bolts in the numerical order shown. O
: Engine front
P
PBIC4345E
EM-45
7. Install oil pan drain plug.
• For installation direction of washer. Refer to EM-42, "Component".
CAUTION:
Do not fill engine with engine oil until at least 30 minutes after oil pan is installed.
1. Check engine oil level and adjust engine oil. Refer to LU-6, "Inspection".
2. Check for leakage of engine oil when engine is warmed.
4. Check engine oil level again. Refer to LU-6, "Inspection".
EM-46
IGNITION COIL, SPARK PLUG AND ROCKER COVER
A
EM
L
PBIC4257E
1. Ignition coil 2. Spark plug 3. PCV hose M

4. Oil filler cap 5. Rocker cover 6. Gasket
7. Bracket 8. Grommet 9. PCV valve
10. PCV hose N
A. To air duct

O
REMOVAL
1. Remove intake manifold. Refer to EM-29, "Exploded View". P
2. Remove ignition coil.
CAUTION:
• Handle ignition coil carefully and avoid impacts.
3. Remove ground cable (RH).
4. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket and insulator (RH). Refer to EM-89, "Exploded View".
EM-47
5. Remove fuel tube protector.
6. Remove oil filler cap.
7. Remove rocker cover.
• Loosen bolts in reverse order shown.
: Engine front
NOTE:
13 and 14 shown are used to tighten the fuel tube protector.
PBIC3670E
8. Remove rocker cover gasket from rocker cover.

9. Use scraper to remove all traces of liquid gasket from cylinder head and front cover.
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION
1. Install the rocker cover with the following procedure.
a. Install the gasket to the rocker cover.
• Check for damage or foreign material.
• Make sure that it is securely inserted in the mounting groove of
rocker cover.
• For the 2 bolt holes shown, push the gasket into the boss for
the rocker cover bolt hole to prevent it from falling.
KBIA3331J
b. Apply liquid gasket to the position shown.
1 : Cylinder head
2 : Front cover
PBIC3671E
2. Install rocker cover to the cylinder head.

CAUTION:
Make sure the gasket is not dropped.
3. Install rocker cover.
EM-48
• Tighten bolts in two steps separately in numerical order as
shown. A
: Engine front
EM
PBIC3670E
D
4. Install in the reverse order of removal, for the remaining parts.
EM-49
TIMING CHAIN
TIMING CHAIN
PBIC3709E
1. Timing chain slack guide 2. Chain tensioner (for timing chain) 3. Camshaft sprocket (EXH)
4. Camshaft sprocket (INT) 5. Plug 6. Front oil seal
7. Crankshaft pulley 8. Crankshaft pulley bolt 9. Front cover
10. Crankshaft sprocket 11. Oil pump sprocket 12. Oil pump drive chain
13. Chain tensioner (for oil pump drive chain) 14. Timing chain 15. Timing chain tension guide
A. Refer to EM-50
CAUTION:
The rotation direction indicated in the text indicates all directions seen from the engine front direction.
REMOVAL
1. Remove front wheel (RH). Refer to WT-6, "Rotation".
2. Remove front fender protector (RH). Refer to EXT-22, "Removal and Installation".
CAUTION:
Be sure to perform this step when engine is cold.
EM-50
TIMING CHAIN
4. Remove the following parts.
• Intake manifold: Refer to EM-29, "Exploded View". A
• Drive belt: Refer to EM-16, "Removal and Installation".
• Water pump pulley: Refer to CO-20, "Exploded View".
• Ground cable (RH)
EM
6. Remove rocker cover. Refer to EM-47, "Exploded View".
C
7. Set No. 1 cylinder at TDC of its compression stroke with the following procedure:
a. Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover. D
PBIC3673E
G
b. Make sure the matching marks on each camshaft sprocket are
positioned as shown.
1 : Camshaft sprocket (EXH) H

2 : Camshaft sprocket (INT)
A : Matching mark (stamp)
B : Matching mark (peripheral stamp line) I
• If not, rotate crankshaft pulley one more turn to align matching
marks to the positions.
J
PBIC3872E
8. Remove crankshaft pulley with the following procedure:

K
a. Secure crankshaft pulley (1) using a suitable tool (A).
b. Loosen and pull out crankshaft pulley bolts.
CAUTION:
Never remove the mounting bolts as they are used as a sup- L
porting point for the pulley puller.
N
PBIC3710E
c. Attach a pulley puller [SST: KV11103000] (A) in the M 6 thread

hole on crankshaft pulley, and remove crankshaft pulley. O
B : M6 bolt
P
PBIC3711E
EM-51
TIMING CHAIN
9. Remove front cover with the following procedure:
KBIA3429J
b. Cut liquid gasket by prying the position ( ) shown, and then

remove the front cover.
PBIC3712E
10. Remove front oil seal from front cover.

• Remove by lifting it up using a suitable tool.
CAUTION:
Be careful not to damage the front cover.
11. Remove chain tensioner (1) with the following procedure.
a. Fully push down the chain tensioner lever (A), and then push the
plunger (C) into the inside of tensioner.
• The tab (B) is released by fully pushing the lever down. As a
result, the plunger can be moved.
b. Pull up the lever to align its hole position with the body hole posi-
tion.
• When the lever hole is aligned with the body hole position, the
plunger is fixed.
• When the protrusion parts of the plunger ratchet and the tab
face each other, both hole positions are not aligned. At that PBIC3713E
time, correctly engage them and align these hole positions by

slightly moving the plunger.
c. Insert the stopper pin (D) into the body hole through the lever hole, and then fix the lever at the upper
position.
• The example that a hexagonal wrench for 2.5 mm (0.098 in) is used as shown.
d. Remove chain tensioner.
EM-52
TIMING CHAIN
12. Remove the timing chain tension guide (2) and the timing chain
slack guide (1). A
EM
PBIC3714E
D
13. Remove the timing chain (2).
• Pull the looseness of timing chain toward the camshaft
sprocket (EXH) (1), and then remove the timing chain and
E
start the removal from camshaft sprocket (EXH) side.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston. F
G
PBIC3715E
14. Remove the crankshaft sprocket and the oil pump drive related parts with the following procedure.
H
a. Remove chain tensioner (1).
• Pull out from the shaft (B) and spring fixing holes (A).
I
K
PBIC3716E
b. Hold the top of the oil pump shaft using the TORX socket (size:
E8), and then loosen the oil pump sprocket nuts and remove L
them.
c. Remove the crankshaft sprocket (1), the oil pump drive chain
(2), and the oil pump sprocket (3) at the same time. M
PBIC3720E
O
INSTALLATION
NOTE:
P
EM-53
TIMING CHAIN
The illustration shows the relationship between the matching mark
on each timing chain and that on the corresponding sprocket, with
the components installed.
1 : Timing chain
2 : Camshaft sprocket (EXH)
3 : Timing chain slack guide
4 : Chain tensioner
5 : Oil pump drive chain
6 : Oil pump sprocket
7 : Crankshaft sprocket
8 : Timing chain tension guide
A : Dark blue link
B : Matching mark (stamp)
C : Orange link
D : Matching mark (stamp)
E : Crankshaft key (point straight up)
F : Matching mark (peripheral stamp line)
G : Dark blue link
PBIC3718E
1. Install the crankshaft sprocket and the oil pump drive related parts with the following procedure:
a. Install the crankshaft sprocket (1), the oil pump drive chain (2),
and the oil pump sprocket (3) at the same time.
: Engine front
• Install the crankshaft sprocket so that its invalid gear area (A)
is towards the back of the engine.
• Install the oil pump sprocket so that its hexagonal surface
faces (B) the front of engine.
NOTE:
There is no matching mark in the oil pump drive related parts.
PBIC3719E
b. Hold the top of the oil pump shaft using the TORX socket (size:
E8), and then tighten the oil pump sprocket nuts.
2 : Oil pump drive chain
PBIC3720E
EM-54
TIMING CHAIN
c. Install chain tensioner (1).
• Insert the body into the shaft (B) while inserting the spring into A
the fixing hole (A) of cylinder block front surface.
• Make sure that the tension is applied to the oil pump drive
chain after installing.
EM
PBIC3716E
D
2. Install timing chain with the following procedure.
A : Dark blue link

E
C : Orange link
F
G : Dark blue link
G
• Install by aligning matching marks on each sprocket and tim-
ing chain.
• If these matching marks are not aligned, rotate the camshaft H
slightly to correct the position.
CAUTION:
• Check matching mark position of each sprocket and tim-
ing chain again after installing the timing chain, keep I
matching marks aligned by holding them with a hand.
• To avoid skipped teeth, never rotate crankshaft and cam-
shaft until front cover is installed. J
PBIC3721E
K
3. Install timing chain tension guide (2) and timing chain slack
guide (1).
L
N
PBIC3714E
4. Install chain tensioner (1). O

• Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
• Securely pull out the stopper pin after installing the chain ten-
sioner. P
PBIC3722E
EM-55
TIMING CHAIN
5. Check matching mark position of timing chain and each sprocket again.
6. Install the front oil seal to the front cover. Refer to EM-78, "FRONT OIL SEAL : Removal and Installation"
7. Install front cover with the following procedure:
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front cover as shown.
1 : Cylinder head
2 : Cylinder block
3 : Oil pan (upper)
A : Liquid gasket application area φ 3.0 - 4.0 mm (0.12 - 0.16 in)
PBIC3724E
b. Apply a continuous bead of liquid gasket with suitable tool to

front cover as shown.
PBIC3725E
EM-56
TIMING CHAIN
c. Tighten bolts in the numerical order shown.
d. After all bolts are tightened, retighten them to specified torque in A
numerical order as shown.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to EM
surface.
G
KBIA3429J
8. Insert crankshaft pulley by aligning with crankshaft key. H

• When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Never damage front oil seal lip section. I
9. Tighten crankshaft pulley bolt with the following procedure:
• Secure crankshaft pulley with a suitable tool, and tighten crankshaft pulley bolt.
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. J
b. Tighten crankshaft pulley bolt.
: 35.0 N·m (3.6 kg-m, 26 ft-lb) K
c. Put a paint mark (B) on crankshaft pulley, mating with any one of
six easy to recognize angle marks (A) on crankshaft bolt flange L
(1).
d. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
M
PBIC3726E
O
10. Make sure that crankshaft turns smoothly by rotating by hand clockwise.
Inspection INFOID:0000000001381413 P

Timing Chain
EM-57
TIMING CHAIN
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain as necessary.
A : Crack
B : Wear
JPBIA0091ZZ

Inspection for Leaks
• 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-19, "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.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise
will stop after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
E M - 5 8
CAMSHAFT
CAMSHAFT
A
EM
J
PBIC3672E
1. Camshaft bracket (No. 2 to 5) 2. Camshaft bracket (No.1) 3. Camshaft sprocket (EXH) K

4. Camshaft sprocket (INT) 5. Cylinder head 6. Oil filter (for intake valve timing control)
7. Washer 8. Plug 9. Intake valve timing control solenoid valve
10. O-ring 11. O-ring 12. Camshaft position sensor (PHASE) L
13. Valve lifter 14. Camshaft (INT) 15. Camshaft (EXH)
A. Refer to EM-59
M
CAUTION:
N
The rotation direction in the text indicates all directions seen from the engine front.
REMOVAL
1. Remove front wheel (RH). Refer to WT-6, "Rotation". O
CAUTION: P
Be sure to perform this step when engine is cold.
• Intake manifold: Refer to EM-29, "Exploded View".
• Water pump pulley: Refer to CO-20, "Exploded View".
• Ground cable (RH)
EM-59
CAMSHAFT
6. Remove rocker cover. Refer to EM-47, "Exploded View".
7. Set No. 1 cylinder at TDC of its compression stroke with the following procedure:
a. Rotate crankshaft pulley (2) clockwise and align TDC mark
(without paint mark) (A) to timing indicator (1) on front cover.
PBIC3673E
b. Make sure the matching marks on each camshaft sprocket are

positioned as shown.

A : Matching mark (stamp)
B : Matching mark (peripheral stamp line)
• If not, rotate crankshaft pulley one more turn to align matching
marks to the positions.
PBIC3872E
8. Remove crankshaft pulley with the following procedure:

a. Secure crankshaft pulley (1) using a suitable tool (A).
b. Loosen and pull out crankshaft pulley bolts.
CAUTION:
Never remove the mounting bolts as they are used as a sup-
porting point for the pulley puller.
PBIC3710E
c. Attach a pulley puller [SST: KV11103000] (A) in the M 6 thread

hole on crankshaft pulley, and remove crankshaft pulley.
B : M6 bolt
PBIC3711E
9. Remove front cover with the following procedure:
EM-60
CAMSHAFT
A
EM
G
KBIA3429J
b. Cut liquid gasket by prying the position ( ) shown, and then

remove the front cover. H
PBIC3712E
K
10. Remove camshaft position sensor (PHASE) from rear end of cylinder head.
CAUTION:
Handle it carefully and avoid impacts. L
11. Remove camshaft sprocket (EXH) (1).
CAUTION:
• Hold the camshaft hexagonal part (A), and then secure the M
camshaft.
• Never rotate crankshaft and camshaft separately, so as
not to contact valve with piston in the following steps.
N
O
AWBIA0102ZZ
12. Turn the camshaft sprocket (INT) to the most advanced position. P
CAUTION:
Installation and removal of the camshaft sprocket (INT) must be done in the most advanced posi-
tion for the following reasons.
EM-61
CAMSHAFT
• The sprocket (C) and vane (camshaft coupling) (B) are
designed to spin and move within the range of a certain
angle.
• With the engine stopped and the vane in the most
retarded angle, it will not spin because it is locked to the
sprocket side by the internal lock pin (A).
• If the camshaft sprocket mounting bolts are turned in the
situation described above, the lock pin will become dam-
aged and cause malfunctions because of the increased
horizontal load (cutting force) on the lock pin.
PBIC3679E
a. Remove camshaft bracket (No. 1) (1).
: Engine front
• Loosen the bolts in several steps, and then remove them.
AWBIA0103ZZ
b. Apply the following air pressure to the No. 1 journal oil hole (A)
of camshaft (INT) (1) shown using an air gun.
Pressure : 300 kPa (3.0 bar, 3.1 kg/cm2 , 44 psi) or more

• Apply the air pressure into the oil hole on the second groove
from the front of camshaft thrust (B).
• Proceed all the way through step “e” with the air pressure on.
AWBIA0104ZZ
• Attach the rubber nozzle (B) narrowed to the top of the air gun
(A) to prevent air leakage from the oil hole. Securely apply the
air pressure to the oil hole.
CAUTION:
• There are other oil holes in the side grooves. Never use
the incorrect oil holes.
• Be sure not to damage the oil path with the tip of the air
gun.
• Wipe all the oil off the air gun to prevent oil from being
blown all over along with the air, and the area around the
air gun should be wiped with a rag when applying air
AWBIA0105ZZ
pressure. Eye protection should be worn as needed.
NOTE:
The air pressure is used to move the lock pin into the disengage position.
c. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alter-
natively.
• Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the
arrow ( )].
• Perform the work while applying the air pressure to the oil hole.
EM-62
CAMSHAFT
• If the lock pin is not released by hands, tap the camshaft
sprocket (INT) lightly with a plastic hammer (A). A
• If the camshaft sprocket (INT) is not rotated counterclockwise
even if the above procedures are performed, check the air
pressure and the oil hole position.
EM
AWBIA0106ZZ
D
d. While doing the above, once you hear a click (the sound of the
internal lock pin disengaging) from inside the camshaft sprocket
(INT), start turning the camshaft sprocket (INT) in the counter-
E
clockwise direction in the most advanced angle position.
C : Most retarded angle (lock pin engaged)

D : Most advanced angle F
• Keep the air pressure on.

• If there is no click, as soon as the vane-side (camshaft side)
starts moving independently of the sprocket, the lock pin has G
become disengaged. PBIC3684E
• Make sure that it is in the most advanced angle position by

seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown. H
e. Complete the applying procedure of air pressure and the holding procedure of camshaft (INT).
f. Insert the stopper pin (A) into the stopper pin holes in the cam-
shaft sprocket (INT) and lock in the most advanced angle posi- I
tion.
CAUTION:
No load is exerted on the stopper pin (spring reaction, etc.). J
Since it comes out easily, secure it with tape (B) to prevent
it from coming out.
NOTE:
The stopper pin shows one example of a hexagonal wrench for K
2.5 mm (0.098 in) [length of inserted section: approximately15
mm (0.59 in)].
AWBIA0107ZZ
L
13. Remove camshaft brackets (No. 2 to 5).
• Loosen bolts in several steps in the reverse of the order
shown. M
A : EXH side
B : INT side
N
: Engine front
NOTE:
The camshaft bracket (No. 1) has been already removed. O
PBIC3686E
P
14. Remove camshaft (EXH).
EM-63
CAMSHAFT
15. Remove the camshaft (INT) (1) and the camshaft sprocket (INT)
(2) with the following procedure.
AWBIA0108ZZ
a. Keeping the camshaft hexagonal part (A) still with the wrench,
loosen the bolts for the camshaft sprocket (INT) (2).
1 :Camshaft (INT)
AWBIA0109ZZ
b. Disassemble the camshaft (1) from the camshaft sprocket (INT)

(2).
AWBIA0110ZZ
c. Remove camshaft (INT).

CAUTION:
Never damage the signal plate of rear end.
16. Remove valve lifter.
• Identify installation positions, and store them without mixing them up.
17. Remove intake valve timing control solenoid valve (1).
18. Remove the generator and bracket, remove the plug (2), and
then remove the oil filter. Refer to CHG-15, "Removal and Instal-
lation".
PBIC3692E
INSTALLATION
EM-64
CAMSHAFT
1. Install the oil filter (1).
A
2 : Washer
• The oil filter is assembled to the plug (3), and then install it to
the cylinder head. EM
PBIC3695E
D
2. Install intake valve timing control solenoid valve.
• Insert it straightly into the cylinder head.
• Tighten bolts after placing it completely.
E
3. Install valve lifter.
• If it is reused, install in its original positions.
4. Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT) with the following F
procedure.
NOTE:
It prevents the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and G
the camshaft sprocket (INT).
a. Put the matching marks (A) on a line extending from the knock
pin position of camshaft (INT) (1) front surface. H
• Put the marks on the visible position with the camshaft
sprocket installed. (Example shown)
b. Put the matching marks on a line extending from the knock pin
hole (B) position of camshaft sprocket (INT) (2). (Example I
shown)
• Put the marks on the visible position with it installed to the
camshaft. J
PBIC3696E
K
5. Install camshaft.
1 : Camshaft (EXH)
2 : Camshaft (INT)
L
A : Identification mark
• Distinction between camshaft (INT and EXH) is performed with M
the different shapes of rear end.
N
PBIC3698E
• Install camshafts to the cylinder head so that knock pins (A) on O

front end are positioned as shown.
1 : Camshaft (EXH)
2 : Camshaft (INT) P
: Upper side
NOTE:
Though camshaft does not stop at the portion as shown, for the
placement of cam nose, it is generally accepted camshaft is
placed for the same direction. PBIC3699E
EM-65
CAMSHAFT
6. Install the camshaft sprocket (INT) to the camshaft (INT) with the
following procedure.
a. Align the matching mark (A) put according to step “4”. Securely
align the knock pin and the pin hole, and then install them.
PBIC3700E
b. Temporarily tighten the bolt on the front side of camshaft (INT)

(1).
AWBIA0110ZZ
7. Put a thick shop cloth (B) to the lower surface, and then set the
tools to the bolt camshaft (INT) (1).
8. Tighten the mounting bolt.
CAUTION:
Hold the camshaft hexagonal part (A), and then secure the
camshaft.
PBIC3701E
9. Return the camshaft (INT) to the cylinder head carefully.

10. Install the camshaft (EXH) to the camshaft sprocket (EXH) (2)
while aligning the matching make (marked when timing chain is
removed) (A) and the matching mark (stamp) (B) of camshaft
sprocket (EXH).
1 : Timing chain
C : Matching mark (peripheral stamp line)
• If the positions of knock pin and pin groove are not aligned,
move the camshaft (EXH) slightly to correct these positions.
AWBIA0112ZZ
EM-66
CAMSHAFT
11. Tighten the mounting bolt.
A
CAUTION:
• Hold the camshaft hexagonal part (A), and then secure the EM
camshaft.
• Make sure that the matching mark (marked when timing
chain is removed) and each camshaft sprocket matching
C
mark are in the correct location.
AWBIA0102ZZ
D
12. Install camshaft brackets (No. 2 to 5) aligning the identification
marks on upper surface as shown.
E
A : EXH side
B : INT side
: Engine front
F
• Install so that identification mark can be correctly read when
viewed from the INT side.
G
PBIC3703E
13. Tighten mounting bolts of camshaft brackets in the following

H
steps, in numerical order as shown.
A : EXH side
B : INT side I
: Engine front
a. Tighten No. 9 to 11 in numerical order. J
: 2.0 N·m (0.2 kg-m, 1 ft-lb)

PBIC3686E
b. Tighten No. 1 to 8 in numerical order. K
: 2.0 N·m (0.2 kg-m, 1 ft-lb)

L
c. Tighten all bolts in numerical order.
: 5.9 N·m (0.6 kg-m, 4 ft-lb) M

d. Tighten all bolts in numerical order.
: 10.4 N·m (1.1 kg-m, 8 ft-lb) N
EM-67
CAMSHAFT
14. Install timing chain with the following procedure.
A : Dark blue link

C : Orange link
G : Dark blue link
• Install by aligning matching marks on each sprocket and tim-

ing chain.
• If these matching marks are not aligned, rotate the camshaft
slightly to correct the position.
CAUTION:
• Check matching mark position of each sprocket and tim-
ing chain again after installing the timing chain, keep
matching marks aligned by holding them with a hand.
• To avoid skipped teeth, never rotate crankshaft and cam-
shaft until front cover is installed.
PBIC3721E
15. Install timing chain tension guide (2) and timing chain slack
guide (1).
PBIC3714E
16. Install chain tensioner (1).

• Securely pull out the stopper pin after installing the chain ten-
sioner.
PBIC3722E
EM-68
CAMSHAFT
18. Pull out the stopper pin (A), and then apply the tension to the
timing chain by rotating the crankshaft pulley clockwise slightly. A
1 : Plunger
2 : Chain tensioner EM
B : Lever
C : Lever hole
D : Front cover has been omitted C
PBIC3772E
D
19. Return the camshaft sprocket (INT) in the most retarded position with the following procedure.
a. Remove the stopper pin (A) from the camshaft sprocket (INT).
E
B : Tape
AWBIA0107ZZ
H
b. Turn the crankshaft slowly clockwise and return the camshaft sprocket (INT) to the most retarded angle
position.
I
• When first turning the crankshaft the camshaft sprocket (INT)
will turn. Once it is turned more, and the vane (camshaft) also
turns, then it has reached the most retarded angle position.
J
B : Stopper pin hole
C : Most advanced angle
D : Most retarded angle (lock pin engaged) K
• The most retarded angle position can be checked by seeing if
the stopper pin groove (A) is shifted clockwise.
• After spinning the crankshaft slightly in the counterclockwise L
direction, you can make sure the lock pin has joined by seeing PBIC3705E
if the vane (camshaft) and the sprocket move together.

M
20. Install the front oil seal to the front cover. Refer to EM-78, "FRONT OIL SEAL : Removal and Installation"
21. Install front cover with the following procedure:
N
EM-69
CAMSHAFT
a. Apply a continuous bead of liquid gasket with tube presser
(commercial service tool) to front cover as shown.
1 : Cylinder head
2 : Cylinder block
3 : Oil pan (upper)
PBIC3724E
b. Apply a continuous bead of liquid gasket with suitable tool to

front cover as shown.
PBIC3725E
EM-70
CAMSHAFT
c. Tighten bolts in the numerical order shown.
d. After all bolts are tightened, retighten them to specified torque in A
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to EM
surface.
G
KBIA3429J
22. Insert crankshaft pulley by aligning with crankshaft key.

• When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). H
CAUTION:
Never damage front oil seal lip section.
23. Tighten crankshaft pulley bolt with the following procedure: I
• Secure crankshaft pulley with a suitable tool, and tighten crankshaft pulley bolt.
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt. J
: 35.0 N·m (3.6 kg-m, 26 ft-lb)

K
c. Put a paint mark (B) on crankshaft pulley, mating with any one of
six easy to recognize angle marks (A) on crankshaft bolt flange
(1). L
d. Turn another 60 degrees clockwise (angle tightening).
M
N
PBIC3726E
24. Make sure that crankshaft turns smoothly by rotating by hand clockwise.
O
25. Install the camshaft position sensor (PHASE) to the rear end of cylinder head.
• Tighten bolts with it seated completely.
26. Check and adjust valve clearance. Refer to EM-21, "Inspection and Adjustment". P

Oil Filter
EM-71
CAMSHAFT
• Make sure that there is no foreign material on the oil filter (1) and
check it for clogging.
• Check the oil filter for damage.
• If there is some damage, replace the oil filter, the plug, and the
washer as a set.
PBIC3693E
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour-
nals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on the dial indicator. (Total indicator reading)
PBIC2499E
Standard and Limit:
Refer to EM-123, "Camshaft".
4. If it exceeds the limit, replace camshaft.
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer (A).
Standard and Cam wear Limit:

Refer to EM-123, "Camshaft".
2. If wear exceeds the limit, replace camshaft.
PBIC3178J
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
Standard: Refer to EM-123, "Camshaft".
PBIC3179J
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with the specified torque. Refer to EM-59, "Removal and Installation".
EM-72
CAMSHAFT
• Measure inner diameter (B) of camshaft bracket with a bore gauge
(A). A

EM
PBIC3180J
CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter) E
Standard and Limit: Refer to EM-123, "Camshaft".

• If it exceeds the limit, replace either or both camshaft and cylinder head. F
NOTE:
Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder
head. Replace whole cylinder head assembly. G
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-59, "Removal and Installation".
H
2. Install a dial indicator (A) in thrust direction on front end of cam-
shaft. Measure the camshaft end play on the dial indicator when
camshaft is moved forward/backward (in direction to axis).
I
Standard and Limit: Refer to EM-123, "Camshaft".
K
PBIC3694E
• Measure the following parts if out of the standard.

- Dimension “A” for cylinder head No. 1 journal bearing L
Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)

- Dimension “B” for camshaft thrust M
Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in)

N
• Follow the standards above, and then replace camshaft and/or
cylinder head.
KBIA3345J
O
Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION: P
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
EM-73
CAMSHAFT
2. Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading)
Limit: Refer to EM-123, "Camshaft".

• If it exceeds the limit, replace camshaft sprocket.
KBIA1493J
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-123,
"Camshaft".
KBIA0182E
Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER
Measure the outer diameter of valve lifter with a micrometer (A).
PBIC3185J
VALVE LIFTER HOLE DIAMETER

Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A).
PBIC3184J
VALVE LIFTER CLEARANCE

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

• If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
EM-74
CAMSHAFT
A
The following are procedures for checking fluids leak, lubricates leak.
• Use procedure below to check for fuel leakage. EM
- Start engine. With engine speed increased, check again for fuel leakage at connection points. C
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after D
hydraulic pressure rises.
engine coolant. E
F
Engine coolant Level Leakage Level G
Fuel Leakage Leakage Leakage H
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Inspection of Camshaft Sprocket (INT) Oil Groove I

CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-131, "Diagnosis Pro-
cedure" (EURO-OBD), EC-484, "Diagnosis Procedure" (WITHOUT EURO-OBD). J
• Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-6, "Inspection".
K
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release the fuel pressure. Refer to EC-377, "Inspection" (EURO-OBD), EC-681, "Inspection" (WITHOUT
EURO-OBD). L
b. Remove intake manifold. Refer to EM-29, "Exploded View".
c. Disconnect ignition coil and injector harness connectors. Refer to EM-47, "Exploded View".
M
3. Remove intake valve timing control solenoid valve. Refer to EM-50, "Exploded View".
4. Crank engine, and then make sure that engine oil comes out
from intake valve timing control solenoid valve hole (A). End
crank after checking. N
1 : Plug
:Engine front O
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul- P
ley, and crankshaft pulley, etc.).
CAUTION: PBIC3706E
• Prevent splashing by using a shop cloth so as to prevent
the worker from injury from engine oil and so as to prevent engine oil contamination.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
EM-75
CAMSHAFT
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to EM-71, "Inspection".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-3,
"Engine Lubrication System" and LU-3, "Engine Lubrication System Schematic".
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-3, "Engine Lubrication System" and LU-3, "Engine Lubrica-
tion System Schematic".
7. After inspection, installation is in the reverse order of removal.
EM-76
OIL SEAL
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000001381417
EM
REMOVAL
1. Remove camshafts. Refer to EM-59, "Exploded View".
C
2. Remove valve lifters. Refer to EM-59, "Exploded View".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
D
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet.
• Compress valve spring with the valve spring compressor, the E
attachment and the adapter [SST: KV10116200] (A). Remove
valve collet with a magnet hand (B).
CAUTION: F
Be careful not to damage valve lifter holes.
H
PBIC3727E
5. Remove valve spring retainer, valve spring and valve spring seat. Refer to EM-82, "Disassembly and
Assembly". I
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902] (A).
J
L
PBIC3728E
INSTALLATION
M
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height “H” shown with the valve oil
seal drift [SST: KV10115600] (A).
N
Height “H” : 13.2 - 13.8 mm (0.520 - 0.543 in)
PBIC3211J

FRONT OIL SEAL
EM-77
OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000001381418
REMOVAL
1. Remove the following parts:
• Front fender protector (RH): Refer to EXT-22, "Removal and Installation".
• Crankshaft pulley: Refer to EM-50, "Exploded View".
2. Remove front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crankshaft.
INSTALLATION
1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.
2. Install front oil seal.
• Install front oil seal so that each seal lip is oriented as shown.
A : Dust seal lip

B : Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
• Using a suitable drift, press-fit until the height of front oil seal
(2) is level with the mounting surface.
1 : Front cover
: Engine outside
- Suitable drift (A): outer diameter 50 mm (1.97 in), inner diame-

ter 44 mm (1.73 in).
• Make sure the garter spring is in position and seal lips not
inverted
CAUTION:
PBIC3729E
• Be careful not to damage front timing chain case and
crankshaft.
• Press-fit straight and avoid causing burrs or tilting oil seal.
REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000001381419
REMOVAL
1. Remove transaxle assembly. Refer to TM-210, "Removal and Installation" (A/T), TM-633, "Removal and
Installation" (M/T).
2. Remove clutch cover and clutch disk. Refer to CL-13, "Removal and Installation".
3. Remove flywheel. Refer to EM-100, "Exploded View".
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
EM-78
OIL SEAL
2. Install rear oil seal so that each seal lip is oriented as shown. A
A : Dust seal lip

B : Oil seal lip EM
: Engine outside
: Engine inside
C
PBIC3485J
D
• Press-fit rear oil seal with a drift outer diameter 113 mm (4.45
in) and inner diameter 90 mm (3.54 in) (commercial service E
tool) (A).
CAUTION:
• Be careful not to damage crankshaft and cylinder block. F
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Never touch grease applied onto oil seal lip.
G
PBIC3660E
H
• Press in rear oil seal (1) to the position as shown.
A : Rear end surface of cylinder block I
PBIC3761E
3. After press-fitting rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side. L
EM-79
CYLINDER HEAD
CYLINDER HEAD
PBIC3731E
1. Cylinder head assembly 2. Cylinder head bolt 3. Washer

4. Cylinder head gasket
A. Refer to EM-80
REMOVAL
EURO-OBD).
2. Drain engine coolant and engine oil. Refer to CO-11, "Changing Engine Coolant" and LU-7, "Draining".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant and engine oil on drive belt.
3. Remove the following components and related parts.
• Front fender protector (RH): Refer to EXT-22, "Removal and Installation".
• Generator: Refer to CHG-15, "Removal and Installation".
• Exhaust front tube: Refer to EX-5, "Component".
• Exhaust manifold: Refer to EM-32, "Exploded View".
• Intake manifold: Refer to EM-29, "Exploded View".
• Fuel tube and fuel injector: Refer to EM-35, "Exploded View".
• Water outlet: Refer to CO-24, "Removal and Installation".
• Front cover: Refer to EM-50, "Exploded View".
• Camshaft: Refer to EM-59, "Exploded View".
4. Remove cylinder head loosening bolts in reverse order as
shown with cylinder head wrench (commercial service tool).
A : EXH side
B : INT side
: Engine front
PBIC3732E
EM-80
CYLINDER HEAD
5. Remove cylinder head gasket.
A
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening EM
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.
Limit (“d1”–“d2”): 0.15 mm (0.0059 in) C
• If reduction of outer diameter appears in a position other than “d2”,

use it as “d2” point.
D
PBIC3717E E
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-127, "Cylinder F
Block".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION: G
Never allow gasket debris to enter passages for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions. H
A : Straightedge
B : Feeler gauge
I
Limit : Refer to EM-125, "Cylinder Head".

• If it exceeds the limit, replace cylinder head. J
PBIC3207J
K
INSTALLATION
1. Install new cylinder head gasket.
2. Tighten cylinder head bolts in numerical order as shown with the L
following procedure to install cylinder head.
A : EXH side
M
B : INT side
: Engine front
CAUTION: N
If cylinder head bolts are re-used, check their outer diame-
ters before installation. Follow the “Cylinder Head Bolts
Outer Diameter” measurement procedure. PBIC3732E O
a. Apply new engine oil to threads and seating surfaces of mount-
ing bolts.
b. Tighten all bolts. P
: 66.7 N·m (6.8 kg-m, 49 ft-lb)

c. Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
EM-81
CYLINDER HEAD
In this step, loosen bolts in reverse order of that indicated.
d. Tighten all bolts.
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
e. Turn all bolts 75 degrees clockwise (angle tightening).

CAUTION:
Check and confirm the tightening angle by using the angle
wrench [SST: KV10112100] (A) or protractor. Avoid judg-
ment by visual inspection without the tool.
f. Turn all bolts 75 degrees clockwise again (angle tightening).
PBIC3733E

• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
Exhaust gases — Leakage —
Disassembly and Assembly INFOID:0000000001381422
EM-82
CYLINDER HEAD
EM
H
PBIC3734E
1. Spark plug 2. Valve collet 3. Valve spring retainer

4. Valve spring 5. Valve spring seat 6. Valve oil seal I
7. Valve guide (EXH) 8. Valve guide (INT) 9. Cylinder head
10. Valve seat (EXH) 11. Valve (EXH) 12. Valve seat (INT)
13. Valve (INT) J
A. Refer to EM-82 B. Refer to EM-82
DISASSEMBLY K
1. Remove spark plug with a spark plug wrench (commercial service tool).
• Identify installation positions, and store them without mixing them up. L
• Compress valve spring with the valve spring compressor, the
attachment and the adapter [SST: KV10116200] (A). Remove M
CAUTION:
N
PBIC3727E
P
4. Remove valve spring retainer and valve spring.
5. Push valve stem to combustion chamber side, and remove valve.
EM-83
CYLINDER HEAD
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902] (A).
PBIC3728E
7. Remove valve spring seat.

8. Remove valve seat, if valve seat must be replaced.
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this.
CAUTION:
Never bore excessively to prevent cylinder head from scratching.
9. Remove valve guide, if valve guide must be replaced.
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
JPBIA0184ZZ
b. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US

ton, 2.0 lmp ton) pressure] or a hammer and the valve guide drift
(commercial service tool).
WARNING:
Cylinder head contains heat. Wear protective equipment to
avoid getting burned.
SEM931C
INSPECTION AFTER DISASSEMBLY

Valve Dimensions
• Check the dimensions of each valve. For the dimensions, refer to EM-125, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. Check “VALVE SEAT
CONTACT”.
Valve Guide Clearance
Valve Stem Diameter
EM-84
CYLINDER HEAD
• Measure the diameter of valve stem with micrometer (A).
A
Standard : Refer to EM-125, "Cylinder Head".
Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge. EM

C
• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) PBIC3213J
D
Standard and Limit : Refer to EM-125, "Cylinder Head".
• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
E
replaced, use “VALVE GUIDE REPLACEMENT”.
Valve Seat Contact
• After confirming that the dimensions of valve guides and valves are F
within the specifications, perform this procedure.
• Apply prussian blue (or white lead) 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- G
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace H
valve seat. Refer to EM-82, "Disassembly and Assembly".
A : OK
B : NG
JPBIA0187ZZ
I
Valve Spring Squareness

• Set a try square (A) along the side of valve spring and rotate J
spring. Measure the maximum clearance between the top of spring
and try square.
B : Contact K
Limit : Refer to EM-125, "Cylinder Head".

L
• If it exceeds the limit, replace valve spring.
PBIC3219J M
Valve Spring Dimensions and Valve Spring Pressure Load
• Check the valve spring pressure at specified spring height.
N
• If the installation load or load with valve open is out of the stan-
dard, replace valve spring. O
SEM113
ASSEMBLY
1. When valve guide is removed, install it.
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide.
EM-85
CYLINDER HEAD
a. Using the valve guide reamer (commercial service tool) (A),
ream cylinder head valve guide hole.
For service parts: Oversized [0.2 mm (0.008 in)]

Refer to EM-125, "Cylinder Head".
PBIC3215J
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
PBIC3214J
c. Using the valve guide drift (commercial service tool), press valve
guide (1) from camshaft side to the dimensions as shown.
Projection “H”: Refer to EM-125, "Cylinder Head".

WARNING:
Cylinder head (2) contains heat. Wear protective equipment
to avoid getting burned.
PBIC3217J
d. Using the valve guide reamer (commercial service tool) (A),

apply reamer finish to valve guide.
Standard: Refer to EM-125, "Cylinder Head".
PBIC3215J
2. When valve seat is removed, install it.

CAUTION:
Replace with oversize [0.5 mm (0.020 in)] valve seat.
EM-86
CYLINDER HEAD
a. Ream cylinder head recess diameter (a) for service valve seat.
A
For service parts: Oversize [0.5 mm (0.020 in)]
Refer to EM-125, "Cylinder Head".
EM
• Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly.
JPBIA0188ZZ
D
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
E
G
PBIC3214J
c. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head. H
WARNING:
Cylinder head contains heat. Wear protective equipment to avoid getting burned.
CAUTION: I
Avoid directly touching cold valve seats.
d. Using the valve seat cutter set (commercial service tool) or valve
seat grinder, finish seat to the specified dimensions. Refer to J
EM-125, "Cylinder Head".
CAUTION:
When using the valve seat cutter, firmly grip cutter handle
with both hands. Then, press on the contacting surface all K
around the circumference to cut in a single drive. Improper
pressure on with cutter or cutting many different times may
result in stage valve seat. L
SEM934C
M
e. Using compound, grind to adjust valve fitting.
f. Check again for normal contact. Refer to EM-82, "Disassembly and Assembly".
3. Install valve oil seal. N
• Install with the valve oil seal drift [SST: KV10115600] (A) to
match dimension as shown.
O
Height “H” : 13.2 - 13.8 mm (0.520 - 0.543 in)
PBIC3211J
4. Install valve spring seat.

5. Install valve.
• Install larger diameter to intake side.
EM-87
CYLINDER HEAD
6. Install valve spring.
NOTE:
It can be installed in either direction.
7. Install valve spring retainer.
8. Install valve collet.
• Compress valve spring with the valve spring compressor, the
attachment and the adapter [SST: KV10116200] (A). Install
CAUTION:
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
PBIC3727E

10. Install spark plug with a suitable tool.
EM-88
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [HR16DE]
REMOVAL AND INSTALLATION A

ENGINE ASSEMBLY
EM
PBIC3736E
M
1. Engine mounting insulator (LH) 2. Engine mounting bracket (LH) 3. Mass damper
4. Dynamic damper 5. Engine mounting insulator (RH) 6. Engine mounting stay
N
7. Engine mounting bracket (RH) 8. Rear engine mounting bracket 9. Rear torque rod
10. Washer 11. Engine mounting bracket (LH)
A. Front mark B. M/T models
O
WARNING: P
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Never start working until exhaust system and coolant are cool enough.
EM-89
ENGINE ASSEMBLY
• If items or work required are not covered by the engine section, follow the procedures in the applica-
ble sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-48, "Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL
Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
Preparation
1. Remove the hood assembly. Refer to DLK-214, "Removal and Installation".
2. Remove the cowl top cover and cowl top extension assembly. Refer to EXT-20, "Removal and Installa-
tion".
EURO-OBD).
4. Drain engine coolant from radiator. Refer to CO-11, "Changing Engine Coolant".
CAUTION:
• Never spill engine coolant on drive belt.
5. Drain the transmission fluid. Refer to TM-628, "Draining" (M/T models), TM-171, "Changing A/T Fluid" (A/
T models).
• Engine undercover
• Front road wheels and tires: Refer to WT-6, "Rotation".
• Front fender protector (RH and LH): Refer to EXT-22, "Removal and Installation".
• Battery and battery tray: Refer to PG-6, "Removal and Installation".
• Air duct and air cleaner case assembly: Refer to EM-27, "Exploded View".
• Radiator hose (upper and lower): Refer to CO-16, "Component".
• Disconnect cooling fan controller wiring harness.
• Remove coolant reservoir tank.
• Remove fan shroud and cooling fan assembly. Refer to CO-16, "Component".
Engine Room LH
1. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag against foreign materials.
2. Remove ground cable at transaxle side.
3. Disconnect fuel feed hose at engine side. Refer to EM-35, "Exploded View".
4. Disconnect EVAP purge hose and brake booster vacuum hose.
5. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-24,
"Exploded View".
6. Disconnect control linkage from transaxle. Refer to TM-189, "Exploded View" (A/T), TM-630, "Exploded
View" (M/T).
7. Disconnect the clutch tube at transmission side. Refer to CL-12, "Removal and Installation".
Engine Room RH
1. Remove ground cable between front cover and vehicle.
2. Remove generator and generator bracket; Refer to CHG-15, "Removal and Installation".
3. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. (with A/C models) Refer to HA-34, "Removal and Installation of
Compressor - HR16DE".
EM-90
ENGINE ASSEMBLY
Vehicle Underbody
1. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-83, "Removal and A
Installation".
2. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the
vehicle side with a rope to avoid load on it. Refer to BR-24, "Component". EM
3. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-7, "Removal and Installation".
5. Remove rear torque rod. C
NOTE:
A/T models shown.
D
F
PBIC3737E
6. Remove A/T cooler hoses from transmission (A/T models).

7. Preparation for the separation work of transaxle is as follows: G
• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-89, "Exploded
View".
Removal H
1. Install engine slinger to cylinder head front left side (A) and rear
right side (B) and support the engine with a hoist.
I
K
PBIC3738E
2. Lift with a hoist and secure the engine in appropriate position. L

3. Use a suitable tool to securely support bottom of the engine and
the transaxle assembly and simultaneously adjust hoist tension.
CAUTION: M
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
N
O
PBIC3223J
EM-91
ENGINE ASSEMBLY
4. Remove engine mounting insulator (RH) (1), engine mounting
bracket (RH) (2) and engine mounting stay (3).
4 : Engine mounting insulator (LH)

5. Remove engine mounting through bolt-securing nut (A).
JPBIA0512ZZ
6. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly.
CAUTION:
• Make sure that no part interferes with the vehicle side.
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to
changes in the center of gravity.
• If necessary, support the vehicle by setting jack or suitable tool at the rear.
Separation
1. Remove starter motor. Refer to STR-13, "Removal and Installation".
2. Lift with a hoist and separate the engine from the transaxle assembly. Refer to EM-89, "Exploded View".
INSTALLATION
• Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insu-
lator.
• Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
• Tighten engine mounting insulator (RH) bolts in the numerical
order shown.
: Vehicle front
JPBIA0280ZZ

EM-92
ENGINE ASSEMBLY
Items Before starting engine Engine running After engine stopped A
EM

Exhaust gases — Leakage — C
EM-93
ENGINE STAND SETTING
< DISASSEMBLY AND ASSEMBLY > [HR16DE]
DISASSEMBLY AND ASSEMBLY

Setting INFOID:0000000001381427
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-89, "Exploded View".
2. Remove clutch cover and clutch disc. Refer to CL-13, "Removal and Installation".
3. Remove flywheel.
• Secure flywheel with a stopper plate [SST: KV11105210], and remove mounting bolts.
CAUTION:
• Never disassemble flywheel.
• Never place flywheel with signal plate facing down.
• When handling signal plate, take care not to damage or scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
4. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Intake manifold: Refer to EM-29, "Exploded View".
- Exhaust manifold: Refer to EM-32, "Exploded View".
- Rocker cover: Refer to EM-47, "Exploded View".
NOTE:
The figure shows an example of widely use engine stand that
can support mating surface of transaxle with flywheel removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
PBIC0085E

6. Drain engine coolant by removing water drain plug (1) from
inside of the engine.
: Engine front
PBIC3742E
EM-94
ENGINE UNIT
ENGINE UNIT
A
Disassembly INFOID:0000000001381428
1. Remove intake manifold. Refer to EM-29, "Exploded View". EM

2. Remove exhaust manifold. Refer to EM-32, "Exploded View".
3. Remove oil pan (lower). Refer to EM-40, "Exploded View".
4. Remove ignition coil, spark plug and rocker cover. Refer to EM-47, "Exploded View". C
5. Remove fuel injector and fuel tube. Refer to EM-35, "Exploded View".
6. Remove timing chain. Refer to EM-50, "Exploded View".
D
7. Remove camshaft. Refer to EM-59, "Exploded View".
8. Remove cylinder head. Refer to EM-80, "Removal and Installation".
Assembly INFOID:0000000001381429 E
Assembly is the reverse order of disassembly.

F
EM-95
OIL PAN (UPPER)
OIL PAN (UPPER)
JPBIA0553GB

NOTE:
The oil strainer and oil pump are included in the oil pan (upper). Individual disassembly is prohibited.
REMOVAL
1. Remove the oil pan (lower). Refer to EM-40, "Exploded View".
2. Remove front cover and timing chain. Refer to EM-50, "Exploded View".
3. Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain. Refer to EM-50,
"Exploded View".
4. Remove oil pan (upper) with the following procedure.
EM-96
OIL PAN (UPPER)
a. Loosen oil pan (upper) mounting bolts in the reverse of the order
shown in the figure. A
: Engine front
EM
MBIB1374E
D
b. Insert a flat-bladed offset screwdriver into the arrow ( ) in the
figure and open up a crack between the oil pan (upper) cylinder
block. E
: Engine front
c. Insert the seal cutter [SST: KV10111100] between remove the oil F
pan (upper) and cylinder block. Slide seal cutter by tapping on
the side of tool with a hammer.
CAUTION: G
• Be careful not to damage the mating surface. MBIB1375E
vious types when shipped, so it should not be forced off using a screwdriver, etc. outside the
indicated location. H
• Never remove oil pump and oil strainer from oil pan (upper).
5. Remove oil level sensor, if necessary.
6. Remove rear oil seal from crankshaft. I
INSTALLATION
1. Install the oil pan (upper) in the following procedure. J
• Also remove the old liquid gasket from mating surface of cylinder block.
• Remove old liquid gasket from the bolt holes and threads. K
CAUTION:
Never scratch or damage the mating surfaces when cleaning off old liquid gasket.
b. Install O-ring to the cylinder block.
L
EM-97
OIL PAN (UPPER)
c. Apply a continuous bead of liquid gasket (C) with the tube
presser (commercial service tool) to areas shown.
A : 2 mm (0.08 in) protruded to outside

B : 2 mm (0.08 in) protruded to rear oil seal mounting side
: Engine front
: Oil pan out side
CAUTION:
Attaching should be done within 5 minutes after coating.
PBIC4344E
d. Tighten bolts in the numerical order shown in the figure.
: Engine front
CAUTION:
Install avoiding misalignment of both oil pan gasket and O-
ring.
• The bolts are different according to the installation position.
Follow the numbers shown.
M8 × 179 mm (7.05 in) : No. 9, 10

MBIB1374E
M8 × 25 mm (0.98 in) : No. 4, 7, 8
M8 × 90 mm (3.54 in) : No. 1, 2, 3, 5, 6
2. Install rear oil seal.

CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Never touch oil seal lip.
a. Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a spatula.
b. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial
service tool) (A).
PBIC3660E
EM-98
OIL PAN (UPPER)
• Press-fit to the dimensions specified in the figure.
A
1. Rear oil seal
A. Rear end surface of cylinder block
CAUTION: EM
• Never touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part
of oil pan (upper) and cylinder block or the crankshaft. C
• Press-fit straight make sure that oil seal does not curl or
tilt.
PBIC3761E
d. After press-fitting the rear oil seal, completely wipe off any liquid
D
gasket protruding to rear end surface side.
3. Install crankshaft sprocket, oil pump sprocket, oil pump drive chain, and chain tensioner. Refer to EM-50,
"Removal and Installation".
E
4. Install timing chain and related parts. Refer to EM-50, "Removal and Installation".
5. Install front cover and related parts. Refer to EM-50, "Removal and Installation".
6. Install in the reverse order of removal, for the rest of parts. F
CAUTION:
Pour engine oil at least 30 minutes after oil pan is installed.
Inspection INFOID:0000000001381432 G

1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection". H
2. Start engine, and check there is no leak of engine oil.
4. Check the engine oil level again. Refer to LU-6, "Inspection". I
EM-99
CYLINDER BLOCK
CYLINDER BLOCK
AWBIA0153GB
1. Crankshaft position sensor (POS) cover 2. Crankshaft position sensor (POS) 3. O-ring
4. Water drain plug 5. Cylinder block 6. Oil level gauge
7. Oil level gauge guide 8. O-ring 9. Knock sensor
EM-100
CYLINDER BLOCK
10. Oil pressure switch 11. Top ring 12. Second ring
13. Oil ring 14. Piston pin 15. Piston A
16. Connecting rod 17. Connecting rod bearing (upper) 18. Main bearing (upper)
19. Thrust bearing 20. Crankshaft key 21. Connecting rod cap bolt
22. Connecting rod cap 23. Connecting rod bearing (lower) 24. Main bearing (lower) EM
25. Crankshaft 26. Signal plate 27. Rear oil seal
28. Flywheel 29. Main bearing cap bolt 30. Main bearing cap
A. Refer to EM-101 C
D
DISASSEMBLY
1. Remove oil pan (upper). Refer to EM-96, "Removal and Installation".
2. Remove cylinder head. Refer to EM-80, "Removal and Installation". E
3. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks. F
4. Remove crankshaft position sensor (POS) and cover.
CAUTION:
• Avoid impacts such as a dropping. G
• Keep it away from metal particles.
• Never place the sensor where it is exposed to magnetism.
H
5. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-108, "Inspection". I
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connect- J
ing rod assembly out to the cylinder head side.
CAUTION:
• Be careful not to damage matching surface with connect- K
ing rod cap.
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
L
big end.
M
KBIA3365J
6. Remove connecting rod bearings.

CAUTION: N
Identify installation positions, and store them without mixing up.
7. Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-108, "Inspection". O
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
the piston. P
• Be careful not to damage piston rings by expanding
them excessively.
PBIC3233J
EM-101
CYLINDER BLOCK
8. Remove piston from connecting rod.
• Use a piston pin press stand (SST) and a press to remove the
piston pin.
A : Drift [KV10109730]
B : Center cap [KV10110310]
C : Press stand [ST13030020]
CAUTION:
Be careful not to damage the piston and connecting rod.
NOTE:
The joint between the connecting rod and the piston pin is a
press fit. PBIC5270J
9. Remove the main bearing cap in the following procedure.

• Measure crankshaft end play before loosening main bearing cap bolts. Refer to EM-108, "Inspection"
a. Loosen and remove bolts in several steps in reverse of the
numerical order shown in the figure.
: Engine front
• TORX socket (size: E14) can be used.
PBIC3744E
b. Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer.
10. Remove crankshaft (2).

CAUTION:
• Be careful not damage or deform signal plate (1) mounted
on crankshaft.
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket (size
T40).
PBIC3745E
11. Pull rear oil seal out from rear end of crankshaft.
12. Remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing cap.
CAUTION:
Identify installation positions, and store them without mixing up.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect eyes.
EM-102
CYLINDER BLOCK
2. Install water drain plug (1) to cylinder block as shown in the fig-
ure. A
: Engine front
Use Genuine Liquid Gasket or equivalent. EM
PBIC3742E
D
3. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block.
b. Install thrust bearings to the both sides of the No. 3 journal hous- E
ing (B) on cylinder block.
: Engine front F
• Install thrust bearings with the oil groove (A) facing crankshaft
arm (outside).
G
PBIC3258J H
c. Install the main bearings (1) paying attention to the direction.

• Install the one with oil holes (A) onto cylinder block and the I
one without oil holes onto main bearing cap.
• Before installing main bearings, apply new engine oil to the
bearing surface (inside). Do not apply engine oil to the back
surface, but thoroughly clean it. J
• Ensure the oil holes on cylinder block and those on the corre-
sponding bearing are aligned.
K
PBIC3746E
L
• Install the main bearing in the position shown in the figure.
1 : Cylinder block
M
2 : Main bearing (upper)
3 : Main bearing (lower)
4 : Main bearing cap N
: Engine front
NOTE:
Install the main bearing in the center position with the following O
dimension. For service operation, the center position can be PBIC3747E
checked visually.
P
Journal position No. 1 No. 2 No. 3 No. 4 No. 5

1.65–2.05 1.25–1.65 2.30–2.70 1.25–1.65 1.60–2.00
L1 [Unit: mm (in)]
(0.065-0.081) (0.049-0.065) (0.091-0.106) (0.049-0.065) (0.063-0.079)
1.30–1.70 1.30–1.70 2.30–2.70 1.30–1.70 1.30–1.70
L2 [Unit: mm (in)]
(0.051-0.067) (0.051-0.067) (0.091-0.106) (0.051-0.067) (0.051-0.067)
EM-103
CYLINDER BLOCK
CAUTION:
Dimension L1 of journal No. 3 is the distance from the housing base end surface (bulk) (not the
distance from the thrust bearing mounting end surface).
4. Install signal plate to crankshaft if removed.
a. Set the signal plate (1) with the flange facing toward the counter-
weight side (engine front side) to the crankshaft rear surface.
A : Dowel pin hole

b. After positioning crankshaft and signal plate with positioning
dowel pin, tighten bolt.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
c. Remove dowel pin.
PBIC3748E
CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block.
• Make sure that crankshaft turns smoothly by hand.
CAUTION:
Never install rear oil seal yet.
6. Install main bearing caps.
• Install the main bearing cap while referring to the front mark
(B) and the journal number stamp (A).
: Engine front
NOTE:
Main bearing cap cannot be replaced as a single parts,
because it is machined together with cylinder block.
PBIC3749E
7. Tighten main bearing cap bolts in numerical order shown in the

figure with the following steps.
: Engine front
PBIC3744E
a. Apply new engine oil to threads and seat surfaces of the mounting bolts.
b. Tighten main bearing cap bolts.
: 32.4 N·m (3.3 kg-m, 24 ft-lb)
EM-104
CYLINDER BLOCK
c. Turn main bearing cap bolts 60 degrees clockwise (angle tight-
ening) in numerical order shown in the figure. A
CAUTION:
wrench [SST: KV10112100] (A) or protractor. Avoid judg-
EM
PBIC3750E
D
• After installing the mounting bolts, make sure that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-108, "Inspection".
8. Install piston to connecting rod with the following procedure: E
a. Set so that the front mark (A) on the piston head and the cylin-
der number (C) are in the position shown in the figure.
F
B : Oil hole
D : Connecting rod big end grade
NOTE: G
The symbols without notes are for management.
H
JPBIA0537ZZ
b. Press-fit the piston pin using the piston pin press stand (SST). I
A : Drift [KV10109730]
B : Center cap [KV10110310]
J
C : Press stand [ST13030020]
D : Center shaft [KV10114120]
E : Spring [ST13030030]
K
F : For detail
CAUTION:
Press-fit the piston so as not to damage it. L
NOTE:
The joint between the connecting rod and the piston pin is a
press fit.
M
O
PBIC5271J
EM-105
CYLINDER BLOCK
• Press-fit the piston pin (2) from piston surface “A” to the depth
of 2.35 mm (0.092 in).
1 : Connecting rod
: Press-fit direction
• After finishing work, make sure that the piston (3) moves
freely.
PBIC3751E
9. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown in the figure referring
to the piston front mark (B).
A : Oil ring upper or lower rail gap (either of them)

C : Second ring and oil ring spacer gap
D : Top ring gap
• Install second ring with the stamped mark (E) facing upward.
Stamped mark:
Second ring :R PBIC3588J
10. Install connecting rod bearings to connecting rod and connecting rod cap.
• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply engine oil to the back surface, but thoroughly clean it.
• Install the bearing in the center position.
NOTE:
There is no stopper tab.
• Make sure that the oil holes on connecting rod and connecting rod bearing are aligned.
• Install the connecting rod in the dimension shown in the figure.
1 : Connecting rod
2 : Connecting rod bearing (upper)
3 : Connecting rod bearing (lower)
4 : Connecting rod cap
: Engine front
Dimension “A” : 1.7 - 2.1 mm (0.067 - 0.083 in)

PBIC4169E
NOTE:
Install the connecting rod bearing in the center position with the dimension shown in the figure. For ser-
vice operation, the center position can be checked visually.
11. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number on connecting rod to install.
EM-106
CYLINDER BLOCK
• Using the piston ring compressor (SST: EM03470000) (A) or
suitable tool, install piston with the front mark on the piston A
head facing the front of the engine.
CAUTION:
• Be careful not to damage matching surface with con-
EM
necting rod cap.
• Be careful not to damage the cylinder wall and crank-
shaft pin, resulting from an interference of the connect-
ing rod big end. C
PBIC3765E
D
12. Install connecting rod cap.
• Match the stamped cylinder number marks (C) on connecting
rod with those on connecting rod cap to install.
E
A : Front mark
B : Oil hole
D : Connecting rod big end grade F
JPBIA0537ZZ
13. Inspect outer diameter of connecting rod cap bolts. Refer to EM-108, "Inspection". H
14. Tighten connecting rod bolt with the following procedure:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
I
b. Tighten connecting rod bolts in several steps.
: 19.6 N·m (2.0 kg-m, 14 ft-lb) J

c. Then turn all bolts 60 degrees clockwise (angle tightening).
CAUTION:
Confirm the tightening angle by using the angle wrench K
[SST: KV10112100] (A) or protractor. Avoid judgment by
visual inspection without the tool.
L
M
PBIC3753E
• After tightening connecting rod bolts, make sure that crankshaft rotates smoothly. N
• Check the connecting rod side clearance. Refer to EM-108, "Inspection".
15. Install oil pan (upper). Refer to EM-96, "Exploded View".
NOTE:
O
Install the rear oil seal after installing the oil pan (upper).
16. Install rear oil seal. Refer to EM-96, "Removal and Installation".
17. Install flywheel. P
• Secure crankshaft with a stopper plate [SST: KV11105210], and tighten mounting bolts crosswise over
several times.
EM-107
CYLINDER BLOCK
18. Install knock sensor (1).
: Engine front
• Install connectors so that they are positioned towards the rear

of the engine.
CAUTION:
• Never tighten mounting bolt while holding the connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
• Make sure that there is no foreign material on the cylinder PBIC3754E
block mating surface and the back surface of knock sensor.

• Make sure that knock sensor does not interfere with other parts.
19. Install crankshaft position sensor (POS) and cover.
• Tighten bolts with it seated completely.
20. For the oil level gauge guide (1), fix the position (B) shown in the
figure to the water inlet clip (A) after inserting to the cylinder
block side.
PBIC3755E
21. Assemble in the reverse order of disassembly after this step.

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
Standard and Limit : Refer to EM-127, "Cylinder Block".

• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC3762E
CONNECTING ROD SIDE CLEARANCE

• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).
Standard : Refer to EM-127, "Cylinder Block".

• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the standard, replace crank-
shaft also.
PBIC3763E
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
EM-108
CYLINDER BLOCK
Measure the inner diameter of piston pin hole with an inside
micrometer. A

EM
PBIC0116E
D
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer.
Standard : Refer to EM-127, "Cylinder Block". E
G
PBIC0117E
Piston to Piston Pin Oil Clearance H

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
Standard : Refer to EM-127, "Cylinder Block". I

• If oil clearance is out of the standard, replace piston and piston pin assembly.
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring and piston ring groove J
with a feeler gauge.
Standard and Limit : Refer to EM-127, "Cylinder K

Block".
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also. L
M
SEM024AA
PISTON RING END GAP

• Make sure that cylinder bore inner diameter is within the specifica- N
tion. Check "Cylinder Bore Inner Diameter".
• Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and measure
piston ring end gap with a feeler gauge. O
Standard and Limit : Refer to EM-127, "Cylinder

Block". P
• If the measured value exceeds the limit, replace piston ring.
SEM822B
CONNECTING ROD BEND AND TORSION
EM-109
CYLINDER BLOCK
• Check with a connecting rod aligner.
Limit : Refer to EM-127, "Cylinder Block".

• If it exceeds the limit, replace connecting rod assembly.
PBIC2077E
CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to
the specified torque. Refer to EM-101, "Disassembly and Assembly".
• Measure the inner diameter of connecting rod big end with an
inside micrometer.

• If out of the standard, replace connecting rod assembly.
PBIC1641E
CONNECTING ROD SMALL END CLEARANCE

Connecting Rod Small End Inner Diameter
Measure the inner diameter of connecting rod small end with an
inside micrometer.
PBIC0120E
EM-110
CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer.
A
EM
PBIC0117E
D
Connecting Rod Small End Clearance
(Connecting rod small end clearance) = (Connecting rod small end inner diameter) – (Piston pin outer diame-
ter)
E
• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly. F
• If replacing connecting rod assembly, use "CONNECTING ROD BEARING OIL CLEARANCE" to select con-
necting rod bearing.
G
CYLINDER BLOCK TOP SURFACE DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination. H
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some I
different points in six directions with a straight edge and a feeler
gauge.
Limit : Refer to EM-127, "Cylinder Block". J
• If it exceeds the limit, replace cylinder block.

K
PBIC0121E
L
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified
torque. Refer to EM-101, "Disassembly and Assembly". M
• Measure the position shown in the figure [5 mm (0.196 in) rear-
ward from main bearing housing front side end surface) in the 2
directions as shown in the figure. The smaller one is the measured
N
value.
1 : Cylinder block
2 : Main bearing cap O
: Engine front
P
Standard : Refer to EM-127, "Cylinder Block". PBIC3879E
• If out of the standard, replace cylinder block and main bearing

caps as an assembly.
NOTE:
These components cannot be replaced as a single unit, because they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
EM-111
CYLINDER BLOCK
Cylinder Bore Inner Diameter
• Using a bore gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of
the engine)
A : Unit: mm (in)
NOTE:
When determining cylinder bore grade, measure cylinder bore at
“B” position.
Standard: PBIC3767E
Cylinder bore inner diameter

: Refer to EM-127, "Cylinder Block".
Limit:
Out-of-round (Difference between“X”and“Y”)
Taper (Difference between“A”and“B”
: Refer to EM-127, "Cylinder Block".
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
NOTE:
There is no service setting for oversized piston.
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer.
PBIC0125E
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)
Standard and Limit : Refer to EM-127, "Cylinder Block".

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block.
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a
micrometer (A).

• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing.
PBIC3457J
EM-112
CYLINDER BLOCK
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a micrometer. A

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. EM
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

• Measure the dimensions at four different points as shown in the
C
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in dimensions between
“X” and “Y” at “A” and “B”.
• Taper is indicated by the difference in dimension between “A” and D
“B” at “X” and “Y”.
Limit: E
Out-of-round (Difference between“X”and“Y”)
Taper (Difference between“A”and“B”)
PBIC3459J
: Refer to EM-127, "Cylinder Block". F
• If the measured value exceeds the limit, correct or replace crankshaft.

• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. G
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on H
the both end of crankshaft.
• Place a dial indicator (A) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading) I

• If it exceeds the limit, replace crankshaft. J
PBIC3458J
K
CONNECTING ROD BEARING OIL CLEARANCE
Method by Calculation
L
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-101, "Disassembly and Assembly".
• Measure the inner diameter of connecting rod bearing with an
inside micrometer. M
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)
N
Standard and Limit
: Refer to EM-130, "Connecting Rod Bearing".
• If the clearance exceeds the limit, select proper connecting rod O
bearing according to connecting rod big end diameter and crank-
shaft pin journal diameter to obtain the specified bearing oil clear-
PBIC1642E
ance. Refer to EM-117, "Connecting Rod Bearing". P
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
torque. Refer to EM-101, "Disassembly and Assembly".
CAUTION:
EM-113
CYLINDER BLOCK
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC1149E
MAIN BEARING OIL CLEARANCE

• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the spec-
ified torque. Refer to EM-101, "Disassembly and Assembly".
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
Standard : Refer to EM-131, "Main Bearing".

• If the clearance exceeds the limit, select proper main bearing
according to main bearing inner diameter and crankshaft main
journal diameter to obtain the specified bearing oil clearance.
Refer to EM-119, "Main Bearing".
PBIC1644E

• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the spec-
ified torque. Refer to EM-101, "Disassembly and Assembly".
CAUTION:
• Remove main bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
PBIC1149E
MAIN BEARING CRUSH HEIGHT
EM-114
CYLINDER BLOCK
• When main bearing cap is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing A
must protrude. Refer to EM-101, "Disassembly and Assembly".
Standard: There must be crush height. EM

• If the standard is not met, replace main bearings.
SEM502G
D
CONNECTING ROD BEARING CRUSH HEIGHT
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-101, "Disassembly E
and Assembly".
Standard: There must be crush height. F

• If the standard is not met, replace connecting rod bearings.
PBIC1646E
MAIN BEARING CAP BOLT OUTER DIAMETER H

• Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
• If reduction appears in a position other than “d2 ”, regard it as “d2”.
I
Limit (“d1”–“d2”): 0.2 mm (0.008 in)
• If it exceeds the limit (a large difference in dimensions), replace J
main bearing cap bolt with a new one.
K
PBIC3768E
CONNECTING ROD CAP BOLT OUTER DIAMETER

• Measure the outer diameter “d” at position as shown in the figure. L
• If reduction appears in a position other than “d”, regard it as “d”.
Limit: 7.75 mm (0.3051 in) M

• When “d” falls below the limit (when it becomes thinner), replace
connecting rod cap bolt with a new one.
N
PBIC3769E
O
FLYWHEEL DEFLECTION
P
EM-115
CYLINDER BLOCK
• Measure the deflection of flywheel contact surface to clutch with a
dial indicator.
Standard : 0.25 mm (0.0098 in) or less.

• If measured value is out of the standard, replace flywheel.
PBIC2646E
EM-116
HOW TO SELECT PISTON AND BEARING
A
Description INFOID:0000000001381436
EM
Selection points Selection parts Selection items Selection methods
Determined by match of cylin-
der block bearing housing
C
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal) D
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
E
rod bearing selection.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts. F
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the G
selective fitting parts, follow the procedures.
Connecting Rod Bearing INFOID:0000000001381437
H
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
1. Apply connecting rod big end diameter grade stamped (C) on
connecting rod side face to the row in the “Connecting Rod I
Bearing Selection Table”.
A : Oil hole J
B : Cylinder number
D : Front mark
K
PBIC3756E
L
2. Apply crankshaft pin journal diameter grade stamped (B) on
crankshaft front side to the column in the “Connecting Rod Bear-
ing Selection Table”. M
A : Main journal diameter grade (No. 1 to 5 from left)

B : Crankshaft pin journal diameter grade (No. 1 to 4 from left) N
O
PBIC3757E
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection P
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-108, "Inspection".
EM-117
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
Connecting Rod Bearing Selection Table
PBIC3758E
Connecting Rod Bearing Grade Table
Connecting Rod Bearing Grade Table : Refer to EM-130, "Connecting Rod Bearing".
Undersize Bearings Usage Guide
• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
EM-118
In grinding crankshaft pin to use undersize bearings, keep the
fillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)]. A
Bearing undersize table:

Refer to EM-130, "Connecting Rod Bearing". EM
PBIC3263J
D
Main Bearing INFOID:0000000001381438
HOW TO SELECT MAIN BEARING E

When New Cylinder Block and Crankshaft Are Used
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on left side of cylinder block. F
A : Basic stamp mark

: Engine front G
• If there is a corrected stamp mark (B) on cylinder block, use it
as a correct reference.
H
PBIC3760E
I
2. Apply main journal diameter grade stamped on crankshaft front
side to column in the “Main Bearing Selection Table”.
J
A : Main journal diameter grade (No. 1 to 5 from left)
B : Crankshaft pin journal diameter grade (No. 1 to 4 from left)
K
L
PBIC3757E
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”. M
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower. N
When Cylinder Block and Crankshaft Are Reused
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-108, "Inspection". O
2. Apply the measured dimension to the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
P
EM-119
Main Bearing Selection Table
PBIC3759E
Main Bearing Grade Table
Main Bearing Grade Table : Refer to EM-131, "Main Bearing".

Use Undersize Bearing Usage Guide
• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
EM-120
In grinding crankshaft main journal to use undersize bearings,
keep fillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)]. A
Bearing undersize table:

Refer to EM-131, "Main Bearing". EM
PBIC3263J
EM-121
SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [HR16DE]

General Specification INFOID:0000000001381439
GENERAL SPECIFICATIONS
Engine type HR16DE

Cylinder arrangement In-line 4
Displacement cm3 (cu in) 1,598 (97.51)

Bore and stroke mm (in) 78.0 x 83.6 (3.071 x 3.291)
Valve arrangement DOHC
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1
Number of main bearings 5
Compression ratio 10.7
Standard 1,510 (15.1, 15.4, 219)
Compression pressure
Minimum 1,265 (12.65, 12.9, 183)
kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 6.2 (0.06, 0.06, 0.9)
Valve timing
(Intake valve timing control - “ON”)
JPBIA0552ZZ
Unit: degree
a b c d e f
208 228 -11 (24) 59 (24) 4 24
Drive Belts INFOID:0000000001381440
BELT DEFLECTION:
Deflection adjustment * Unit: mm (in)

Location Used belt
New belt
Limit After adjusted
With A/C models 7.9 (0.31) 4.8 - 5.3 (0.19 - 0.21) 4.2 - 4.5 (0.17 - 0.18)
Drive belt
Without A/C models 7.1 (0.28) 4.3 - 4.7 (0.17 - 0.19) 3.6 - 3.9 (0.14 - 0.15)
Applied pushing force 98 N (10 kg, 22 lb)
*: When engine is cold.
BELT TENSION AND FREQUENCY:
EM-122
Tension adjustment * Unit: N (kg, lb) Frequency adjustment * Unit: Hz A

Location Used belt Used belt
New belt New belt
Limit After adjusted Limit After adjusted
EM
876 - 964 1064 - 1152
With A/C models 500 (51.0, 112) (89.4 - 98.3, (108.5 - 117.5, 163 216 - 225 238 - 246
197 - 217) 239 - 259)
Drive belt C
876 - 964 1064 - 1152
Without A/C models 500 (51.0, 112) (89.4 - 98.3, (108.5 - 117.5, 183 242 - 252 266 - 276
197 - 217) 239 - 259)
*: When engine is cold. D
Spark Plug INFOID:0000000001381441
E
SPARK PLUG (PLATINUM-TIPPED TYPE)
Unit: mm (in)
Make NGK F
Standard type PLZKAR6A-11
Gap (Nominal) 1.1 (0.043)
G
Exhaust Manifold INFOID:0000000001381442
EXHAUST MANIFOLD H
Unit: mm (in)
Items Limit
Surface distortion Exhaust manifold 0.3 (0.012) I
Camshaft INFOID:0000000001381443
J
CAMSHAFT
Unit: mm (in)
Items Standard Limit K

Camshaft runout [TIR*] 0.02 (0.0008) 0.1 (0.004)
SEM671
O
Intake 41.705 - 41.895 (1.6419 - 1.6494) —
Camshaft cam height “A”
Exhaust 40.175 - 40.365 (1.5817 - 1.5892) —
P
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal diameter
No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9831) —
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —
No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028)
EM-123
Items Standard Limit
Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.2 (0.008)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
*: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Valve lifter outer diameter 29.977 - 29.987 (1.1802 - 1.1806)
Valve lifter hole diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)
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
Thickness mm (in) Identification mark
KBIA0119E
3.00 (0.1181) 300

3.02 (0.1189) 302
3.04 (0.1197) 304
3.06 (0.1205) 306
3.08 (0.1213) 308
3.10 (0.1220) 310
3.12 (0.1228) 312
3.14 (0.1236) 314
3.16 (0.1244) 316
3.18 (0.1252) 318
3.20 (0.1260) 320
3.22 (0.1268) 322
3.24 (0.1276) 324
3.26 (0.1283) 326
3.28 (0.1291) 328
3.30 (0.1299) 330
3.32 (0.1307) 332
EM-124
A
3.34 (0.1315) 334
3.36 (0.1323) 336
3.38 (0.1331) 338 EM
3.40 (0.1339) 340
3.42 (0.1346) 342
3.44 (0.1354) 344 C
3.46 (0.1362) 346
3.48 (0.1370) 348
D
3.50 (0.1378) 350
Cylinder Head INFOID:0000000001381444

E
CYLINDER HEAD
Unit: mm (in)
Items Standard Limit F
Head surface distortion — 0.1 (0.004)
Normal cylinder head height “H” 125.0 (4.92) —
G
PBIC0924E
VALVE DIMENSIONS K
Unit: mm (in)
PBIC3878E
O
Valve head diameter “D” Intake 31.0 - 31.3 (1.220 - 1.232)

Exhaust 25.3 - 25.6 (0.996 - 1.008) P
Intake 101.65 (4.002)
Valve length “a”
Exhaust 102.46 (4.034)
Intake
“b” 1.0 (0.039)
Exhaust
EM-125
Intake 2.1 - 2.8 (0.083 - 0.110)
“c”
Exhaust 2.3 - 3.0 (0.091 - 0.118)
Intake 3.0 (0.118)
“c′”
Exhaust –
Intake 4.965 - 4.980 (0.1955 - 0.1961)
Valve stem diameter “d ”
Exhaust 4.955 - 4.970 (0.1951 - 0.1957)
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
VALVE GUIDE
Unit: mm (in)
PBIC2187E
Items Standard Oversize (service) [0.2 (0.008)]

Outer diameter 9.023 - 9.034 (0.3552 - 0.3557) 9.223 - 9.234 (0.3631 - 0.3635)
Valve guide
Inner diameter (Finished size) 5.000 - 5.018 (0.1969 - 0.1976)
Cylinder head valve guide hole diameter 8.975 - 8.996 (0.3533 - 0.3542) 9.175 - 9.196 (0.3612 - 0.3620)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021)
Valve guide clearance 0.1 (0.004)
Exhaust 0.030 - 0.063 (0.0012 - 0.0025)
Projection length “H” 11.4 - 11.8 (0.449 - 0.465)
VALVE SEAT
Unit: mm (in)
PBIC2745E
Items Standard Oversize (service) [0.5 (0.02)]

Cylinder head seat recess diameter “D” Intake 31.400 - 31.416 (1.2362 - 1.2368) 31.900 - 31.916 (1.2559 - 1.2565)
Exhaust 25.900 - 25.916 (1.0197 - 1.0203) 26.400 - 26.416 (1.0394 - 1.0400)
Intake 31.497 - 31.513 (1.2400 - 1.2407) 31.997 - 32.013 (1.2597 - 1.2604)
Valve seat outer diameter “d”
Exhaust 25.997 - 26.013 (1.0235 - 1.0241) 26.497 - 26.513 (1.0432 - 1.0438)
EM-126
Intake
Valve seat interference fit 0.081 - 0.113 (0.0032 - 0.0044) A
Exhaust
Intake 29.0 (1.142)
Diameter “d1”*1
Exhaust 23.0 (0.906) EM
Intake 30.6 - 30.8 (1.205 - 1.213)
Diameter “d2”*2
Exhaust 24.9 - 25.1 (0.980 - 0.988)
Intake 60° C
Angle “α1”
Exhaust 45°
Intake
Angle “α2” 89°45′ - 90°15′ D
Exhaust
Intake
Angle “α3” 120°
Exhaust E
Intake 1.05 - 1.35 (0.0413 - 0.0531)
Contacting width “W”*3
Exhaust 1.25 - 1.55 (0.0492 - 0.0610)
F
Intake 5.45 (0.215)
Height “h” 6.0 (0.236)
Exhaust 5.43 (0.214)
Depth “H” 6.0 (0.236) G
*1 : Diameter made by intersection point of conic angles α1 and α2
*2 : Diameter made by intersection point of conic angles α2 and α3
H
*3 : Machining data
VALVE SPRING
I
Items Standard
Free height 42.26 mm (1.6638 in)
J
Installation height 32.40 mm (1.2756 in)
Installation load 136 - 154 N (13.9 - 15.7 kg, 31 - 35 lb)
Height during valve open 23.96 mm (0.9433 in) K
Load with valve open 262 - 296 N (26.7 - 30.2 kg, 59 - 67 lb)
Items Limit L
Valve spring squareness 1.8 mm (0.071 in)
Cylinder Block INFOID:0000000001381445 M
CYLINDER BLOCK
Unit: mm (in) N
PBIC3924E
Cylinder block top surface distortion Limit 0.1 (0.004)
EM-127
Cylinder bore inner diameter Standard 78.000 - 78.015 (3.0709 - 3.0715)
Out-of-round 0.015 (0.0006)
Limit
Taper 0.010 (0.0004)
Grade No. A 51.997 - 51.998 (2.0471 - 2.0472)
Grade No. B 51.998 - 51.999 (2.0472 - 2.0472)
Grade No. C 51.999 - 52.000 (2.0472 - 2.0472)
Grade No. D 52.000 - 52.001 (2.0472 - 2.0473)
Grade No. E 52.001 - 52.002 (2.0473 - 2.0473)
Grade No. F 52.002 - 52.003 (2.0473 - 2.0474)
Grade No. G 52.003 - 52.004 (2.0474 - 2.0474)
Grade No. H 52.004 - 52.005 (2.0474 - 2.0474)
Grade No. J 52.005 - 52.006 (2.0474 - 2.0475)
Grade No. K 52.006 - 52.007 (2.0475 - 2.0475)
Cylinder block main bearing housing inner diameter grade
Grade No. L 52.007 - 52.008 (2.0475 - 2.0476)
Grade No. M 52.008 - 52.009 (2.0476 - 2.0476)
Grade No. N 52.009 - 52.010 (2.0476 - 2.0476)
Grade No. P 52.010 - 52.011 (2.0476 - 2.0477)
Grade No. R 52.011 - 52.012 (2.0477 - 2.0477)
Grade No. S 52.012 - 52.013 (2.0477 - 2.0478)
Grade No. T 52.013 - 52.014 (2.0478 - 2.0478)
Grade No. U 52.014 - 52.015 (2.0478 - 2.0478)
Grade No. V 52.015 - 52.016 (2.0478 - 2.0479)
Grade No. W 52.016 - 52.017 (2.0479 - 2.0479)
Difference in inner diameter between cylinders Standard Less than 0.015 (0.0006)
AVAILABLE PISTON
Unit: mm (in)
PBIC0188E
Item Standard Limit

Piston skirt diameter “A” 77.965 - 77.980 (3.0695 - 3.0701) —
Measure point “H” 37.1 (1.461) —
Piston pin hole diameter 19.006 - 19.012 (0.7483 - 0.7485) —
Piston to cylinder bore clearance 0.020 - 0.050 (0.0008 - 0.0020) 0.09 (0.0035)
PISTON RING
Unit: mm (in)
Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)
Piston ring side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil (rail ring) 0.045 - 0.125 (0.0018 - 0.0049) —
Top 0.20- 0.30 (0.0079 - 0.0118) 0.50 (0.0197)
Piston ring end gap 2nd 0.35 - 0.50 (0.0138 - 0.0197) 0.66 (0.0260)
Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.92 (0.0362)
PISTON PIN
EM-128
Unit: mm (in)
Piston pin outer diameter 18.996 - 19.002 (0.7479 - 0.7481) A

Piston to piston pin oil clearance Standard 0.008 - 0.012 (0.0003 - 0.0005)
CONNECTING ROD EM
Unit: mm (in)
Center distance 129.84 - 129.94 (5.11 - 5.12)

Bend [per 100 (3.94)] Limit 0.15 (0.0059) C
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod small end clearance Standard –0.018 - –0.044 (–0.0007 - –0.0017)
D
Connecting rod small end inner diameter Standard 18.958 - 18.978 (0.7464 - 0.7472)
Connecting rod side clearance Standard 0.200 - 0.352 (0.0079 - 0.0139)
Grade No. A 43.000 - 43.001 (1.6929 - 1.6929) E
Grade No. B 43.001 - 43.002 (1.6929 - 1.6930)
Grade No. C 43.002 - 43.003 (1.6930 - 1.6930)
Grade No. D 43.003 - 43.004 (1 6930 - 1.6931)
Grade No. E 43.004 - 43.005 (1.6931 - 1.6931) F
Grade No. F 43.005 - 43.006 (1.6931 - 1.6931)
Connecting rod big end diameter Grade No. G 43.006 - 43.007 (1.6931 - 1.6932)
Grade No. H 43.007 - 43.008 (1.6932 - 1.6932)
Grade No. J 43.008 - 43.009 (1.6932 - 1.6933)
G
Grade No. K 43.009 - 43.010 (1.6933 - 1.6933)
Grade No. L 43.010 - 43.011 (1.6933 - 1.6933)
Grade No. M 43.011 - 43.012 (1.6933 - 1.6934) H
Grade No. N 43.012 - 43.013 (1.6934 - 1.6934)
CRANKSHAFT
Unit: mm (in) I
PBIC3459J
SEM645
Center distance “r” 41.68 - 41.76 (1.6409 - 1.6441) M

Out-of-round Limit 0.003 (0.0001)
Taper Limit 0.004 (0.0002)
N
Runout [TIR*] Limit 0.10 (0.0039)
Standard 0.098 - 0.260 (0.0039 - 0.0102)
Crankshaft end play
Limit 0.35 (0.0138) O
EM-129
Grade No. A 39.971 - 39.970 (1.5737 - 1.5736)
Grade No. B 39.970 - 39.969 (1.5736 - 1.5736)
Grade No. C 39.969 - 39.968 (1.5736 - 1.5735)
Grade No. D 39.968 - 39.967 (1.5735 - 1.5735)
Grade No. E 39.967 - 39.966 (1.5735 - 1.5735)
Grade No. F 39.966 - 39.965 (1.5735 - 1.5734)
Grade No. G 39.965 - 39.964 (1.5734 - 1.5734)
Grade No. H 39.964 - 39.963 (1.5734 - 1.5733)
Grade No. J 39.963 - 39.962 (1.5733 - 1.5733)
Crankshaft pin journal diameter grade. “Dp”
Grade No. K 39.962 - 39.961 (1.5733 - 1.5733)
Grade No. L 39.961 - 39.960 (1.5733 - 1.5732)
Grade No. M 39.960 - 39.959 (1.5732 - 1.5732)
Grade No. N 39.959 - 39.958 (1.5732 - 1.5731)
Grade No. P 39.958 - 39.957 (1.5731 - 1.5731)
Grade No. R 39.957 - 39.956 (1.5731 - 1.5731)
Grade No. S 39.956 - 39.955 (1.5731 - 1.5730)
Grade No. T 39.955 - 39.954 (1.5730 - 1.5730)
Grade No. U 39.954 - 39.953 (1.5730 - 1.5729)
Grade No. A 47.979 - 47.978 (1.8889 - 1.8889)
Grade No. B 47.978 - 47.977 (1.8889 - 1.8889)
Grade No. C 47.977 - 47.976 (1.8889 - 1.8888)
Grade No. D 47.976 - 47.975 (1.8888 - 1.8888)
Grade No. E 47.975 - 47.974 (1.8888 - 1.8887)
Grade No. F 47.974 - 47.973 (1.8887 - 1.8887)
Grade No. G 47.973 - 47.972 (1.8887 - 1.8887)
Grade No. H 47.972 - 47.971 (1.8887 - 1.8886)
Grade No. J 47.971 - 47.970 (1.8886 - 1.8886)
Grade No. K 47.970 - 47.969 (1.8886 - 1.8885)
Crankshaft main journal diameter grade. “Dm”
Grade No. L 47.969 - 47.968 (1.8885 - 1.8885)
Grade No. M 47.968 - 47.967 (1.8885 - 1.8885)
Grade No. N 47.967 - 47.966 (1.8885 - 1.8884)
Grade No. P 47.966 - 47.965 (1.8884 - 1.8884)
Grade No. R 47.995 - 47.964 (1.8884 - 1.8883)
Grade No. S 47.994 - 47.963 (1.8883 - 1.8883)
Grade No. T 47.963 - 47.962 (1.8883 - 1.8883)
Grade No. U 47.962 - 47.961 (1.8883 - 1.8882)
Grade No. V 47.961 - 47.960 (1.8882 - 1.8882)
Grade No. W 47.960 - 47.959 (1.8882 - 1.8881)
Connecting Rod Bearing INFOID:0000000001381446
CONNECTING ROD BEARING GRADE TABLE

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

0 1.498 - 1.501 (0.0590 - 0.0591) Black
1 1.501 - 1.504 (0.0591 - 0.0592) Brown
Grade and color are the same
2 1.504 - 1.507 (0.0592 - 0.0593) Green
for upper and lower bearings.
3 1.507 - 1.510 (0.0593 - 0.0594) Yellow
4 1.510 - 1.513 (0.0594 - 0.0596) Blue
UPR 1.498 - 1.501 (0.0590 - 0.0591) Black
01
LWR 1.501 - 1.504 (0.0591 - 0.0592) Brown
UPR 1.501 - 1.504 (0.0591 - 0.0592) Brown
12 Grade and color are different
LWR 1.504 - 1.507 (0.0592 - 0.0593) Green for upper and lower bearings.
UPR 1.504 - 1.507 (0.0592 - 0.0593) Green
23
LWR 1.507 - 1.510 (0.0593 - 0.0594) Yellow
UPR 1.507 - 1.510 (0.0593 - 0.0594) Yellow
34
LWR 1.510 - 1.513 (0.0594 - 0.0596) Blue
EM-130
UNDERSIZE TABLE
Unit: mm (in) A
Item Thickness Crankshaft pin journal diameter
US 0.25 (0.0098) 1.627 - 1.635 (0.0641 - 0.0644) Grind so that bearing clearance is the specified value.
EM
CONNECTING ROD BEARING OIL CLEARANCE
Unit: mm (in)
Standard 0.029 - 0.039 (0.0011 - 0.0015) C
Connecting rod bearing oil clearance
Limit 0.10 (0.0039)
Main Bearing INFOID:0000000001381447 D
MAIN BEARING GRADE TABLE

Unit: mm (in) E
SEM685D
Grade number Thickness Identification color Remarks I

0 1.996 - 1.999 (0.0786 - 0.0787) Black
1 1.999 - 2.002 (0.0787 - 0.0788) Brown
J
2 2.002 - 2.005 (0.0788 - 0.0789) Green Grade and color are the same
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow for upper and lower bearings.
4 2.008 - 2.011 (0.0791 - 0.0792) Blue K

5 2.011 - 2.014 (0.0792 - 0.0793) Pink
UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
01 L
LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown
12
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green M
Grade and color are different
UPR 2.002 - 2.005 (0.0788 - 0.0789) Green for upper and lower bearings.
23
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
N
34
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue
UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue
45 O
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
UNDERSIZE TABLE
Unit: mm (in) P
Items Thickness Main journal diameter

0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value.

Unit: mm (in)
Main bearing oil clearance Standard 0.024 - 0.034 (0.0009 - 0.0013)
EM-131
< SYMPTOM DIAGNOSIS > [MR18DE]
SYMPTOM DIAGNOSIS
WBIA0769E
1. Piston pin noise 2. Piston slap noise 3. Main bearing noise

4. Water pump noise 5. Timing chain and tensioner noise 6. Drive belt noise (stick/slipping)
7. Tappet noise 8. Camshaft bearing noise 9. Connecting rod noise
EM-132
< SYMPTOM DIAGNOSIS > [MR18DE]
A. Rotational mechanism B. Water pump C. Timing chain
D. Drive belt E. Crankshaft pulley F. A/C compressor A
G. Water pump H. Generator I. Tension pulley
J. Valve mechanism K. Valves
EM
1. Locate the area where noise occurs. C

4. Check specified noise source. D
Operating condition of engine E

up up ing F
Top of en- Ticking or Tappet
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil G
EM-186
Cylinder Rattle C A — A B C bearing clearance
EM-186
head noise Camshaft runout
Piston to piston pin oil H

Slap or Piston pin clearance EM-219
— A — B B —
knock noise Connecting rod bushing EM-219
oil clearance
I
Piston to cylinder bore
Crank- clearance
EM-219
shaft pul- Piston ring side clear-
Slap or Piston EM-219
ley A — — B B A ance J
rap slap noise EM-219
Cylinder Piston ring end gap
EM-219
block Connecting rod bend
(Side of and torsion
K
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-219
Knock A B C B B B
bearing Connecting rod bearing EM-219
noise oil clearance L
Main bearing oil clear-
Main bear- EM-219
Knock A B — A B C ance
ing noise EM-219
Crankshaft runout M
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-177
Front cov- ticking Timing chain tensioner N
sioner
er operation
noise
Drive belt
Squeak-
(Sticking O
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-142
ping)
Front of
Drive belt Idler pulley bearing op- P
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
Creak
noise
EM-133
PRECAUTIONS
< PRECAUTION > [MR18DE]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
WARNING:
an authorized NISSAN/INFINITI dealer.
ness connectors.
the lower end of windshield.
PIIB3706J

INFOID:0000000001337764
NOTE:
TEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
• Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech-
steering wheel rotation will become impossible.
OPERATION PROCEDURE
NOTE:
EM-134
PRECAUTIONS
rotated. A
the battery cables. (At this time, the steering lock mechanism will engage.) EM
6. Perform a self-diagnosis check of all control units using CONSULT-II.
C
• Drain coolant when engine is cooled.
D
• After disconnecting pipes, plug openings to stop fuel leakage. E
• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid F
• Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. G
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
H
where noted in the step.
I
• Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
Precaution for Assembly and Installation INFOID:0000000001337769 J
• Use torque wrench to tighten bolts or nuts to specification.

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, K
do exactly as specified.
• Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction L
and blockage.
Before assembly, oil sliding surfaces well.
M
• Release air within route after draining coolant.
• After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for N
leakage.
O
• Use an angle wrench for the final tightening of the following engine parts:
- Camshaft sprocket (INT) P
- Main bearing cap bolts
- Connecting rod cap nuts
tightening)

EM-135
PRECAUTIONS
• Ensure thread and seat surfaces are clean and coated with engine oil.
REMOVAL OF LIQUID GASKET SEALING

• After removing the bolts and nuts, separate the mating surface and
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 RTV Silicone Sealant is applied.
Use a plastic hammer to slide the cutter (2) by tapping on the side.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed WBIA0566E
screwdriver is used, be careful not to damage the mating sur-

faces.
1. Using a scraper, remove the old Silicone RTV Sealant adhering
to the gasket application surface and the mating surface.
• Remove the sealant completely from the groove of the gasket
application surface, bolts, and bolt holes.
2. Thoroughly clean the gasket application surface and the mating
surface and remove adhering moisture, grease and foreign
materials.
3. Attach the sealant tube to the tube presser.
PBIC0003E

Tool.

• If there is a groove for the sealant application, apply the seal-
ant to the groove.
• As for the bolt holes, normally apply the sealant inside the
holes. If specified, it should be applied outside the holes. Make
sure to read the text of this manual.
• Within five minutes of the sealant application, install the mat-
ing component. WBIA0567E
• If the sealant protrudes, wipe it off immediately.

• After 30 minutes or more have passed from the installation, fill
the engine with the specified oil and coolant. Refer to MA-19,
"Fluids and Lubricants".
SEM159F
CAUTION:
EM-136
PRECAUTIONS
Follow all specific instructions in this manual.
A
EM
EM-137
PREPARATION
< PREPARATION > [MR18DE]
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000001337772
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number Description
(Kent-Moore No.)
Tool name
KV10111100 Removing steel oil pan and rear timing
(J-37228) chain case
Seal cutter
NT046

(BT-8653-A) head, etc.
Angle wrench
NT014
KV10107902 Removing valve oil seal

(J-38959)
Valve oil seal puller
S-NT011
EM03470000 Installing piston assembly into cylinder

(J-8037) bore
NT044
KV101092S0 Disassembling and assembling valve

(J-26336-B) mechanism
Valve spring compressor
1 KV10109210
(J-26336-20)
Attachment
2 KV10109220
( — )
3. KV10109230 NT718
Adapter (M8)
WS39930000 Pressing the tube of liquid gasket
( — )
Tube presser
NT052
EM-138
PREPARATION
Tool number Description
(Kent-Moore No.) A
Tool name
ST16610001 Removing crankshaft pilot bushing
(J-23907) EM
Pilot bushing puller
NT045
KV11103000 Removing crankshaft pulley D

(—)
Pulley puller
E
NT676 F
KV991J0050 Loosening or tightening air fuel ratio A/F
(J-44626) sensor
Air fuel sensor Socket a: 22 mm (0.87 in) G
H
LBIA0444E
KV10114400 Loosening or tightening rear heated oxy-

(J-38365) gen sensor I
Heated oxygen sensor wrench a: 22 mm (0.87 in)
NT636
K
KV11105210 Securing driveplate and flywheel
(J-44716)
Stopper plate
L
M
ZZA0009D
KV10115600 Installing valve oil seal

(J-38958) Use side A.
N
Valve oil seal drift a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia. O
e: 10.7 (0.421)
f: 5 (0.20)
S-NT603
KV10115801 Removing and installing oil filter P

( — ) a: 64.3 mm (2.531 in)
Oil filter wrench
S-NT375
EM-139
PREPARATION
Commercial Service Tool INFOID:0000000001337773
(Kent-Moore No.) Description

Tool name
(BT-3373-F) Checking drive belt tension
Belt tension gauge
AMA126
Power tool Loosening bolts and nuts
PBIC0190E
Spark plug wrench Removing and installing spark plug
PBIC2982E
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030
KV10109300 Removing and installing crankshaft pulley

( — )
Pulley holder
NT628
EM-140
PREPARATION
(Kent-Moore No.) Description
Tool name A
KV10111800 Removing and installing valve guide
Valve guide drift
EM
C
PBIC4012E
Valve guide reamer (1): Reaming valve guide inner hole

(2): Reaming hole for oversize valve guide D
PBIC4013E
F
(J-43897-18) Reconditioning the exhaust system threads
(J-43897-12) before installing a new oxygen sensor (Use
Oxygen sensor thread cleaner with anti-seize lubricant shown below.)
a: J-43897-18 (18 mm dia.) for zirconia ox- G
ygen sensor
b: J-43897-12 (12 mm dia.) for titania oxy-
gen sensor
H
AEM488
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 I
AEM489
E20 Torx® Socket Removing and installing drive plate and fly- K
(J-45816) wheel bolts
LBIA0285E M
EM-141
DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [MR18DE]
ON-VEHICLE MAINTENANCE
DRIVE BELTS
PBIC3137J
1. Generator 2. Drive belt auto–tensioner 3. Crankshaft pulley

A/C compressor (models with A/C)
4. 5. Water pump 6. Drive belt
Idler pulley (models without A/C)
A. Possible use range B. Range when new drive belt is installed C. Indicator
Checking Drive Belts INFOID:0000000001337777
WARNING:
Be sure to perform this step when the engine is stopped.
• Make sure that the indicator (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(A).
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B).
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension Adjustment INFOID:0000000001337778
Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

REMOVAL
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a wrench securely. Then move the wrench handle in the direc-
tion of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.
2. Insert a rod such as short-length screwdriver approximately 6
mm (0.24 in) in diameter into the hole (B) of the retaining boss to
fix drive belt auto-tensioner.
PBIC3936E
INSTALLATION
EM-142
DRIVE BELTS
1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a box wrench securely. Then move the wrench handle in the A
direction of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
EM
the holding tool accidentally comes off.
2. Insert a rod such as short-length screwdriver approximately 6
mm (0.24 in) in diameter into the hole (B) of retaining boss to fix
drive belt auto-tensioner. C
3. Install drive belt.
CAUTION: PBIC3936E
• Confirm drive belt is completely set to pulleys. D

• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
4. Release drive belt auto-tensioner, and apply tension to drive belt. E
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-142, "Checking Drive Belts". F
EM-143
AIR CLEANER FILTER
AIR CLEANER FILTER
REMOVAL
the inside (B).
2. Pull up the air cleaner cover (1) and remove it (C).
PBIC3557J
3. Remove air cleaner filter (1) and holder (2) assembly from the
air cleaner case.
PBIC3558J

conditions. Refer to MA-7, "Periodic Maintenance".
out.
SMA384C
INSTALLATION
2 : Air cleaner filter

3 : Holder
PBIC3559J
EM-144
SPARK PLUG
SPARK PLUG
A
EM
J
PBIC3536J
1. PCV hose 2. Rocker cover 3. Spark plug K

4. Ignition coil 5. PCV hose 6. PCV valve
7. O-ring 8. Gasket
A. To air duct B. Refer to EM-145. C. To intake manifold L
M
REMOVAL
2. Remove ignition coil. N
CAUTION:
• Handle it carefully and avoid impacts.
• Never disassemble. O
EM-145
SPARK PLUG
3. Remove spark plug using suitable tool.
CAUTION:
Never drop or shock it.
PBIC3871E

CAUTION:
• Checking and adjusting spark plug gap is not required
between change intervals.
SMA806CA
• If spark plug tip is covered with carbon, a spark plug cleaner may be used.
Cleaner air pressure : Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi)
Cleaning time : Less than 20 seconds
• Never use wire brush for cleaning spark plug.
SMA773C
INSTALLATION
1. Install spark plug using suitable tool.
Plug type : Platinum tipped

Make : NGK
Part number : PLZKAR6A-11
Gap (nominal) : 1.1 mm (0.043 in)
CAUTION:
PBIC3871E
2. Install ignition coil.
EM-146
SPARK PLUG
CAUTION:
• Handle it carefully and avoid impacts. A
3. Install intake manifold. Refer to EM-156, "Removal and Installation".
EM
EM-147
Valve Clearance INFOID:0000000001337799
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-173, "Removal and Installation".
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front
cover.
C : White paint mark (Not use for service)
PBIC3960E
• At the same time, make sure that both intake and exhaust cam
noses of No. 1 cylinder face inside ( ) as shown.
1 : Camshaft (INT)
2 : Camshaft (EXH)
: Engine front
• If they do not face inside, rotate crankshaft pulley once more

(360 degrees) and align as shown.
PBIC3359J
b. Use a feeler gauge, measure the clearance between valve lifter

and camshaft.
PBIC3192J
Valve clearance:
Unit: mm (in)
Cold Hot * (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)
EM-148
• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below [locations A
indicated with black arrow ( )] with a feeler gauge.
• No. 1 cylinder compression TDC
EM
No. 1 cylinder at EXH × ×

compression TDC INT × × C
A : Exhaust side PBIC3193J
B : No.1 cylinder D
C : No.2 cylinder
D : No.3 cylinder
E : No.4 cylinder E
F : Intake side
: Engine front
F
c. Set No.4 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) one revolution (360 degrees) and
align TDC mark (no paint) (B) to timing indicator (A) on front
G
cover.

H
PBIC3960E
J
• By referring to the figure, measure the valve clearance at loca-
tions marked “×” as shown in the table below [locations indi-
cated with black arrow ( )] with a feeler gauge.
• No. 4 cylinder compression TDC K
L
No. 4 cylinder at EXH × ×
compression TDC INT × ×
M
A : Exhaust side PBIC3194J
B : No.1 cylinder
C : No.2 cylinder
N
D : No.3 cylinder
E : No.4 cylinder
F : Intake side
O
: Engine front
3. If out of standard, perform adjustment procedure.

P
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-186, "Removal and Installation".
2. Remove valve lifters at the locations that are out of the standard.
EM-149
3. Measure the center thickness of the removed valve lifters with a
micrometer (A).
PBIC3195J
4. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1 – C2)

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)
Exhaust : 0.33 mm (0.013 in)
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder).
Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.
PBIC3196J
NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-238, "Standard and Limit".
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-186, "Removal and Installation".
7. Install timing chain and related parts. Refer to EM-176.
8. Manually rotate crankshaft pulley a few rotations.
9. Make sure that the valve clearances is within the standard.
10. Installation of the remaining components is in the reverse order of removal.
EM-150
A
Checking Compression Pressure INFOID:0000000001346452
1. Warm up engine thoroughly. Then, stop it. EM

2. Release fuel pressure. Refer to EC-1035, "Inspection".
3. Disconnect fuel pump fuse (1) to avoid fuel injection during mea-
surement. C
: Vehicle front
D
PBIA9861J
F
4. Remove engine cover. Refer to EM-156, "Component".
5. Remove ignition coil and spark plug from each cylinder. Refer to EM-145, "Removal and Installation".
6. Connect an engine tachometer (not required in use of CONSULT-III). G
7. Install a suitable compression tester with an adapter onto spark
plug hole.
H
LBIA0459E
K
• Use the adapter whose picking up end inserted to spark plug
hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
L
N
SBIA0533E
8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each O
cylinder.
Compression pressure:
Unit: kPa (bar, kg/cm2 psi) /rpm P
Standard Minimum Differential limit between cylinders
1,500 (15.0, 15.3, 217.6) / 200 1,200 (12.0, 12.2, 174) / 200 100 (1, 1, 15) / 200
CAUTION:
Always use a fully charged battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
EM-151
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder
head gasket.
10. Start the engine, and confirm that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-781, "Description".
EM-152
DRIVE BELT AUTO TENSIONER
< ON-VEHICLE REPAIR > [MR18DE]
ON-VEHICLE REPAIR A
DRIVE BELT AUTO TENSIONER
EM
PBIC4698E J
1. Front cover 2. Drive belt auto–tensioner 3. Idler pulley (models without A/C)
4. Bracket (models without A/C) 5. Shaft (models without A/C)
K
Removal and Installation of Drive Belt Auto Tensioner INFOID:0000000001337781
REMOVAL L
2. Release the fixed drive belt auto-tensioner pulley.
M
3. Loosen bolt and remove drive belt auto-tensioner.
NOTE:
Use TORX socket (size T50).
N
4. Remove idler pulley and bracket (models without A/C).
INSTALLATION
Installation is the reverse order of removal. O
CAUTION:
• When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
• If there is damage greater than peeled paint, replace drive belt auto-tensioner and/or idler pulley.
P
EM-153
WBIA0770E
1. Air cleaner filter 2. Holder 3. Air cleaner cover

4. Seal 5. Mass air flow sensor 6. Air duct
7. PCV hose 8. Air duct (Inlet) 9. Air duct (Front)
10. Clip 11. Resonator 12. Grommet
13. Air cleaner case A. To electronic throttle control actuator B. To rocker cover
REMOVAL
1. Remove the air duct (inlet).
2. Remove the air cleaner filter from the air cleaner case. Refer to EM-144, "Removal and Installation".
3. Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.
4. Remove the PCV hose.
5. Remove the air duct (between air cleaner case and electronic throttle control actuator).
• Add marks as necessary for easier installation.
6. Remove air cleaner case with the following procedure.
a. Remove battery. Refer to PG-6, "Removal and Installation".
b. Disconnect harness connector from mass air flow sensor.
c. Remove the air cleaner case.
7. Remove the mass air flow sensor from the air cleaner case, if necessary.
CAUTION:
• Do not touch sensor part.
INSTALLATION
EM-154
• Align marks.
• Attach each joint securely. A
• Screw clamps firmly.
EM
EM-155
INTAKE MANIFOLD
INTAKE MANIFOLD
WBIA0771E
1. PCV hose 2. Gasket 3. Intake manifold

4. Bracket 5. O-ring 6. EVAP canister purge volume control
solenoid valve
7. Water hose 8. Water hose 9. Electronic throttle control actuator
10. Gasket A. To water outlet
REMOVAL
1. Remove engine cover (1).
2. Drain engine coolant. Refer to CO-35, "Changing Engine Cool-
ant".
CAUTION:
Perform this step when engine is cold.
NOTE:
This step is unnecessary when putting plugs to water hoses (to
electronic throttle control actuator)
a. Disconnect water hoses from electronic throttle control actuator.
b. Remove electronic throttle control actuator.
CAUTION: WBIA0845E
• Handle carefully to avoid any shock to electronic throttle

control actuator.
3. Remove oil level gauge.

CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
EM-156
INTAKE MANIFOLD
4. Loosen and remove intake manifold (1) bolts (A) (B).
A
: Engine front
EM
G
PBIC3939E
5. Loosen bolts in reverse order as shown.

H
: Engine front
CAUTION: I
6. Remove EVAP canister purge volume control solenoid valve
from intake manifold, if necessary.
J
CAUTION:
Handle it carefully and avoid impacts.
7. Remove intake manifold. PBIC3527J
K
INSTALLATION
1. Install intake manifold.
NOTE: L
Be sure the intake manifold gasket is seated correctly in groove of intake manifold.
2. Tighten bolts in numerical order as shown.
M
: Engine front
WBIA0788E
EM-157
INTAKE MANIFOLD
3. Tighten intake manifold bolt (A). Then tighten intake manifold
bolt (B).
1 : Intake manifold
: Engine front
PBIC3939E
4. Install electronic throttle control actuator

5. Install water hoses (3), (5) to electronic throttle control actuator
as shown.
1 : Electronic throttle control actuator

2 : Clamp
4 : Water outlet
A : Paint Mark
B : The clamp shall not interfere with the bulged section.
C : 3 - 7 mm (0.12 - 0.28 in)
AWBIA0115GB

• Check for leaks of engine coolant. Refer to CO-35, "Inspection".
• Start and warm up the engine. Visually check for engine coolant leaks.
EM-158
EXHAUST MANIFOLD
EXHAUST MANIFOLD
A
EM
I
WBIA0778E
1. Exhaust manifold cover 2. Exhaust manifold 3. Gasket J

4. Stud bolt 5. Bracket 6. Heated oxygen sensor 1
7. Exhaust manifold stay Engine front
K
REMOVAL L
2. Remove exhaust manifold cover.
3. Remove the heated oxygen sensor 1, using Tool (A). M
Tool number :KV991J0050 (J-44626)

CAUTION: N
Handle it carefully and avoid impacts.
WBIA0772E
P
4. Remove exhaust manifold side bolt of exhaust manifold stay.
EM-159
EXHAUST MANIFOLD
5. Loosen nuts in reverse order as shown and remove exhaust
manifold.
: Engine front
CAUTION:
PBIC3529J

Surface Distortion
• Using straightedge (B) and feeler gauge (A), check the surface dis-
tortion of exhaust manifold mating surface in each exhaust port
and entire part.
Limit:
Each exhaust port : 0.3 mm (0.012 in)
Entire part : 0.7 mm (0.028 in)
• If it exceeds the limit, replace exhaust manifold.
PBIC3530J
INSTALLATION
1. Install exhaust manifold gasket to cylinder head as shown.
: Engine front
PBIC3943E
2. Tighten exhaust manifold nuts to specification in two stages in

the numerical order as shown.
: Engine front
WBIA0854E
EM-160
EXHAUST MANIFOLD
3. Install exhaust manifold stay (2) in the direction as shown.
A
1 : Exhaust manifold
A : Upper mark
: Engine front EM
PBIC3944E
D
4. Install the heated oxygen sensor 1, using Tool
Tool number : KV991J0050 (J-44626) E

CAUTION:
• Before installing a new heated oxygen sensor, clean the F
exhaust tube threads using suitable tool and approved
anti-seize lubricant.
• Do not over-tighten the heated oxygen sensor. Doing so
may damage the heated oxygen sensor, resulting in the G
MIL coming on. WBIA0772E
Tool number : — (J-43897-12) H

Tool number : — (J-43897-18)
I
5. Installation of the remaining parts is in the reverse order of removal.
EM-161
WBIA0779E
1. Bracket 2. Bracket 3. Fuel tube

4. Clip 5. Fuel injector 6. O-ring (green)
7. O-ring (black)
REMOVAL
WARNING:
• 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.
1. Release the fuel pressure. Refer to EC-1035, "Inspection".
2. Remove quick connector cap (1) from quick connector connec-
tion.
PBIC3664E
EM-162
3. Disconnect fuel feed hose from hose clamp.
A
1 : Quick connector cap
NOTE:
There is no fuel return path. EM
PBIC3771E
D
4. With the sleeve side of quick connector release facing quick connector, install quick connector release
onto fuel tube.
E
5. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold quick connector release on
that position.
CAUTION: F
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
G
H
KBIA0702E
6. Draw and pull out quick connector straight from fuel tube.
CAUTION: I
• Pull quick connector holding “A” position.
• 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. J
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Do not expose parts to battery electrolyte or other acids. K
• Do not bend or twist connection between quick connector and fuel feed hose during installation/
removal.
• To keep clean the connecting portion and to avoid dam- L
age and foreign materials, cover them completely with
plastic bags or something similar.
M
PBIC2205E
O
7. Remove intake manifold. Refer to EM-156.
P
EM-163
8. Remove fuel tube.
• Loosen bolts in reverse order as shown.
: Engine front
PBIC3154J
9. Remove the fuel tube and fuel injector assembly.

CAUTION:
• When removing, be careful to avoid any interference with fuel injector.
• Use a shop cloth to absorb any fuel leaks from fuel tube.
10. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip.
b. Remove fuel injector from fuel tube by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel tube.
• Be careful not to damage fuel injector nozzle during removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector.
INSTALLATION
1. Note the following, and install O-rings to fuel injector.
CAUTION:
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Black

Nozzle side : Green
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Make sure that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert O-ring straight into fuel tube. Never twist it.
EM-164
2. Install fuel injector (4) to fuel tube (1) with the following proce-
dure: A
3 : O–ring (black)
5 : O–ring (green) EM
a. Insert clip (2) into clip groove (F) on fuel injector.
• Insert clip so that protrusion (G) of fuel injector matches cut-
out (D) of clip. C
CAUTION:
• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring. D
b. Insert fuel injector into fuel tube with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (B) of fuel tube matches E
cut-out (C) of clip.
• Make sure that fuel tube flange (A) is securely fixed in flange
fixing groove (E) on clip.
F
c. Make sure that installation is complete by making sure that fuel
injector does not rotate or come off.
G
PBIC3155J
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.
CAUTION: H
For installation, be careful not to interfere with fuel injector nozzle.
I
: Engine front
PBIC3154J
L
EM-165
OIL PAN
OIL PAN
AWBIA0156GB
1. Oil level gauge 2. Oil level gauge guide 3. Oil level sensor
7. Oil pump drive chain 8. Crankshaft sprocket 9. Oil pump sprocket
10. Timing chain tensioner (for oil pump) 11. Oil pump 12. Drain plug
13. Drain plug washer 14. Oil pan (lower) 15. Oil filter
16. Connector bolt 17. Oil cooler 18. O-ring
19. O-ring A. Refer to EM-166 :Oil pan side
REMOVAL
WARNING:
• Be careful not to burn yourself, as the engine oil is hot.
• Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin
contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as
possible.
1. Drain engine oil. Refer to LU-16, "Changing Engine Oil".
EM-166
OIL PAN
2. Remove engine and transaxle assembly. Refer to EM-207.
3. Remove oil filter using Tool. A
Tool number : KV10115801 ( — )

CAUTION: EM
When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
4. Remove oil pan (lower) bolts in reverse order as shown.
C
: Engine front
PBIC3146J
F
5. After removing the bolts and nuts, separate the mating surface
and remove the sealant using Tool.
G
Tool number : KV10111100 (J-37228)
CAUTION:
Be careful not to damage the mating surfaces. H
I
WBIA0566E
6. Remove the following parts: J

• Flywheel; Refer to EM-211.
• Front cover, timing chain, oil pump drive chain; Refer to EM-176.
7. Remove oil pump. K
1 : Oil pump
L
2 : Oil pan (upper)
: Engine front
N
PBIC3532J
8. Remove oil pan (lower) bolts in reverse order as shown.

O
: Engine front
PBIC3533J
EM-167
OIL PAN
9. Insert a screwdriver shown by the arrow ( ) and open up a

crack between oil pan (upper) and cylinder block.
: Engine front
CAUTION:
A more adhesive liquid gasket is applied compared to previ-
ous types when shipped, so it should not be forced off the
position not specified.
PBIC3534J
10. After removing the bolts, separate the mating surface and
Tool number : KV10111100 (J-37228)

• Slide (1) the Tool by tapping (2) its side with a hammer to
remove the lower oil pan from the upper oil pan.
CAUTION:
WBIA0566E
11. Remove O-ring between cylinder block and oil pan (upper).
Oil Filter
Clean oil strainer portion (part of the oil pump) if any object attached.
INSTALLATION
1. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Remove the old liquid gasket from mating surface of cylinder
block.
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
PBIC3949E
EM-168
OIL PAN
Tool. A
EM
1 : Oil pan (upper)

C
A : 2 mm protruded to outside
B : 2 mm protruded to rear oil seal mounting side
: Engine front D
: Engine outside
CAUTION:
Apply liquid gasket to outside of bolt hole for the positions E
shown by marks.
G
PBIC4587E
3. Install new O-ring at cylinder block side.

CAUTION: H
Install avoiding misalignment of O-ring.
I
: Engine front
PBIC3533J
L
5. Install rear oil seal with the following procedure.
CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan M
(upper).
• Always replace rear oil seal with new one.
• Never touch oil seal lip. N
a. Wipe off liquid gasket protruding to the rear oil seal mating part of oil pan (upper) and cylinder block using
a scraper.
b. Apply engine oil to entire outside area of rear oil seal. O
EM-169
OIL PAN
mm (4.53 in) and inner diameter 90 mm (3.54 in) (A) (commer-
cial service tool).
PBIC3951E
• Press-fit to the specified dimensions as shown.
1 : Rear oil seal

A : Cylinder block rear end surface
CAUTION:
• Never touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part of
oil pan (upper) and cylinder block or the crankshaft.
• Press-fit straight, making sure that rear oil seal does not
curl or tilt.
NOTE: PBIC3952E
The standard surface of the dimension is the rear end surface of

cylinder block.
6. Install oil pump.
• Tighten bolts in numerical order as shown.
1 : Oil pump
2 : Oil pan (upper)
: Engine front
7. Install oil pump sprocket, oil pump drive chain and other related
parts if removed.
PBIC3532J
8. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan
(upper).
• Remove old liquid gasket from the bolt holes and threads.
PBIC3953E
EM-170
OIL PAN
Tool. A
EM
1 : Oil pan (lower)

C
: Engine outside
G
PBIC4590E

H
: Engine front
11. Install oil filter with the following procedure: I

a. Remove foreign materials adhering to the oil filter installation
surface.
b. Apply new engine oil to the oil seal contact surface of new oil fil- J
ter.
PBIC3146J
K
c. Screw oil filter manually until it touches the installation surface,
then tighten it by 2/3 turn. Or tighten to specification.
L
Oil filter: : 17.7 N·m (1.8 kg-m, 13 ft-lb)
N
SMA229B
12. Installation of the remaining components is in the reverse order of removal. O
EM-171
IGNITION COIL
IGNITION COIL
PBIC3536J
1. PCV hose 2. Rocker cover 3. Spark plug

7. O-ring 8. Gasket
A. To air duct B. Refer to EM-173. C. To intake manifold
REMOVAL
2. Remove ignition coil.
CAUTION:
INSTALLATION
CAUTION:
2. Install intake manifold. Refer to EM-156, "Removal and Installation".
EM-172
ROCKER COVER
ROCKER COVER
A
EM
J
PBIC3536J
1. PCV hose 2. Rocker cover 3. Spark plug K

7. O-ring 8. Gasket
A. To air duct B. Refer to EM-173. C. To intake manifold L
M
REMOVAL
2. Remove ignition coil. N
CAUTION:
• Never disassemble. O
EM-173
ROCKER COVER
CAUTION:
PBIC3871E
4. Remove rocker cover.

• Engine front
PBIC3151J

CAUTION:
• Checking and adjusting spark plug gap is not required
between change intervals.
SMA806CA
• If spark plug tip is covered with carbon, a spark plug cleaner may be used.
Cleaner air pressure : Less than 588 kPa (5.88 bar, 6 kg/cm2, 85 psi)
Cleaning time : Less than 20 seconds
• Never use wire brush for cleaning spark plug.
SMA773C
INSTALLATION
1. Install rocker cover gasket to rocker cover.
EM-174
ROCKER COVER
2. Install rocker cover.
• Tighten bolts in two steps separately in numerical order as A
shown.
1st step : 1.96 N·m (0.20 kg-m, 17 in-lb) EM

2nd step : 8.33 N·m (0.85 kg-m, 73 in-lb)
• Engine front
CAUTION: C
Check if rocker cover gasket is not dropped from the instal-
lation groove of rocker cover. PBIC3151J
D
CAUTION:
E
G
PBIC3871E

H
CAUTION:
5. Install intake manifold. Refer to EM-156, "Removal and Installation". I
EM-175
TIMING CHAIN
TIMING CHAIN
PBIC3538J
1. Timing chain slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH)
4. Timing chain 5. Oil filler cap 6. Front cover
Intake valve timing control solenoid
7. O-ring 8. 9. Crankshaft pulley bolt
valve
10. Crankshaft pulley 11. Front oil seal 12. Drive belt auto-tensioner
Timing chain tension guide (front cov-
13. 14. Crankshaft sprocket 15. Oil pump sprocket
er side)
EM-176
TIMING CHAIN
16. Oil pump drive chain 17. Camshaft sprocket (INT) 18. Timing chain tension guide
19. O-ring 20. Chain tensioner (for oil pump) A
Removal and Installation INFOID:0000000001337796 EM
CAUTION:
The rotating direction indicated in the text indicates all directions seen from the engine front.
C
REMOVAL
1. Remove front RH wheel. Refer to WT-6, "Rotation".
2. Remove front fender protector (RH). Refer to EXT-22, "Removal and Installation". D
3. Drain engine oil. Refer to LU-16, "Changing Engine Oil".
NOTE:
Perform this step when engine is cold. E
• Rocker cover: Refer to EM-173, "Removal and Installation".
• Drive belt: Refer to EM-142, "Component". F
• Water pump pulley: Refer to CO-44, "Component".
• Ground cable (between engine bracket (RH) and radiator core support)
5. Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and
G
insulator (RH). Refer to EM-207.
6. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front H
cover.

I
PBIC3960E
b. At the same time, make sure that the cam noses of the No.1 cyl- L
inder are located ( ) as shown.
1 : Camshaft (INT) M
2 : Camshaft (EXH)
: Engine front
N
• If not, rotate crankshaft pulley one revolution (360 degrees)
and align as shown.
PBIC3359J
O
EM-177
TIMING CHAIN
7. Hold crankshaft pulley (1) using suitable tool (A) loosen crank-
shaft pulley bolt, and locate bolt seating surface at 10 mm (0.39
in) from its original position.
CAUTION:
Never remove the crankshaft pulley bolt as it will be used as
a supporting point for the pulley puller.
PBIC3961E
8. Attach a pulley puller (A) in the M6 thread hole on crankshaft

pulley (1), and remove crankshaft pulley.
PBIC3962E
9. Remove oil pan (lower). Refer to EM-166.

NOTE:
When crankshaft sprocket, oil pump sprocket and other related parts are not removed, this step is unnec-
essary.
10. Remove intake valve timing control solenoid valve.
11. Remove drive belt auto-tensioner.
PBIC3164J
EM-178
TIMING CHAIN
13. Cut liquid gasket by prying the position ( ) shown, and then
remove the front cover. A
CAUTION:
• A more adhesive liquid gasket is applied compared to pre- EM
the position not specified.
PBIC3357J
D
14. Remove front oil seal from front cover.
• Lift up front oil seal using a suitable tool.
CAUTION:
E
Be careful not to damage front cover.
15. Push in timing chain tensioner plunger.
16. Insert a stopper pin (A) into the body hole to retain the plunger in
F
collapsed position.
NOTE:
Use approximately 1.5 mm (0.059 in) diameter. hard metal pin
as a stopper pin. G
17. Remove timing chain tensioner (1).

H
PBIC3165J
I
18. Remove timing chain slack guide (2), timing chain tension guide J
(3) and timing chain (1).
CAUTION:
Never rotate each crankshaft and camshaft individually
while timing chain is removed. It causes interference K
between valve and piston.
P
AWBIA0138ZZ
EM-179
TIMING CHAIN
19. Press stopper tab (A) in the direction shown to push the timing
chain slack guide (B) toward timing chain tensioner (for oil
pump) (1).
• The slack guide (B) is released by pressing the stopper tab
(A). As a result, the slack guide (B) can be moved.
20. Insert stopper pin (D) into tensioner body hole (C) to secure tim-
ing chain slack guide (B).
NOTE:
Use a hard metal pin with a diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
21. Remove timing chain tensioner (for oil pump).
PBIC5314E
22. Hold the WAF part of oil pump shaft (A), and then loosen the oil pump sprocket bolt and remove them.
1 : Oil pan (upper)

2 : Oil pump
: Engine front
CAUTION:
• Secure the oil pump shaft with the WAF part.
• Never loosen the oil pump sprocket bolt by tightening the
oil pump drive chain.
PBIC3539J
23. Remove crankshaft sprocket, oil pump sprocket and oil pump drive chain as a set.
24. Remove timing chain tension guide (front cover side) from front cover if necessary.

Timing Chain
EM-180
TIMING CHAIN
• Check timing chain and oil pump drive chain for cracks (A) and any
excessive wear (B) at the roller links of timing chain. A
• Replace timing chain and/or oil pump drive chain if necessary.
EM
PBIC3169J
D
INSTALLATION
NOTE:
The figure shows the relationship between the matching mark on
each timing chain and that on the corresponding sprocket, with the E
components installed.
1. Make sure that crankshaft key points straight up.
F
1 : Timing chain
3 : Timing chain slack guide G
4 : Timing chain tensioner
6 : Oil pump drive chain H
7 : Chain tensioner (for oil pump)
9 : Timing chain tension guide I
A : Matching mark (dark blue link)
B : Matching mark (stamping) J
C : Crankshaft key position (straight up)
D : Matching mark (orange link)
E : Matching mark (orange link) K
AWBIA0140ZZ
F : Matching mark (outer groove*)
NOTE:
*: There are two outer grooves in camshaft sprocket (INT). The wider one is a matching mark. L
2. If the timing chain tension guide (front cover side) is removed, install it to the front cover.
CAUTION:
Check the joint condition by sound or feeling. M
3. Install crankshaft sprocket (2), oil pump sprocket (3) and oil
pump drive chain (1).
N
A : Matching mark (stamping)
B : Matching mark (orange link)
C : Matching mark (dark blue link) O
• Install it by aligning matching marks on each sprocket and oil
pump drive chain.
• If these matching marks are not aligned, rotate the oil pump P
shaft slightly to correct the position.
CAUTION: PBIC3171J
Check matching mark position of each sprocket after

installing the oil pump drive chain.
EM-181
TIMING CHAIN
4. Hold the WAF part of oil pump shaft (A), and then tighten the oil
pump sprocket bolt.
1 : Oil pan (upper)

2 : Oil pump
: Engine front
CAUTION:
• Secure the oil pump shaft with the WAF part.
• Never loosen the oil pump sprocket bolt by tightening the
oil pump drive chain.
PBIC3539J
5. Install chain tensioner (for oil pump) (1).

• Securely pull out ( ) the stopper pin after installing the chain
tensioner (for oil pump).
• Check matching mark position of oil pump drive chain and
each sprocket again.
AWBIA0139ZZ
6. Align the matching marks of each sprocket with the matching

marks of timing chain.

3 : Timing chain
A : Matching mark (dark blue link)
B : Matching mark (stamping)
C : Matching mark (outer groove*)
D : Matching mark (orange link)
E : Matching mark (stamping)
NOTE:
*: There are 2 outer grooves in camshaft sprocket (INT). The
wider one is a matching mark.
• If these matching marks are not aligned, rotate the camshaft
slightly by holding the hexagonal portion to correct the posi-
tion.
CAUTION:
Check matching mark position of each sprocket and timing
chain again after installing the timing chain.
PBIC3172J
EM-182
TIMING CHAIN
7. Install the timing chain tension guide (3) and the timing chain
slack guide (2). A
1 : Timing chain
EM
G
AWBIA0138ZZ
8. Install timing chain tensioner (1).

• Fix the plunger at the most compressed position using a stop- H
• Securely pull out the stopper pin after installing the timing
chain tensioner. I
PBIC3165J
K
10. Apply new engine oil to new front oil seal joint surface.
L
11. Using a suitable tool install front oil seal so that each seal lip is oriented as shown.
A : Dust seal lip

B : Oil seal lip M
: Engine front
: Engine rear
N
• Press-fit front oil seal until it is flush with front end surface of
front cover as shown below with a suitable tool.
O
Within 0.3 mm (0.012 in) toward engine front
Within 0.5 mm (0.020 in) toward engine rear PBIC3485J
CAUTION: P
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting.
• Never touch grease applied onto oil seal lip.
12. Install new O-ring to cylinder block.

CAUTION:
EM-183
TIMING CHAIN
Be sure O-rings a aligned properly.
Tool.
A : Liquid gasket application area

: Engine outside
PBIC3959E
14. Make sure that matching marks of timing chain and each sprocket are still aligned.
CAUTION:
• Make sure O-ring on cylinder block is correctly installed.
• Be careful not to damage front oil seal by interference with front end of crankshaft.
15. Install front cover, and tighten bolts in numerical order as shown.
CAUTION:
Attaching should be done within 5 minutes after liquid gas-
ket application.
NOTE:
Follow the installation position of bolts as shown.
M6 bolts : No. 1
M10 bolts : No. 6, 7, 10, 11, 14
M12 bolts : No. 2, 4, 8, 12
M8 bolts : Except the above
16. Tighten all bolts are in two stages to specified torque in numeri-
cal order as shown.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking.
PBIC3164J
17. Install crankshaft pulley.

CAUTION:
• Never damage front oil seal lip section.
• If needed use a plastic hammer, tap on its center portion (not circumference) to seat crankshaft
pulley.
EM-184
TIMING CHAIN
18. Secure crankshaft pulley (1) using tool (A).
19. Apply new engine oil to thread and seat surfaces of crankshaft A
pulley bolt.
20. Tighten crankshaft pulley bolt in three steps.
EM
Step 1 : 68.6 N·m (7.0 kg-m, 51 ft-lb)
Step 2 : 0 N·m (0 kg-m, 0 ft-lb)
Step 3 : 29.4 N·m (3.0 kg-m, 22 ft-lb) C
PBIC3961E
D
21. Put a paint mark (B) on crankshaft pulley (2), matching with any
one of six easy to recognize angle marks (A) on crankshaft pul-
ley bolt (1) flange.
E
22. Turn another 60 degrees clockwise (angle tightening) using
Tool.
F
G
PBIC3963E
23. Make sure that crankshaft rotates clockwise smoothly.

24. Installation of the remaining components is in the reverse order of removal. H
EM-185
CAMSHAFT
CAMSHAFT
PBIC4589E
1. O-ring 2. Camshaft position sensor (PHASE) 3. Camshaft bracket

4. Camshaft sprocket (EXH) 5. Camshaft sprocket (INT) 6. Camshaft (EXH)
7. Camshaft (INT) 8. Valve lifter (EXH) 9. Valve lifter (INT)
10. Cylinder head
A. Refer to EM-186.
REMOVAL
WARNING:
2. Disconnect negative battery cable. Refer to PG-6, "Removal and Installation".
3. Remove front RH wheel. Refer to WT-6, "Rotation".
5. Drain engine coolant. Refer to CO-35, "Changing Engine Coolant".
NOTE:
Perform this step when engine is cold.
• Intake manifold; Refer to EM-156.
• Rocker cover; Refer to EM-173, "Removal and Installation".
EM-186
CAMSHAFT
• Fuel tube and fuel injector assembly; Refer to EM-162.
• Front cover, timing chain and related parts; Refer to EM-176. A
7. Remove camshaft position sensor (PHASE) from camshaft bracket.
CAUTION:
• Handle carefully to avoid dropping and shocks. EM
• Never allow metal powder to adhere to magnetic part at sensor tip.
• Never place sensor in a location where it is exposed to magnetism.
C
8. Put the matching mark (A) on the camshaft sprocket (INT) (2)
and the camshaft bracket (1) as shown.
: Engine front D
NOTE:
It prevents the knock pin of the camshaft (INT) from engaging
with the incorrect pin hole when installing the camshaft sprocket E
(INT).
F
PBIC3992J
9. Remove camshaft sprockets (INT) (1) and (EXH) (2).

• Secure hexagonal part (A) of camshaft with a wrench. Loosen G
camshaft sprocket bolts and remove camshaft sprocket.
CAUTION:
• Never rotate crankshaft or camshaft while timing chain H
is removed. It causes interference between valve and
piston.
• Never loosen the bolts with securing anything other
than the camshaft hexagonal part or with tensioning the I
timing chain.
PBIC3454J
J

K
: Engine front
PBIC3176J
N
11. Cut liquid gasket by prying the position ( ) shown, and then
remove the camshaft bracket.
O
: Engine front
CAUTION:
• Be careful not to damage the mating surface. P
the position not specified.
PBIC3358J
12. Remove camshafts.
EM-187
CAMSHAFT
13. Remove valve lifters.
NOTE:
Identify installed positions, and store them without mixing them up.
Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour-
nal of camshaft.
CAUTION:
four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
PBIC3177J
Standard : Less than 0.02 mm (0.0008 in).
Limit : 0.05 mm (0.0020 in)
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer (A).
Standard:
Intake : 44.605 - 44.795 mm (1.7560 - 1.7635 in)
Exhaust : 43.175 - 43.365 mm (1.6997 - 1.7072 in)
Limit:
Intake : 44.405 mm (1.7482 in)
Exhaust : 42.975 mm (1.6919 in)
PBIC3178J

Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A).
Standard:
No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2, 3, 4, 5 : 24.950 - 24.970 mm (0.9823 - 0.9831 in)
PBIC3179J
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with specified torque. Use the "INSTALLATION" procedure.
EM-188
CAMSHAFT
• Measure the inner diameter of camshaft bracket with a bore gauge
(A). A
B : Measuring direction of inner diameter
EM
Standard:
No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2, 3, 4, 5 : 25.000 - 25.021 mm (0.9843 - 0.9851 in) C
PBIC3180J
D
CAMSHAFT JOURNAL OIL CLEARANCE
• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
E
Standard:
No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in)
No. 2, 3, 4, 5 : 0.030 - 0.071 mm (0.0012 - 0.0028 in) F
Limit:
: 0.15 mm (0.0059 in)
G
• If it exceeds the limit, replace camshaft or cylinder head, or both.
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly. H
Camshaft End Play

1. Install camshaft in cylinder head. I
2. Install dial indicator in thrust direction on front end of camshaft.
Read the end play of dial indicator (A) when camshaft is moved
forward/backward (in direction to axis). J
Standard : 0.075 - 0.153 mm (0.0030 - 0.0060 in)
Limit : 0.24 mm (0.0094 in)
K
L
PBIC3181J
• Measure the following parts if out of the standard. M

- Dimension “A” for groove of cylinder head No. 1 journal
Standard : 4.000 - 4.030 mm (0.1575 - 0.1587 in)

N
- Dimension “B” for camshaft flange
Standard : 3.877 - 3.925 mm (0.1526 - 0.1545 in) O

• Refer to the standards above, and then replace camshaft and/
or cylinder head.
PBIC3183J P
Camshaft Sprocket Runout
1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
EM-189
CAMSHAFT
2. Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
Limit : 0.15 mm (0.0059 in)

• If it exceeds the limit, replace camshaft sprocket.
PBIC3182J
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-148,
"Valve Clearance".
KBIA0182E
Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter with a micrometer (A).
Standard:
Intake : 33.977 - 33.987 mm (1.3377 - 1.3381 in)
Exhaust : 29.977 - 29.987 mm (1.1802 - 1.1806 in)
PBIC3185J
VALVE LIFTER HOLE DIAMETER

Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A).
Standard:
Intake : 34.000 - 34.021 mm (1.3386 - 1.3394 in)
Exhaust : 30.000 - 30.021 mm (1.1811 - 1.1819 in)
VALVE LIFTER CLEARANCE
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter
outer diameter)
PBIC3184J
Standard: 0.013 - 0.044 mm (0.0005 - 0.0017 in)

• If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSTALLATION
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
EM-190
CAMSHAFT
• Clean camshaft journal to remove any foreign material.
• Distinguish between the intake and the exhaust by looking at A
the different shapes of the front and rear ends of the camshaft
or using the identification colors (A) and (B).
EM
1 : Camshaft (EXH)
2 : Camshaft (INT)
C
Identification color A B
Camshaft (EXH) — Yellow
Camshaft (INT) Yellow — PBIC3188J D
• Install camshafts so that camshaft dowel pins (A) on the front

side are positioned as shown. E
1 : Camshaft (EXH)
2 : Camshaft (INT) F
NOTE:
Though camshaft does not stop at the positions as shown, for
the placement of cam nose, it is generally accepted camshaft G
is placed for the same direction as shown.
PBIC3189J
H
3. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.
4. Apply liquid gasket (A) to camshaft bracket as shown. I
J
B : Plug hole inner wall K

: Engine front
: Engine outside
L
PBIC3964E
P
EM-191
CAMSHAFT
5. Install camshaft bracket bolts in three stage in numerical order
as shown in numerical order as shown.
: Engine front
• There are two types of bolts. Refer to the following for locating
bolts.
M6 bolts [thread length: 57.5 mm (2.264 in)]

: 13, 14 and 15 in the figure
M6 bolts [thread length: 35.00 mm (1.378 in)] PBIC3176J
: Except the above

6. Tighten all bolts in numerical order in three steps.
Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)

Step 2 : 5.88 N·m (0.60 kg-m, 52 in-lb)
Step 3 : 9.5 N·m (0.97 kg-m, 84 in-lb)
7. Install the camshaft sprocket (INT) to the camshaft (INT).
NOTE:
When the camshaft sprocket (INT) (2) is removed, refer to the
paint mark (A) put according to step “3”. Securely align the
knock pin and the pin hole, and then install them.
1 : Camshaft bracket
: Engine front
PBIC3992J
8. Tighten camshaft (INT) sprocket bolt.
Camshaft sprocket bolt (INT) : 35.0 N·m (3.6 kg-m, 26 ft-lb)

NOTE:
Secure the hexagonal part of camshaft (INT) using wrench to tighten bolt.
9. Turn 67 degrees clockwise (angle tightening) using Tool.

A : Camshaft (INT) hexagonal part
CAUTION:
Never judge by visual inspection without an angle wrench.
PBIC3455J
EM-192
CAMSHAFT
10. Install camshaft sprocket (EXH) (2).
A
Camshaft sprocket : 88.2 N·m (9.0 kg-m, 65 ft-lb) EM

bolt (EXH)
NOTE:
Secure the hexagonal part (A) of camshaft (EXH) using wrench C
to tighten bolt.
PBIC3454J
D
11. Install timing chain and related parts. Refer to EM-176.
12. Inspect and adjust valve clearance. Refer to EM-148, "Valve Clearance".
13. Installation of the remaining components is in the reverse order of removal. E

F
The following are procedures for checking fluids leak, lubricates leak.
quantity, fill to the specified level. Refer to GI-27, "Recommended Chemical Products and Sealants".
• Use procedure below to check for fuel leakage. G
- Start engine. With engine speed increased, check again for fuel leakage at connection points. H
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after I
hydraulic pressure rises.
engine coolant. J
K
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level L
M
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc. N
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III O
and it is directed according to inspection procedure of EC section. Refer to EC-796, "Diagnosis Pro-
cedure".
• Check when engine is cold so as to prevent burns from the splashing engine oil.
P
1. Check engine oil level. Refer to LU-15, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Remove intake manifold. Refer to EM-156, "Component".
b. Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to EM-176, "Component".
EM-193
CAMSHAFT
4. Clean the mating area of intake valve timing control solenoid
valve. Insert a clean shop cloth (with no oil adhesion) into the oil
hole (A) of the cylinder head.
1 : Front cover
:Vehicle front
5. Install engine mounting bracket (RH), engine mounting insulator,

and torque rod (RH) under the Step 4 condition. (With intake
valve timing control solenoid valve removed, and a shop cloth
inserted into the oil hole.) Refer to EM-207, "Component". WBIA0781E
6. Crank engine, and then make sure that engine oil comes out
from intake valve timing control solenoid valve hole (A). End crank after checking.
• Check engine oil leakage by oil amount adhered to the waste inserted into the oil hole.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).
CAUTION:
• Do not perform cranking without installing right engine mount bracket, right engine mount insu-
lator, and right torque rod.
• Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil
and so as to prevent engine oil contamination.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
• Remove oil filter (for intake valve timing control), and then clean it. Refer to EM-186, "Component".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-11,
"Lubrication Circuit".
8. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-11, "Lubrication Circuit".
9. Installation of the remaining components is in the reverse order of removal
EM-194
OIL SEAL
OIL SEAL
A
Removal and Installation of Valve Oil Seal INFOID:0000000001337800
REMOVAL EM
1. Remove camshafts. Refer to EM-186, "Component".
2. Remove valve lifters. Refer to EM-186.
C
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain. D
• Compress valve spring using Tool, the attachment and the
adapter (A). Remove valve collet with a suitable magnet hand E
(B).
CAUTION:
When working, be careful not to damage valve lifter holes.
F
Tool number : KV101092S0 (J-26336-B)
PBIC3727E
H
5. Remove valve spring retainer, valve spring and valve spring seat.
6. Remove valve oil seal using Tool (A).
I
Tool number :KV10107902 (J-38959)
PBIC3728E
INSTALLATION L
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height “H” shown using Tool (A).
M
Height “H” : 15.1 - 15.7 mm (0.594 - 0.618 in)
N
PBIC3211J
P
Removal and Installation of Front Oil Seal INFOID:0000000001337801
REMOVAL
• Front fender protector (RH); Refer to EXT-22, "Removal and Installation".
EM-195
OIL SEAL
• Drive belt; Refer to EM-142, "Component".
• Crankshaft pulley; Refer to EM-176, "Component".
2. Remove front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
A : Dust seal lip

B : Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
• Install front oil seal (2) using a suitable tool with outer diameter
57 mm (2.24 in) and inner diameter 45 mm (1.77 in) (A) to the
dimension as shown.
Within 0.3 mm (0.012 in) toward engine front

Within 0.5 mm (0.020 in) toward engine rear
CAUTION:
• Be careful not to damage front cover and crankshaft.
ing.
PBIC3729E
• Do not touch grease applied on oil seal lip.
Removal and Installation of Rear Oil Seal INFOID:0000000001337802
REMOVAL
1. Remove transaxle assembly. Refer to TM-681, "Removal and Installation".
2. Remove clutch cover and clutch disk. Refer to CL-13, "Removal and Installation".
3. Remove flywheel. Refer to EM-211, "Component".
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-27, "Recommended Chemical Prod-
ucts and Sealants".
EM-196
OIL SEAL
2. Install rear oil seal so that each seal lip is oriented as shown.
A
A : Dust seal lip
B : Oil seal lip
: Engine outside EM
: Engine inside
PBIC3485J
D
• Install rear oil seal with a suitable tool with an outer diameter
115 mm (4.53 in) and inner diameter 90 mm (3.54 in) (A).
CAUTION: E
• Be careful not to damage crankshaft and cylinder block.
ing.
• Do not touch grease applied onto oil seal lip. F
G
PBIC3951E
• Install rear oil seal (1) to the position as shown. H
A : Rear end surface of cylinder block

I
NOTE:
The standard surface of the dimension is the rear end surface of
cylinder block.
J
K
PBIC3761E

L
EM-197
CYLINDER HEAD
CYLINDER HEAD
PBIC3542J
1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket

A. Refer to EM-198
REMOVAL
WARNING:
2. Drain engine coolant and engine oil. Refer to CO-35, "Changing Engine Coolant" and LU-16, "Changing
Engine Oil".
5. Remove the following components and related parts.
• Exhaust manifold; Refer to EM-159.
• Intake manifold; Refer to EM-156.
• Fuel tube and fuel injector assembly; Refer to EM-162.
• Water outlet; Refer to CO-47, "Removal and Installation".
• Rocker cover; Refer to EM-173, "Removal and Installation".
• Front cover, timing chain; Refer to EM-176.
• Camshaft; Refer to EM-186.
6. Remove cylinder head.
: Engine front
• Using TORX socket (size E18), loosen cylinder head bolts.

PBIC3206J
EM-198
CYLINDER HEAD
A
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one. EM
Limit (“d1” – “d2”): 0.15 mm (0.0059 in)

• If reduction of outer diameter appears in a position other than “d2”, C
use it as “d2” point.
PBIC3994E
Cylinder Head Distortion E

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-219, "Inspec-
tion After Disassembly".
F
CAUTION:
Use utmost care not to allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head, G
measure the distortion in six directions using straightedge (A)
and feeler gauge (B).
H
Limit: 0.1 mm (0.004 in)
• If it exceeds the limit, replace cylinder head.
I
J
PBIC3207J
INSTALLATION
K
1. Install cylinder head gasket.
2. Apply new engine oil to threads and seating surface of bolts.
CAUTION: L
If cylinder head bolts re-used, check their outer diameters before installation. Follow the "Cylinder
Head Bolts Outer Diameter" measurement procedure.
3. Install cylinder head, follow the steps below to tighten cylinder
head bolts in numerical order as shown. M
Step a : 40 N·m (4.1 kg-m, 30 ft-lb)

Step b : 100° clockwise N
Step c : Loosen to 0 N·m in the reverse order of tight-
ening.
O
Step d : 40 N·m (4.1 kg-m, 30 ft-lb)
Step e : 100° clockwise
PBIC3206J
Step f : 100° clockwise P
EM-199
CYLINDER HEAD
: Engine front
CAUTION:
Check and confirm the tightening angle by using Tool (A) or
protractor. Never judge by visual inspection without the
tool.
PBIC3208J

PBIC3543J
Valve spring (EXH)

1. Valve collet 2. Valve spring retainer 3.
(with valve spring seat)
4. Valve oil seal 5. Valve guide (EXH) 6. Valve seat (EXH)
7. Valve (EXH) 8. Valve (INT) 9. Valve seat (INT)
10. Cylinder head 11. Valve guide (INT) 12. Spark plug
Valve spring (INT)
13.
(with valve spring seat)
DISASSEMBLY
EM-200
CYLINDER HEAD
2. Remove valve lifter. A
• Compress valve spring using Tool, attachment and adapter EM
(A). Remove valve collet using a suitable magnet hand.
CAUTION:
C
Tool number : KV101092S0 (J-26336-B)
D
PBIC3209J E
4. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Never remove valve spring seat from valve spring. F
5. Push valve stem to combustion chamber side, and remove valve.
NOTE:
Identify installed positions, and store them without mixing them up. G
6. Remove valve oil seal using Tool (A).
Tool number : KV10107902 (J-38959) H
J
PBIC3210J
7. When valve seat must be replaced, refer to EM-202, "Inspection After Disassembly" to removal. K
8. When valve guide must be replaced, refer to EM-202, "Inspection After Disassembly" to removal.
ASSEMBLY
L
1. Install valve guide if removed. Refer to EM-202, "Inspection After Disassembly".
2. Install valve seat if removed. Refer to EM-202, "Inspection After Disassembly".
3. Install valve oil seal.
M
• Install with a valve oil seal using Tool (A) to match dimension
as shown.
Tool number : KV10115600 (J-38958) N

NOTE:
Dimension “H” is height that measured before installing valve
spring (with valve spring seat). O
Height “H” : 15.1 - 15.7 mm (0.594 - 0.618 in)

PBIC3211J
P
4. Install valve.
• Install larger diameter to intake side.
EM-201
CYLINDER HEAD
5. Install valve spring (with valve spring seat).
• Install smaller pitch (valve spring seat side) to cylinder head
side (B).
• Confirm identification color (A) of valve spring.
1 : Valve spring seat (Do not remove from valve spring.)
Intake : White
Exhaust : Orange
PBIC3462J
6. Install valve spring retainer.

7. Install valve collet.
• Compress valve spring using Tool (A). Install valve collet with a magnet hand.
Tool number : KV101092S0 (J-26336 B)

CAUTION:
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
PBIC3209J

• Install it in the original position.
Inspection After Disassembly INFOID:0000000001337808
VALVE DIMENSIONS
• Check dimensions of each valve. For dimensions, refer to EM-238, "Standard and Limit".
• If dimensions are out of the standard, replace valve.
VALVE GUIDE CLEARANCE
Valve Stem Diameter
Measure the diameter of valve stem with a micrometer (A).
Standard
Intake : 5.465 - 5.480 mm (0.2152 - 0.2157 in)
Exhaust : 5.455 - 5.470 mm (0.2148 - 0.2154 in)
PBIC3213J
Valve Guide Inner Diameter

Measure the inner diameter of valve guide with a bore gauge.
Standard
: 5.500 - 5.518 mm (0.2165 - 0.2172 in)
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
EM-202
CYLINDER HEAD
Valve guide clearance: A

Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
EM
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
: 0.1 mm (0.004 in) C
• If it exceeds the limit, replace valve guide and/or valve.
VALVE GUIDE REPLACEMENT
D
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.
1. To remove valve guide, heat cylinder head to 110° to 130°C
(230° to 266°F) by soaking in heated oil (A).
E
PBIC3214J
H
2. Drive out valve guide using suitable tools.
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned. I
K
SEM931C
3. Ream cylinder head valve guide hole using suitable tool (A). L
Valve guide hole diameter (for service parts):

: 9.675 - 9.696 mm (0.3809 - 0.3817 in) M
PBIC3215J O
EM-203
CYLINDER HEAD
4. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking
in heated oil (A).
PBIC3214J
5. Press valve guide (1) from camshaft side to dimensions as

shown.
2 : Cylinder head
Projection “H” : 13.35 - 13.65 mm (0.526 - 0.537 in)

CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
PBIC3217J
6. Apply reamer finish to valve guide using suitable tool (A).
Standard
: 5.500 - 5.518 mm (0.2165 - 0.2172 in)
PBIC3215J
VALVE SEAT CONTACT

• After confirming that the dimensions of valve guides and valves are within specifications, perform this proce-
dure.
• Apply prussian blue (or white lead) 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-
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has NG conditions even after the re-check, replace
valve seat.
SBIA0322E
VALVE SEAT REPLACEMENT

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-238, "Standard and Limit".
EM-204
CYLINDER HEAD
2. Ream cylinder head (1) recess diameter for service valve seat.
A
2 : Valve seat
Oversize [0.5 mm (0.020 in)] EM

Intake : 35.200 - 35.227 mm (1.3858 - 1.3869 in)
Exhaust : 29.200 - 29.227 mm (1.1496 - 1.1507 in)
C
• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
PBIC3218J
D
3. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking
in heated oil (A).
E
G
PBIC3214J
4. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head. H
CAUTION:
• Never touch cold valve seats directly.
• Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
I
5. Using valve seat cutter set or valve seat grinder, finish valve
seat to the specified dimensions. For dimensions, refer to EM-
238, "Standard and Limit".
CAUTION: J
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper K
pressure on with the cutter or cutting many different times
may result in stage valve seat.
L
SEM934C
6. Using compound, grind to adjust valve fitting.

M
7. Check again for normal contact.
VALVE SPRING SQUARENESS
• Set try square along the side of valve spring and rotate the spring. N
Measure the maximum clearance between the top of valve spring
and try square.
CAUTION:
Never remove valve spring seat from valve spring. O
Limit: 1.9 mm (0.075 in)

P
• If it exceeds the limit, replace valve spring (with valve spring seat).
PBIC0080E
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
EM-205
CYLINDER HEAD
• Check valve spring pressure with valve spring seat installed at the
specified spring height.
CAUTION:
Never remove valve spring seat from valve spring.
SEM113
Standard:
Items Intake Exhaust
Free height 44.90 - 45.10 mm (1.7677 - 1.7755 in) 45.74 - 45.94 mm (1.8007 - 1.8086 in)
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 153 - 173 N (15.6 - 17.6 kg, 34 - 39 lb) 139 - 157 N (14.2 - 16 kg, 10 - 35 lb)
Height during valve open 26.36 mm (1.0377 in) 27.80 mm (1.0944 in)
Load with valve open 335 - 377 N (34.2 - 38.5 kg, 75 - 85 lb) 266 - 297 N (27.1 - 3.03 kg, 60 - 67 lb)
Identification color White Orange
• If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring
seat).
EM-206
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [MR18DE]
REMOVAL AND INSTALLATION A

ENGINE ASSEMBLY
EM
WBIA0846E
M
1. Engine mounting Insulator (RH) 2. Engine mounting shim (RH) (if equipped) 3. Engine mounting bracket (RH)
4. Bracket 5. Rear torque rod 6. Engine through bolt
N
7. Engine mounting bracket (LH) 8. Engine mounting insulator (LH) 9. Torque rod (RH)
A. Front mark B. Silicone lubricant
Removal and Installation INFOID:0000000001337810 O
WARNING:
• Situate the vehicle on a flat and solid surface. P
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
• Do not start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, follow the procedures in the applica-
ble sections.
EM-207
ENGINE ASSEMBLY
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
• For supporting points for lifting and jacking point at rear axle, refer to GI-48, "Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
1. Remove engine undercover
2. Drain engine coolant from radiator. Refer to CO-35, "Changing Engine Coolant".
CAUTION:
• Do not spill engine coolant on drive belt.
3. Remove front fender protector (RH and LH); Refer to EXT-22, "Removal and Installation".
4. Remove exhaust front tube; Refer to EX-10, "Component".
5. Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-7, "Removal and Installation".
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-207, "Compo-
nent".
7. Remove rear torque rod (1).
LBIA0460E
8. Remove hood assembly. Refer to DLK-214, "Removal and Installation".

9. Remove cowl top cover and cowl top extension assembly. Refer to EXT-20, "Removal and Installation".
10. Release fuel pressure. Refer to EC-1035, "Inspection".
11. Remove battery and battery tray; Refer to PG-6, "Removal and Installation".
12. Remove drive belt; Refer to EM-142, "Component".
13. Remove air duct and air cleaner case assembly; Refer to EM-154.
14. Remove cooling fan assembly.
15. Remove radiator hose (upper and lower). Refer to CO-40, "Component".
16. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then tem-
porarily secure the engine harness into the engine side.
CAUTION:
Protect connectors using a resin bag to protect against foreign materials during the operation.
17. Disconnect fuel feed hose at engine side. Refer to EM-162, "Component".
18. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-47,
"Component".
19. Disconnect control cable from transaxle. Refer to TM-674, "Exploded View".
20. Remove ground cable at transaxle side.
21. Remove ground cable between front cover and vehicle.
22. Remove generator. Refer to CHG-29, "Removal and Installation".
23. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side
with a rope to avoid putting load on it. Refer to HA-32, "Removal and Installation of Compressor -
MR18DE".
EM-208
ENGINE ASSEMBLY
24. Remove the intake manifold to prevent the hanging chain from interfering. Refer to EM-156, "Removal
and Installation". A
25. Install engine slinger to cylinder head front left side (A) and rear
right side (B) and support the engine position with a hoist.
EM
: Engine front
Slinger bolts : 25.5 N·m (2.6 kg-m, 19 ft-lb) C
D
LBIA0461E
26. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position.
E
27. Use a manual lift table caddy (A) or equivalently rigid tool such
as a transmission jack. Securely support bottom of the engine
and the transaxle, and simultaneously adjust hoist tension.
CAUTION: F
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
G
H
PBIC3223J
28. Remove torque rod (RH) (1), engine insulator (RH) (2) and
engine bracket (RH) (3). I
4 : Engine insulator (LH)

A : Engine front side J
B : Transaxle side
29. Remove engine through bolt-securing nut (C). K
WBIA0784E
L
30. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating sup-
porting tools.
CAUTION: M
• During the operation, make sure that no part interferes with the vehicle side.
• During the removal operation, always be careful to prevent the vehicle from falling off the lift due
N
to changes in the center of gravity.
• If necessary, support the vehicle by setting jack or suitable tool at the rear.
• During operation, securely support the engine by placing a piece of wood under the engine oil
pan and transaxle oil pan. Securely support the engine slingers with a hoist. O
31. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left
side and rear right side. Refer to EM-207, "Component".
32. Remove starter motor. Refer to STR-24, "Removal and Installation". P
33. Lift with a hoist and position above engine.
34. Separate the engine and the transaxle. Refer to EM-207, "Component" .
INSTALLATION
Note the following, and install in the reverse order of removal.
• Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insu-
lator.
EM-209
ENGINE ASSEMBLY
• When installation directions are specified, install parts according to the directions. Refer to EM-207, "Com-
ponent".
• Prior to installing the upper torque rod, apply a light coat of silicone
lubricant (A) to the washer facing side of the bushing inner tube as
shown.
NOTE:
• Apply silicone lubricant (A) by dabbing the outward facing tube
surface with a sponge or suitable tool.
• Do not apply excess lubricant.
: Vehicle front
LBIA0470E
• Make sure that each mounting insulator is seated properly, and tighten nuts and bolts.
• Tighten engine mounting insulator (RH) bolts in the numerical
order shown.
: Vehicle front
WBIA0785E

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
quantity, fill to the specified level. Refer to LU-15, "Inspection", CO-35, "Inspection".
Item Before starting engine Engine running After engine stopped
* Transmission/transaxle fluid, power steering fluid, brake fluid, etc.
EM-210
ENGINE UNIT
< DISASSEMBLY AND ASSEMBLY > [MR18DE]
DISASSEMBLY AND ASSEMBLY A

ENGINE UNIT
EM
AWBIA0116GB
EM-211
ENGINE UNIT
1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS)

Crankshaft position sensor (POS) Oil filter (for intake valve timing con-
4. 5. 6. Knock sensor
cover trol)
7. Oil pressure switch 8. Top ring 9. Second ring
10. Oil ring 11. Snap ring 12. Piston
13. Piston pin 14. Connecting rod 15. Thrust bearing
16. Connecting rod bearing upper 17. Main bearing upper 18. Crankshaft key
19. Main bearing lower 20. Connecting rod bearing lower 21. Connecting rod bearing cap
22. Connecting rod bolt 23. Main bearing cap 24. Main bearing cap bolt
25. Crankshaft 26. Signal plate 27. Rear oil seal
28. Flywheel
A. Refer to EM-212
DISASSEMBLY
1. Remove engine and transaxle assembly from vehicle, separate transaxle from engine. Refer to EM-207.
2. Install engine to engine stand as follows;
a. Remove flywheel.
• Secure flywheel using Tool (A), and remove bolts.
Tool number : KV 11105210 (J-44716)

CAUTION:
Be careful not to damage or scratch contact surface for
clutch disc of flywheel.
AWBIA0117ZZ
b. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Exhaust manifold; Refer to EM-159.
- Rocker cover; Refer to EM-173, "Removal and Installation".
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel
removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
PBIC3227J
3. Remove oil pan (upper and lower). Refer to EM-166.

4. Remove cylinder head. Refer to EM-198, "Removal and Installation".
5. Remove thermostat housing. Refer to CO-45, "Removal and Installation".
6. Remove knock sensor.
CAUTION:
EM-212
ENGINE UNIT
Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS). A
CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble. EM
8. Remove oil filter (for intake valve timing control). C

9. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
NOTE:
Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to D
EM-219, "Inspection After Disassembly".
10. Remove connecting rod cap.
11. Using a suitable tool, push piston and connecting rod assembly E
out to the cylinder head side.
CAUTION:
• Be careful not to damage matching surface with connect- F
ing rod cap.
• Be careful not to damage the cylinder wall and crankshaft
big end. G
PBIC0259E
H
12. Remove connecting rod bearings.

CAUTION: I
When removing them, note the installation position. Keep them in the correct order.
13. Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-219, "Inspection After
J
Disassembly".
14. Using a suitable tool (A) remove piston rings.
CAUTION:
• When removing piston rings, be careful not to damage the K
piston.
• Be careful not to damage piston rings by expanding them
excessively. L
PBIC3233J
N
15. Using snap ring pliers (A), remove snap rings.
PBIC3230J
EM-213
ENGINE UNIT
16. Heat piston to 60° to 70°C (140° to 158°F) using a suitable tool
(A).
PBIC3231J
17. Push out piston pin using a suitable tool of an outer diameter
approximately 18 mm (0.71 in).
PBIC0262E
18. Loosen main bearing cap bolts in reverse order as shown, and
remove them.
NOTE:
Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-219, "Inspection After Disassembly".
: Engine front
19. Remove main bearing caps.

• Tap main bearing caps lightly using a suitable tool for removal.
CAUTION:
PBIC3235J
Be careful not to damage the mounting surface.
20. Remove crankshaft.
CAUTION:
• Be careful not to damage or deform signal plate (1)
mounted on rear end of crankshaft (A).
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
• Never remove signal plate unless it is necessary to do so.
21. Pull rear oil seal out from rear end of crankshaft.
22. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
CAUTION:
Identify installation positions, and store them without mix- PBIC3234J
ing them up.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
EM-214
ENGINE UNIT
2. Install water drain plug (1) to cylinder block.
A
: Engine front
• Apply liquid gasket to the drain plug thread.

Use Genuine Silicone RTV Sealant or equivalent. Refer to EM
9.8 N·m (1.0 kg-m, 87 in-lb) C

3. Remove dust, dirt, and engine oil on the bearing mating sur-
faces of cylinder block and main bearing cap. PBIC3228J
D
4. Install thrust bearings to the both sides of the No. 3 journal hous-
ing (B) on cylinder block.
E
: Engine front
• Install thrust bearings with the oil groove (A) facing crankshaft
arm (outside). F
G
PBIC3258J
5. Install the main bearings paying attention to the direction. H

CAUTION:
• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not
apply new engine oil to the back surface, but thoroughly clean it.
• When installing, align main bearing to the center position of cylinder block and main bearing I
cap.
• The difference (A) between main bearing upper (1) and
main bearing lower (3) should be 0.85 mm (0.033 in) or J
less when installing.
2 : Cylinder block
K
4 : Main bearing cap
PBIC3237J
M
• Ensure the oil holes on cylinder block and oil holes (A) on
the main bearings (1) are aligned.
N
P
PBIC3236J
6. Install signal plate to crankshaft if removed.

7. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crank-
shaft rear surface.
8. Apply new engine oil to threads and seat surfaces of bolts.
EM-215
ENGINE UNIT
9. Position crankshaft (2) and signal plate (1) using a dowel pin
(service part), and tighten bolts in numerical order as shown.
A : Dowel pin hole

NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
11. Remove dowel pin. (service parts)
CAUTION:
PBIC3238J
Be sure to remove dowel pin.
12. Install crankshaft to cylinder block.
• While turning crankshaft by hand, make sure that it turns smoothly.
13. Install main bearing caps referring to the journal No. stamp (A)
and front mark (B) as shown.
: Engine front
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
PBIC3239J
14. Apply new engine oil to threads and seat surfaces of bolts.
15. Tighten main bearing cap bolts in two steps.
NOTE:
Tighten main bearing cap bolts in numerical order as shown:
: Engine front
Step 1 : 34.3 N·m (3.5 kg-m, 25 ft-lb)

Step2 60° clockwise
PBIC3235J
PBIC3240J
• After installing bolts, make sure that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-219, "Inspection After Disassembly".
16. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
17. Assemble piston to connecting rod.
EM-216
ENGINE UNIT
• Using a suitable tool, heat the piston until the piston pin can be pushed in by hand without excess force
[approximately 60° to 70 °C (140° to 158 °F)]. From the front to the rear, insert piston pin into piston and A
connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (C) on connecting rod
EM
are positioned as shown.
D : Big end diameter grade

C
E : Small end diameter grade
F : Front mark (connecting rod bearing cap)
18. Install new snap ring to the groove of the piston front side. D
• Insert it fully into groove to install.
• After installing, make sure that connecting rod moves PBIC3587J
smoothly.
E
19. Using a suitable tool, install piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively. F
• Position each ring with the gap as shown referring to the pis-
ton front mark.
G
A : Oil ring upper or lower rail gap
B : Front mark
C : Second ring and oil ring spacer gap
H
D : Top ring gap
E : Stamped mark
CAUTION: I
Never contact the rail end gap under the oil ring with the PBIC3588J
oil drain cast groove of piston.
• Install second ring with the stamped surface facing upward.
J
20. Install connecting rod bearing upper (2) and lower (3) to con-
necting rod (1) and connecting rod cap (4).
K
C : Oil hole (connecting rod)
D : Arrow view
: Engine front
L
• Install the connecting rod in the dimension shown.

• Make sure that connecting rod bearing oil hole (A) is com-
M
pletely in the inside of connecting rod oil hole chamfered area
(B).
• When installing connecting rod bearings, apply new engine oil
to the bearing surface (inside). Do not apply new engine oil to N
the back surface, but thoroughly clean it.
NOTE:
• There is no positioning tab.
O
• Install the connecting rod bearings in the center of connect-
ing rod and connecting rod bearing cap as shown. For ser-
vice operation, the center position can be checked, visually.
P
PBIC4541E
21. Install piston and connecting rod assembly to crankshaft.

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
EM-217
ENGINE UNIT
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number (C) on
connecting rod to install.
B : Oil hole
• Install so that front mark (A) on the piston head faces the front
of engine.
PBIC3587J
• Using a piston ring compressor [SST: EM03470000 (J-8037)]

(A) or suitable tool, install piston with the front mark on the pis-
ton head facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
big end.
PBIC3244J
22. Install connecting rod cap.

• Match the stamped cylinder number marks (C) on connecting
rod with those on connecting rod cap to install.
A : Front mark (piston)

B : Oil hole
PBIC3587J
23. Tighten connecting rod bolt with the following procedure:

CAUTION:
• Make sure that there is no gap in the thrust surface (A) of
the joint between connecting rod (1) and connecting rod
bearing cap (2) and that these parts are in the correct
position. And then, tighten the connecting rod bolts.
• If the connecting rod bolts are reused, measure the outer
diameter. Refer to EM-219, "Inspection After Disassem-
bly".
24. Apply new engine oil to the threads and seats of connecting rod
bolts.
25. Tighten bolts in three steps
PBIC3510J
Step 1 : 27.4 N·m (2.8 kg-m, 20 ft-lb)

Step 2 : 0 N·m (0 kg-m, 0 ft-lb)
Step 3 : 19.6 N·m (2.0 kg-m, 14 ft-lb)
• After tightening connecting rod bolt, make sure that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-219, "Inspection After Disassembly".
26. Install oil pan (upper). Refer to EM-166.
EM-218
ENGINE UNIT
NOTE:
Install the rear oil seal after installing the oil pan (upper). A
27. Install rear oil seal. Refer to EM-166.
28. Install flywheel.
• Secure crankshaft using Tool. (A), and tighten bolts crosswise EM
over several times.
Tool number : KV11105210 (J-44716) C
AWBIA0117ZZ
E
29. Install knock sensor (1) with connector facing toward the rear of
engine.
F
A : Cylinder block left side
: Engine front
CAUTION: G
• Never tighten bolts while holding the connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one. H
NOTE:
PBIC3246J
• Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of knock sensor.
I
• Make sure that knock sensor does not interfere with other parts.
30. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover.
CAUTION:
• Avoid impacts such as a dropping. J
K
31. Install oil filter (for intake valve timing control) (1) in the direction
shown.
• Make sure that the oil filter does not protrude from the upper L
surface of cylinder block (2) after installation.
N
PBIC3260J
32. Assemble in the reverse order of disassembly. O
Inspection After Disassembly INFOID:0000000001337814
P
CRANKSHAFT END PLAY
EM-219
ENGINE UNIT
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit : 0.30 mm (0.012 in)
• If the measured value exceeds the limit, replace thrust bearings,
also.
PBIC3252J
CONNECTING ROD SIDE CLEARANCE

• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit : 0.40 mm (0.0157 in)
• If the measured value exceeds the limit, replace connecting rod,
also.
PBIC3251J
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
Standard: 19.993 - 19.999 mm (0.7871 - 0.7874 in)
PBIC3265J

Measure the outer diameter of piston pin with a micrometer (A).
Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)
PBIC3266J
Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)

• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, rfollow the "Piston to Cylinder Bore Clearance" procedure.
NOTE:
• Piston is available together with piston pin as assembly.
EM-220
ENGINE UNIT
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.) A
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge (A). EM
Standard:
Top ring : 0.04 - 0.08 mm (0.002 - 0.003 in) C
2nd ring : 0.03 - 0.07 mm (0.001 - 0.003 in)
Oil ring : 0.015 - 0.185 mm (0.001 - 0.007 in)
D
Limit:
PBIC3280J
Top ring : 0.11 mm (0.0043 in) E
2nd ring : 0.10 mm (0.0039 in)
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also. F
PISTON RING END GAP

• Make sure that cylinder bore inner diameter is within specification.
• Lubricate with new engine oil to piston (1) and piston ring (2), and G
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).
H
Standard:
Top ring : 0.20 - 0.30 mm (0.008 - 0.012 in)
2nd ring : 0.50 - 0.65 mm (0.020 - 0.026 in) I
Oil ring : 0.15 - 0.45 mm (0.006 - 0.018 in)
(rail ring)
J
PBIC3267J
Limit:
Top ring : 0.51 mm (0.020 in) K
2nd ring : 0.83 mm (0.033 in)
Oil ring : 0.78 mm (0.031 in)
(rail ring) L
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversized piston and piston rings.
M
CONNECTING ROD BEND AND TORSION
EM-221
ENGINE UNIT
• Check with a connecting rod aligner.
C : Feeler gauge
Bend (A):
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion (B):
Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
• If it exceeds the limit, replace connecting rod assembly.
PBIC3268J
CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod bolts to the specified
torque. Refer to EM-212, "Disassembly and Assembly" for the
tightening procedure.
2 : Connecting rod
A : Example
B : Measuring direction of inner diameter
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
PBIC3269J
Standard: 47.000 - 47.013 mm (1.8504 - 1.8509 in)

• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)
PBIC3270J
EM-222
ENGINE UNIT
Measure the outer diameter of piston pin with a micrometer (A).
A
Standard: 19.989 - 19.995 mm (0.7870 - 0.7872 in)
EM
PBIC3266J
D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
Standard : 0.005 - 0.023 mm (0.0002 - 0.0009 in)
Limit : 0.03 mm (0.0012 in)
F
• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly, refer to "PISTON TO PISTON PIN OIL CLEARANCE".
• If replacing connecting rod assembly, refer to "Connecting Rod Bushing Oil Clearance" to select connecting G
rod bearing.
CYLINDER BLOCK TOP SURFACE DISTORTION H

other contamination.
CAUTION: I
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and feeler
J
gauge (B).
Limit: 0.1 mm (0.004 in)

K
PBIC3250J
MAIN BEARING HOUSING INNER DIAMETER M

• Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified
torque. Refer to EM-212, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore gauge. N
• Measure the position shown [5 mm (0.20 in)] backward from main
bearing housing front side in the 2 directions as shown. The
smaller one is the measured value.
O
1 : Cylinder block
2 : Main bearing cap
: Engine front P
Standard: 55.997 - 56.017 mm (2.2046 - 2.2054 in)

• If out of the standard, replace cylinder block and main bearing PBIC4005E
caps assembly.
NOTE:
Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block.
EM-223
ENGINE UNIT
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using a bore gauge (A), measure the cylinder bore for wear, out-
of-round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of
engine)
NOTE:
When determining cylinder bore grade, measure the cylinder bore
“X” direction at “B” position.
Standard inner diameter:

84.000 - 84.020 mm (3.3071 - 3.3079 in)
Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”):
0.01 mm (0.0004 in)
• If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, replace cylinder block.
NOTE:
Oversize piston is not provided.
PBIC4014E
Piston Skirt Diameter

Measure the outer diameter of piston skirt with a micrometer (A).
Measure point
: Distance from the top 39.9 mm (1.571 in)
Standard
: 83.970 - 83.990 mm (3.3059 - 3.3067 in)
PBIC3272J
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)
Standard : 0.020 - 0.040 mm (0.0008 - 0.0016 in)

Limit : 0.08 mm (0.0031 in)
• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-230, "How
to Select Piston and Bearing".
EM-224
ENGINE UNIT
• Measure the outer diameter of crankshaft main journals with a
micrometer (A). A
Standard: 51.959 - 51.979 mm (2.0456 - 2.0464 in) dia.

• If out of the standard, measure the main bearing oil clearance. EM
Then use undersize bearing. Refer to "MAIN BEARING OIL
CLEARANCE".
C
PBIC3457J
D
• Measure the outer diameter of crankshaft pin journal with a micrometer.
E
Standard: 43.953 - 43.971 mm (1.7304-1.7311 in) dia.
• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to "CONNECTING ROD BEARING OIL CLEARANCE". F
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

• Measure the dimensions at four different points as shown on each
G
main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in dimensions between
“X” and “Y” at “A” and “B”.
• Taper is indicated by the difference in dimension between “A” and H
“B” at “X” and “Y”.
Limit: I
Out-of-round (Difference between “X” and “Y”)
: 0.0035 mm (0.0001 in)
PBIC3459J
Taper (Difference between “A” and “B”) J
: 0.0035 mm (0.0001 in)
• If the measured value exceeds the limit, correct or replace crankshaft. K
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to "MAIN BEARING OIL CLEARANCE" and/or "CON-
NECTING ROD BEARING OIL CLEARANCE".
L
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft. M
• Place a dial indicator (A) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)
N
Standard : 0.05 mm (0.0020 in)
Limit : 0.10 mm (0.0040 in)
O
• If it exceeds the limit, replace crankshaft.
PBIC3458J
CONNECTING ROD BEARING OIL CLEARANCE P
EM-225
ENGINE UNIT
• Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod bolts to the
specified torque. Refer to EM-212, "Disassembly and Assembly"
for tightening procedure.
A : Example
B : Inner diameter measuring direction
• Measure the inner diameter of connecting rod bearing with an
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter) PBIC3275J
Standard : 0.037 - 0.047 mm (0.0015 - 0.0019 in)

Limit : 0.07 mm (0.0028 in)
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-230,
"How to Select Piston and Bearing".
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
holes.
torque. Refer to EM-212, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
PBIC3276J

• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-212, "Disassembly and Assembly" for the tightening
procedure.
A : Example
B : Inner diameter measuring direction
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
PBIC3277J
Standard:
No. 1, 4 and 5 journals
: 0.024 - 0.034 mm (0.0009 - 0.0013 in)
No. 2 and 3 journals
: 0.012 - 0.022 mm (0.0005 - 0.0009 in)
Limit : 0.065 mm (0.0026 in)
EM-226
ENGINE UNIT
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-230, "How to Select A
Piston and Bearing".
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely. EM
holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the spec- C
ified torque. Refer to EM-212, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
• Remove main bearing cap and bearings, and using the scale (A) D
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is E
PBIC3278J G
MAIN BEARING CRUSH HEIGHT
• When main bearing cap is removed after being tightened to the
H
specified torque with main bearings (1) installed, the tip end of
bearing must protrude (B). Refer to EM-212, "Disassembly and
Assembly" for the tightening procedure.
I
A : Example
Standard : There must be crush height. J

• If the standard is not met, replace main bearings.
PBIC3279J
K
CONNECTING ROD BEARING CRUSH HEIGHT
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed, L
the tip end of bearing must protrude. Refer to EM-212, "Disassem-
bly and Assembly" for the tightening procedure (B).
A : Example M
Standard : There must be crush height.

N
• If the standard is not met, replace connecting rod bearings.
PBIC3279J
MAIN BEARING CAP BOLT OUTER DIAMETER O
EM-227
ENGINE UNIT
• Measure the outer diameters (“d1”, “d2”) at two positions as shown.
A : “d1” measuring position

B : “d2” measuring position
• If reduction appears in places other than “B” range, regard it as
“d2”.
Limit (“d1” – “d2”): 0.15 mm (0.0059 in)

• If it exceeds the limit (a large difference in dimensions), replace
main bearing cap bolt with a new one. PBIC4015E
CONNECTING ROD BOLT OUTER DIAMETER

• Measure the outer diameter “d” at position as shown.
• If reduction appears in a position other than “d”, regard it as “d”.
Limit: 7.75 mm (0.3051 in)

• When “d” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with a new one.
PBIC4016E
CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)

• Make sure that there is no foreign material on the oil filter and
check it for clogging.
- Clean it if necessary.
• Check the oil filter for damage.
- Replace it if necessary.
PBIC3273J
FLYWHEEL DEFLECTION (M/T MODELS)

• Measure the deflection of flywheel contact surface to clutch with a
dial indicator (A).
• Measure the deflection at 210 mm (8.27 in) diameter.
Limit : 0.45 mm (0.0177 in) or less.

• If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft. PBIC4006E
MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS)

CAUTION:
Never disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
• Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard : 1.8 mm (0.071 in) or less
EM-228
ENGINE UNIT
Movement Amount in Radial (Rotation) Direction A
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install clutch cover bolt (1) to clutch cover mating hole, and
place a torque wrench (A) on the extended line of the flywheel EM
(2) center line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it
from loosening. C
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points). D
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side. PBIC4007E
E
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transaxle side.
F
Limit: 33.2 mm (1.307 in) or less.
G
EM-229
How to Select Piston and Bearing INFOID:0000000001337813
DESCRIPTION
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston outer diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, follow the procedures.
HOW TO SELECT PISTON
When New Cylinder Block is Used
• Check the cylinder bore grade on rear left side of cylinder block (L),
and select piston of the same grade.
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front
• If there is a correction stamp mark on the cylinder block, use it as a

correct reference.
PBIC3264J
When Cylinder Block is Reused

1. Measure the cylinder bore inner diameter. Refer to EM-219, "Inspection After Disassembly".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.
EM-230
3. Select piston of the same grade.
A
A : Identification code
B : Front mark
C : Piston grade number EM
D : Sub grade number
PBIC3589J
D
Piston Selection Table
Unit: mm (in)
Grade number (Mark) 1 2 [or no mark (piston only)]
E
Cylinder bore Inner diameter 84.000 - 84.010 (3.3071 - 3.3075) 84.010 - 84.020 (3.3075 - 3.3079)
Piston skirt diameter 83.970 - 83.980 (3.3059 - 3.3063) 83.980 - 83.990 (3.3063 - 3.3067)
NOTE: F
• Piston is available together with piston pin as an assembly.
• There is no piston pin (piston pin hole) grade.
G
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used
H
1. Apply connecting rod big end diameter grade stamped (C) on
connecting rod side face to the row in the “Connecting Rod
Bearing Selection Table”.
I
A : Oil hole
B : Cylinder number
J
D : Small end diameter grade
E : Front mark
K
PBIC3262J
2. Apply crankshaft pin journal diameter grade stamped on crank- L

shaft front side to the column in the “Connecting Rod Bearing
Selection Table”.
A : No. 1 pin journal diameter grade

M
B : No. 2 pin journal diameter grade
C : No. 3 pin journal diameter grade
N
D : No. 4 pin journal diameter grade
E : No. 1 main journal diameter grade
F : No. 2 main journal diameter grade PBIC3261J
O
G : No. 3 main journal diameter grade
H : No. 4 main journal diameter grade
I : No. 5 main journal diameter grade
P
Table”.
When Crankshaft and Connecting Rod are Reused
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-219, "Inspection After Disassembly" and EM-219, "Inspection After Disassembly".
EM-231
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
Table”.
Connecting Rod Bearing Selection Table
PBIC4077E
Connecting Rod Bearing Grade Table

Unit: mm (in)

0 1.494 - 1.497 (0.0588 - 0.0589) Black
1 1.497 - 1.500 (0.0589 - 0.0591) Brown
2 1.500 - 1.503 (0.0591- 0.0592) Green
3 1.503 - 1.506 (0.0592 - 0.0593) Yellow
4 1.506 - 1.509 (0.0593 - 0.0594) Blue
EM-232
A
UPR 1.494 - 1.497 (0.0588 - 0.0589) Black
01
LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown
UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown EM
12
LWR 1.500 - 1.503 (0.0591 - 0.0592) Green Grade and color are different
between upper and lower bear-
UPR 1.500 - 1.503 (0.0591 - 0.0592) Green ings.
23
LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow C
UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
34
LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue
D
Undersize Bearings Usage Guide
• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings. E
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the F
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
I
PBIC3263J
Bearing undersize table

Unit: mm (in) J
Size Thickness
US 0.25 (0.0098) 1.623 - 1.631 (0.0639 - 0.0642)
K
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used
L
EM-233
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear left side of cylinder block (L).
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front
• If there is a correction stamp mark on cylinder block, use it as

a correct reference.
PBIC3264J
2. Apply main journal diameter grade stamped on crankshaft front

side to column in the “Main Bearing Selection Table”.
A : No. 1 pin journal diameter grade

B : No. 2 pin journal diameter grade
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade
E : No. 1 main journal diameter grade
F : No. 2 main journal diameter grade
G : No. 3 main journal diameter grade PBIC3261J
H : No. 4 main journal diameter grade

I : No. 5 main journal diameter grade
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.
NOTE:
Service part is available as a set of both upper and lower.
When Cylinder Block and Crankshaft are Reused
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-219, "Inspection After Disassembly" and EM-219, "Inspection
After Disassembly".
2. Apply the measured dimension to the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4 and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.
NOTE:
EM-234
Service part is available as a set of both upper and lower.
Main Bearing Selection Table (No. 1, 4 and 5 journals) A
EM
PBIC4078E
M
EM-235
Main Bearing Selection Table (No. 2 and 3 journals)
PBIC4079E
Main Bearing Grade Table (All Journals)

Unit: mm (in)

0 1.996 - 1.999 (0.0786 - 0.0787) Black
1 1.999 - 2.002 (0.0787 - 0.0788) Brown
2 2.002 - 2.005 (0.0788- 0.0789) Green
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are the same
4 2.008 - 2.011 (0.0791 - 0.0792) Blue for upper and lower bearings.
5 2.011 - 2.014 (0.0792 - 0.0793) Pink

6 2.014 - 2.017 (0.0793 - 0.0794) Purple
7 2.017 - 2.020 (0.0794 - 0.0795) White
EM-236
A
UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
01
LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown EM
12
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green
UPR 2.002 - 2.005 (0.0788- 0.0789) Green
23
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow C
UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are different
34 between upper and lower bear-
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue ings. D
UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue
45
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink E
56
LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple
UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple
67 F
LWR 2.017 - 2.020 (0.0794 - 0.0795) White
Use Undersize Bearing Usage Guide

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under- G
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
H
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
I
K
PBIC3263J
Bearing undersize table

L
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) M
EM-237
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR18DE]

Standard and Limit INFOID:0000000001337815
Engine type MR18DE

Displacement cm3 (cu in) 1,798 (109.71)
Bore and stroke mm (in) 84.0 x 81.1 (3.307 x 3.192)
Valve arrangement DOHC
Compression 2
Oil 1
Standard 1,500 (15.0, 15.3, 217.6)
Compression pressure
Minimum 1,200 (12.0, 12.2, 174)
kPa (bar, kg/cm2 , psi) / 250 rpm
Differential limit between cylinders 100 (1.0, 1.0, 15)
DRIVE BELT
Tension of drive belt Auto adjustment by auto-tensioner
WATER CONTROL VALVE
Valve opening temperature 93.5 - 96.5°C (200 - 206°F)

Maximum valve lift 8 mm/ 108°C (0.315 in/ 226°F)
Valve closing temperature More than 90°C (194°F)
EXHAUST MANIFOLD
Unit: mm (in)
Items Limit
Each exhaust port 0.3 (0.012)
Surface distortion
Entire part 0.7 (0.028)
THERMOSTAT
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8 mm/ 95°C (0.315 in/ 203°F)
Valve closing temperature More than 77°C (171°F)
SPARK PLUG
Unit: mm (in)
Plug type Platinum-tipped TYPE

Make NGK
Standard type PLZKAR6A-11
Spark plug gap Nominal: 1.1 (0.043)
CYLINDER HEAD
EM-238
Unit: mm (in)
Items Standard Limit A

Head surface distortion — 0.1 (0.004)
Normal cylinder head height “H” 130.9 (5.15) —
EM
PBIC0924E
VALVE F
Valve Timing
Unit: degree
G
J
PBIC5304E
Position a b c d e f
8 (-32) 52 (12) K
Valve timing 212 224 7 25
ATDC ABDC
( ): Valve timing control “ON”
L
Valve Dimensions
Unit: mm (in)
SEM188A
P
Intake 33.8 - 34.1 (1.331 - 1.343)
Valve head diameter “D”
Exhaust 27.6 - 27.9 (1.087 - 1.098)
Intake 106.27 (4.184)
Valve length “L”
Exhaust 105.26 (4.144)
EM-239
Intake 5.465 - 5.480 (0.2152 - 0.2157)
Valve stem diameter “d”
Exhaust 5.455 - 5.470 (0.2148 - 0.2154)
Valve seat angle “α” 45°15′ - 45°45′
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.2 (0.047)
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)
Available Valve Lifter
KBIA0119E
3.00 (0.1181) 300

3.02 (0.1189) 302
3.04 (0.1197) 304
3.06 (0.1205) 306
3.08 (0.1213) 308
3.10 (0.1220) 310
3.12 (0.1228) 312
3.14 (0.1236) 314
3.16 (0.1244) 316
3.18 (0.1252) 318
3.20 (0.1260) 320
3.22 (0.1268) 322
3.24 (0.1276) 324
3.26 (0.1283) 326
3.28 (0.1291) 328
3.30 (0.1299) 330
3.32 (0.1307) 332
3.34 (0.1315) 334
3.36 (0.1323) 336
3.38 (0.1331) 338
3.40 (0.1339) 340
3.42 (0.1346) 342
EM-240
A
3.44 (0.1354) 344
3.46 (0.1362) 346
3.48 (0.1370) 348 EM
3.50 (0.1378) 350
Valve Spring
C
Items Intake Exhaust
Free height 44.90 - 45.10 mm (1.7677 - 1.7755 in) 45.74 - 45.94 mm (1.8007 - 1.8086 in)
D
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 153 - 173 N (15.6 - 17.6 kg, 34 - 39 lb) 139 - 157 N (14.2 - 16.0 kg, 31 - 35 lb)
Height during valve open 26.36 mm (1.0377 in) 27.80 mm (1.0944 in) E
Load with valve open 335 - 377 N (34.2 - 38.5 kg, 75 - 85 lb) 266 - 297 N (27.1 - 30.3 kg, 60 - 67 lb)
Identification color White Orange
F
Valve Lifter
Unit: mm (in)
Items Standard
G
Intake 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter outer diameter
Exhaust 29.977 - 29.987 (1.1802 - 1.1806)
Intake 34.000 - 34.021 (1.3386 - 1.3394) H
Valve lifter hole diameter
Exhaust 30.000 - 30.021 (1.1811 - 1.1819)
I
Valve Guide
Unit: mm (in)
J
M
PBIC0184E
Items Standard part Service part

Outer diameter 9.523 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832)
N
Valve guide
Inner diameter (Finished size) 5.500 - 5.518 (0.2165 - 0.2172)
Cylinder head valve guide hole diameter 9.475 - 9.496 (0.3730 - 0.3739) 9.675 - 9.696 (0.3809 - 0.3817) O
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021) P
Valve guide clearance 0.1 (0.004)
Exhaust 0.030 - 0.063 (0.0012 - 0.0025)
Projection length “L” 13.35 - 13.65 (0.526 - 0.537)
Valve Seat
EM-241
Unit: mm (in)
PBIC2745E
Items Standard Oversize [0.5 (0.02)] (Service)

Intake 34.700 - 34.727 (1.3661 - 1.3672) 35.200 - 35.227 (1.3858 - 1.3869)
Cylinder head seat recess diameter “D”
Exhaust 28.700 - 28.727 (1.1299 - 1.1310) 29.200 - 29.227 (1.1496 - 1.1507)
Intake 34.808 - 34.824 (1.3704 - 1.3710) 35.308 - 35.324 (1.3901 - 1.3907)
Valve seat outer diameter “d”
Exhaust 28.808 - 28.824 (1.1342 - 1.1348) 29.308 - 29.324 (1.1539 - 1.1545)
Valve seat interference fit 0.081 - 0.124 (0.0032 - 0.0049)
Intake 31.8 (1.252)
Diameter “d1”*1
Exhaust 25.3 (0.996)
Intake 33.1 - 33.6 (1.303 - 1.323)
Diameter “d2”*2
Exhaust 26.9 - 27.4 (1.059 - 1.079)
Intake 60°
Angle “α1”
Exhaust 45°
Angle “α2” 88°45′ - 90°15′
Angle “α3” 120°
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.9 - 6.0 (0.232 - 0.236) 5.03 - 5.13 (0.1980 - 0.2020)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)
Intake 6.04 (0.2378)
Depth “H”
Exhaust 6.05 (0.2382)
*: Diameter made by intersection point of conic angles “α1” and “α2”
*2 : Diameter made by intersection point of conic angles “α2” and “α3”
*3 : Machining data
CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in)

No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028)
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9381) —
Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.24 (0.0094)
Intake 44.605 - 44.795 (1.7560 - 1.7635) 44.405 (1.7482)
Exhaust 43.175 - 43.365 (1.6997 - 1.7072) 42.975 (1.6919)
EM-242
Camshaft runout [TIR*] Less than 0.02 mm (0.0008) 0.05 (0.0020)
A
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
EM
SEM671
E
CYLINDER BLOCK
Unit: mm (in) F
PBIC4017E
Top surface distortion Limit 0.1 (0.004)

J
Grade No. 1 84.000 - 84.010 (3.3071 - 3.3075)

Cylinder bore Inner diameter Standard
Grade No. 2 84.010 - 84.020 (3.3075 - 3.3079) K
Out-of-round (Difference between “X” and “Y”) 0.015 (0.0006)
Limit
Taper (Difference between “A” and “C”) 0.01 (0.0004)
Grade No. A 55.997 - 55.998 (2.2046 - 2.2046) L
Grade No. B 55.998 - 55.999 (2.2046 - 2.2047)
Grade No. C 55.999 - 56.000 (2.2047 - 2.2047)
Grade No. D 56.000 - 56.001 (2.2047 - 2.2048)
Grade No. E 56.001 - 56.002 (2.2048 - 2.2048)
M
Grade No. F 56.002 - 56.003 (2.2048 - 2.2048)
Grade No. G 56.003 - 56.004 (2.2048 - 2.2049)
Grade No. H 56.004 - 56.005 (2.2049 - 2.2049) N
Grade No. J 56.005 - 56.006 (2.2049 - 2.2050)
Grade No. K 56.006 - 56.007 (2.2050 - 2.2050)
Main bearing housing inner diameter grade
Grade No. L 56.007 - 56.008 (2.2050 - 2.2050)
Grade No. M 56.008 - 56.009 (2.2050 - 2.2051) O
Grade No. N 56.009 - 56.010 (2.2051 - 2.2051)
Grade No. P 56.010 - 56.011 (2.2051 - 2.2052)
Grade No. R 56.011 - 56.012 (2.2052 - 2.2052)
Grade No. S 56.012 - 56.013 (2.2052 - 2.2052) P
Grade No. T 56.013 - 56.014 (2.2052 - 2.2053)
Grade No. U 56.014 - 56.015 (2.2053 - 2.2053)
Grade No. V 56.015 - 56.016 (2.2053 - 2.2053)
Grade No. W 56.016 - 56.017 (2.2053 - 2.2054)
PISTON, PISTON RING AND PISTON PIN

Available Piston
EM-243
Unit: mm (in)
PBIC0188E
Grade No. 1 83.970 - 83.980 (3.3059 - 3.3063)

Piston skirt diameter “A” Standard
Grade No. 2 83.980 - 83.990 (3.3063 - 3.3067)
Piston height “H” dimension 39.9 (1.571)
Piston pin hole diameter 19.993 - 19.999 (0.7871 - 0.7874)
Standard 0.020 - 0.040 (0.0008 - 0.0016)
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
Piston Ring
Unit: mm (in)

Top 0.04 - 0.08 (0.002 - 0.003) 0.11 (0.0043)
Side clearance 2nd 0.03 - 0.07 (0.001 - 0.003) 0.10 (0.0039)
Oil ring 0.015 - 0.185 (0.001 - 0.007) —
Top 0.20 - 0.30 (0.008 - 0.012) 0.51 (0.020)
End gap 2nd 0.50 - 0.65 (0.020 - 0.026) 0.83 (0.033)
Oil (rail ring) 0.15 - 0.45 (0.006 - 0.018) 0.78 (0.031)
Piston Pin
Unit: mm (in)

Piston pin outer diameter 19.989 - 19.995 (0.7870 - 0.7872) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.023 (0.0002 - 0.0009) 0.03 (0.0012)
CONNECTING ROD
Unit: mm (in)
Center distance 143.44 - 143.54 (5.647 - 5.650)

Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod bushing inner diameter* 20.000 - 20.012 (0.7874 - 0.7879)
EM-244
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance A
Limit 0.40 (0.0157)
Grade No. A 47.000 - 47.001 (1.8504 - 1.8504)
Grade No. B 47.001 - 47.002 (1.8504 - 1.8505)
Grade No. C 47.002 - 47.003 (1.8505 - 1.8505) EM
Grade No. D 47.003 - 47.004 (1.8505 - 1.8505)
Grade No. E 47.004 - 47.005 (1.8505 - 1.8506)
Grade No. F 47.005 - 47.006 (1.8506 - 1.8506)
Connecting rod big end diameter Grade No. G 47.006 - 47.007 (1.8506 - 1.8507)
C
Grade No. H 47.007 - 47.008 (1.8507 - 1.8507)
Grade No. J 47.008 - 47.009 (1.8507- 1.8507)
Grade No. K 47.009 - 47.010 (1.8507- 1.8508) D
Grade No. L 47.010 - 47.011 (1.8508 - 1.8508)
Grade No. M 47.011 - 47.012 (1.8508 - 1.8509)
Grade No. N 47.012 - 47.013 (1.8509 - 1.8509)
*: After installing in connecting rod
E
CRANKSHAFT
Unit: mm (in)
F
SEM645 PBIC3459J
Center distance “r” 40.41 - 40.49 (1.5909 - 1.5940) J

Out-of-round (Difference between “X” and “Y”) Limit 0.0035 (0.0001)
Taper (Difference between “A” and “B”) Limit 0.0035 (0.0001)
K
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0040)
Standard 0.10 - 0.26 (0.0039 - 0.0102) L
Crankshaft end play
Limit 0.30 (0.012)
EM-245
Grade No. A 43.970 - 43.971 (1.7311 - 1.7311)
Grade No. B 43.969 - 43.970 (1.7311 - 1.7311)
Grade No. C 43.968 - 43.969 (1.7310 - 1.7311)
Grade No. D 43.967 - 43.968 (1.7310 - 1.7310)
Grade No. E 43.966 - 43.967 (1.7309 - 1.7310)
Grade No. F 43.965 - 43.966 (1.7309 - 1.7309)
Grade No. G 43.964 - 43.965 (1.7309 - 1.7309)
Grade No. H 43.963 - 43.964 (1.7308 - 1.7309)
Grade No. J 43.962 - 43.963 (1.7308 - 1.7308)
Pin journal diameter grade. “Dp”
Grade No. K 43.961 - 43.962 (1.7307 - 1.7308)
Grade No. L 43.960 - 43.961 (1.7307 - 1.7307)
Grade No. M 43.959 - 43.960 (1.7307 - 1.7307)
Grade No. N 43.958 - 43.959 (1.7306 - 1.7307)
Grade No. P 43.957 - 43.958 (1.7306 - 1.7306)
Grade No. R 43.956 - 43.957 (1.7305 - 1.7306)
Grade No. S 43.955 - 43.956 (1.7305 - 1.7305)
Grade No. T 43.954 - 43.955 (1.7305 - 1.7305)
Grade No. U 43.953 - 43.954 (1.7304 - 1.7305)
Grade No. A 51.978 - 51.979 (2.0464 - 2.0464)
Grade No. B 51.977 - 51.978 (2.0463 - 2.0464)
Grade No. C 51.976 - 51.977 (2.0463 - 2.0463)
Grade No. D 51.975 - 51.976 (2.0463 - 2.0463)
Grade No. E 51.974 - 51.975 (2.0462 - 2.0463)
Grade No. F 51.973 - 51.974 (2.0462 - 2.0462)
Grade No. G 51.972 - 51.973 (2.0461 - 2.0462)
Grade No. H 51.971 - 51.972 (2.0461 - 2.0461)
Grade No. J 51.970 - 51.971 (2.0461 - 2.0461)
Grade No. K 51.969 - 51.970 (2.0460 - 2.0461)
Main journal diameter grade. “Dm”
Grade No. L 51.968 - 51.969 (2.0460 - 2.0460)
Grade No. M 51.967 - 51.968 (2.0459 - 2.0460)
Grade No. N 51.966 - 51.967 (2.0459 - 2.0459)
Grade No. P 51.965 - 51.966 (2.0459 - 2.0459)
Grade No. R 51.964 - 51.965 (2.0458 - 2.0459)
Grade No. S 51.963 - 51.964 (2.0458 - 2.0458)
Grade No. T 51.962 - 51.963 (2.0457 - 2.0458)
Grade No. U 51.961 - 51.962 (2.0457 - 2.0457)
Grade No. V 51.960 - 51.961 (2.0457 - 2.0457)
Grade No. W 51.959 - 51.960 (2.0456 - 2.0457)
MAIN BEARING
Unit: mm (in)

0 1.996 - 1.999 (0.0786 - 0.0787) Black
1 1.999 - 2.002 (0.0787 - 0.0788) Brown
2 2.002 - 2.005 (0.0788 - 0.0789) Green
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are the same
4 2.008 - 2.011 (0.0791 - 0.0792) Blue for upper and lower bearings.
5 2.011 - 2.014 (0.0792 - 0.0793) Pink

6 2.014 - 2.017 (0.0793 - 0.0794) Purple
7 2.017 - 2.020 (0.0794 - 0.0795) White
EM-246
UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
01 A
LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown
12
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green EM
UPR 2.002 - 2.005 (0.0788 - 0.0789) Green
23
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are different C
34 between upper and lower bear-
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue ings.
UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue
45 D
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink
56
LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple E
UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple
67
LWR 2.017 - 2.020 (0.0794 - 0.0795) White
F
Undersize
Unit: mm (in)
Item Thickness Main journal diameter G

Bearing Oil Clearance H

Unit: mm (in)
No. 1, 4 and 5 0.024 - 0.034 (0.0009 - 0.0013)

Standard
Main bearing oil clearance No. 2 and 3 0.012 - 0.022 (0.0005 - 0.0009) I
Limit 0.065 (0.0026)
CONNECTING ROD BEARING J
Grade number Thickness mm (in) Identification color Remarks

0 1.494 - 1.497 (0.0588 - 0.0589) Black K
1 1.497 - 1.500 (0.0589 - 0.0591) Brown
2 1.500 - 1.503 (0.0591 - 0.0592) Green
3 1.503 - 1.506 (0.0592 - 0.0593) Yellow L
4 1.506 - 1.509 (0.0593 - 0.0594) Blue
UPR 1.494 - 1.497 (0.0588 - 0.0589) Black
01 M
LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown
UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown
12
LWR 1.500 - 1.503 (0.0591 - 0.0592) Green Grade and color are different N
between upper and lower bear-
UPR 1.500 - 1.503 (0.0591 - 0.0592) Green ings.
23
LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
O
UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
34
LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue
Undersize P
Unit: mm (in)
Item Thickness Crank pin journal diameter

Bearing Oil Clearance

Unit: mm (in)
EM-247
Standard 0.037 - 0.047 (0.0015 - 0.0019)
Connecting rod bearing oil clearance
Limit 0.07 (0.0028)
EM-248
< SYMPTOM DIAGNOSIS > [K9K]
SYMPTOM DIAGNOSIS A
EM
MBIB0554E
EM-249
< SYMPTOM DIAGNOSIS > [K9K]
1. Locate the area where noise occurs.

4. Check specified noise source.
Operating condition of engine

up up ing
Top of en-
gine
Rocker Ticking or Tappet
cover clicking noise
Cylinder
head
Crank-
shaft pul-
ley
Cylinder Slap or Piston
A — — B B A Piston ring end gap EM-330
block rap slap noise
(Side of
engine)
Oil pan
Front of Timing
engine Tapping or belt ten- Timing belt tensioner
A A — B B B EM-291
Timing ticking sioner operation
belt cover noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection EM-263
or slip-
Front of ing
ping)
engine
Water
Squall
Creak
noise
EM-250
PRECAUTIONS
< PRECAUTION > [K9K]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
WARNING: D
an authorized NISSAN/INFINITI dealer. E
F
ness connectors.
G
the lower end of windshield with urethane, etc. H
PIIB3706J
K
INFOID:0000000001527631
NOTE: L
TEM).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the M
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech- N
steering wheel rotation will become impossible. O
OPERATION PROCEDURE P
NOTE:
EM-251
PRECAUTIONS
rotated.
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT-III.
Drain coolant when engine is cooled.

• After disconnecting pipes, plug openings to stop fuel leakage.
• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
• Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
Precaution for Assembly and Installation INFOID:0000000001381454
• Use torque wrench to tighten bolts or nuts to specified value.

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly same as specified.
• Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
Before assemble, spread the oil on sliding surfaces well.
• Release air within route when refilling after draining coolant.
• After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leakage.
• Use an angle wrench for the final tightening of the following engine parts.
- Lower cylinder block bolts
- Connecting rod cap bolts
tightening)
• Ensure thread and seat surfaces are clean and coated with engine oil.
EM-252
PRECAUTIONS
A
REMOVAL OF LIQUID GASKET
• After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket. EM
CAUTION:
• In areas where the cutter is difficult to use, use a plastic hammer to C
lightly tap the liquid gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur- D
faces.
PBIC0275E
E
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface. F
• Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering G
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent. H
PBIC0003E
I
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
gasket to the groove. J
L
EMA0622D
• As for the bolt holes, normally apply the gasket inside the M
holes. If specified, it should be applied outside the holes. Make
sure to read the instruction in this manual.
• Within five minutes of gasket application, install the mating
component. N
• If the liquid gasket protrudes, wipe it off immediately.
• After 30 minutes or more have passed from the installation, fill O
the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
SEM159F
P
Precaution for Diesel Equipment INFOID:0000000001381457
CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM
Risks relating to contamination
EM-253
PRECAUTIONS
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
• Damage or destruction of the high pressure injection system and the engine,
• Seizing or leaking of a component.
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the filter to the injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
• Metal or plastic chips,
• Paint,
• Fibres:
- Boxes,
- Brushes,
- Paper,
- Clothing,
- Cloths,
• Foreign bodies such as hair,
• Ambient air,
• Etc.
IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of dam-
aging connections. In addition, moisture may collect in the connectors and create electrical connection mal-
functions.
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS-
TEM
• Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan
part No.: 16609 00Q0B, Renault part No.: 77 01 476 857). Plugs are to be used once only. After use, they
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.
• Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away.
• Lint-free towelettes to be used for high pressure supply pump related service purpose. The use of a normal
cloth or paper for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit
of the system. Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinners to clean the connections to be opened.
• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered.
• Wash your hands before and during the operation if necessary.
• When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Stores - Nissan part No.: 16609 00Q0B, Renault part No.:
77 01 476 857. They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con-
tamination.
• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted.
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system.
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.
Instructions for Fitting the Plugs
Nissan part number: 16609 00Q0B
EM-254
PRECAUTIONS
(Renault part number: 77 01 476 857)
A
EM
E1BIA0029GB
CAUTION:
P
• The engine must not run with:
- Diesel containing more than 10% diester
- Petrol, even in very small amounts.
• The system can inject the diesel into the engine at a pressure of up to 140,000 kPa (1,400 bar, 1,428
kg/cm2, 20,300 psi). Before carrying out any work, check that the injector rail is no longer pressur-
ized and that the fuel temperature is not too high.
• You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
EM-255
PRECAUTIONS
SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Diesel engine fuel containing more than 10% diester,
- Petrol, even in tiny quantities.
• The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out
any work, check that the injector rail is not under pressure and that the fuel temperature is not too
high.
• You must respect the cleaning and safety advice specified in this document for any work on the high
pressure injection system.
• Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the fuel tem-
perature sensor and the venturi can be replaced.
• For safety reasons, it is strictly forbidden to slacken a injection tube union when the engine is run-
ning.
• It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the pressure sensor fails, the pressure sensor, the rail and the five
injection tubes must be replaced.
• It is strictly forbidden to remove any high pressure supply pump pulley marked number 070 575. If
the pump is being replaced, the pulley must be replaced.
• It is forbidden to repair the wiring connecting the knock sensor (accelerometer) and the CKP sensor
(engine speed sensor). If the wiring should fail, it has to be replaced with new wiring.
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Never start the engine without the battery being connected correctly.
• It is essential to replace all the disconnected air inlet plastic pipes.
INSTRUCTIONS FOR INJECTION TUBES
CAUTION:
All the injection tube removed must be systematically replaced along with the clips.
TIGHTENING THE INJECTION TUBES
NOTE:
fit the pump/rail pipe before the rail/injector pipes.
Rail-pump pipe
• Undo the rail,
• Grease the threads of the injection tube nuts,
• Insert the injection tube olive into the taper of the high pressure pump outlet,
• Insert the injection tube olive into the taper of the high pressure rail inlet.
• Move the nut into position by hand, on the rail side then the pump side,
• Tighten the rail,
• Tighten the injection tube nuts on the rail side then on the pump side.
Rail/injector pipes
• Undo the rail,
• Grease the threads of the injection tube nuts,
• Insert the injection tube olive into the taper of the high pressure injector inlet,
• Insert the injection tube olive into the taper of the high pressure rail outlet,
• Move the nuts into position by hand, on the injector side then the rail side,
• Tighten the rail,
• Ensure that the new clip, supplied with the new injection tube, is fitted,
• Tighten the nuts of the injection tubes on the injector side first and then on the fuel rail side.
NOTE:
Before fitting a new injection tube, move back the nuts on the pipe then lightly lubricate the nut
threads with the oil from the sachet provided in the parts kit.
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there are no diesel leaks.
• Reprime the circuit using the priming pump.
• Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks.
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50°C and provided there are no malfunctions present, carry
out a road test, taking the engine speed up to 4000 rpm at least once to check that there are no leaks.
• Perform a visual inspection after the road test to make sure that there are no high pressure leaks.
• Clean off the tracing fluid.
EM-256
PRECAUTIONS
Installation of Thread Inserts INFOID:0000000001381458
A
Threaded holes on all engine component parts can be repaired by using thread inserts.
EM
EM-257
PREPARATION
< PREPARATION > [K9K]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000001381459
NISSAN tool number

(RENAULT tool No.) Description
Tool name
EM03470000 Installing piston assembly into cylinder bore
( — )
NT044
KV10111100 Removing oil pan

( — )
Seal cutter
NT046

( — ) head, etc. in angle
Angle wrench
NT014
KV113B0020 Inertia extractor

(Emb. 880)
Sliding hammer
MBIB0358E
KV113B0060 Flywheel immobilizing tool.

(Mot. 582-01)
Ring gear stopper
MBIB0363E
KV113B0110 Set of TDC pins

(Mot. 1430)
TDC set pin
EM-258
PREPARATION
NISSAN tool number
(RENAULT tool No.) Description A
Tool name
KV113B0120 Tool for removing the piston bottom oil jets
(Mot. 1485-01) EM
Oil jet remover
MBIB0372E
KV113B0130 TDC setting pin D

(Mot. 1489)
TDC set pin
E
MBIB0373E F
KV113B0140 Tool for installing connecting rod bearing
(Mot. 1492)
Bearing assembling set G
H
MBIB0374E
KV113B0150 Adaptation kit for installing the detachable cap

(Mot. 1492-03) connecting rod bearing I
Bearing assembling adapter
MBIB0375E
K
KV113B0160 Tool for installing main bearing
(Mot. 1493-01)
Bearing insert
L
M
MBIB0376E
KV113B0170 Tool for removing oil jets

(Mot. 1494)
N
Oil jet remover plate
KV113B0190 Pliers for exhaust gas recycling pipe clips
(Mot. 1567)
Clip pliers O
KV113B0210 Tool for installing crankshaft seals, flywheel
(Mot. 1585) end
Front oil seal drift P
MBIB0381E
EM-259
PREPARATION
NISSAN tool number
Tool name
KV113B0220 Tool for installing crankshaft seals, timing end
(Mot. 1586)
Front oil seal drift set
KV113B0230 Tool for installing inlet camshaft seals
(Mot. 1632)
Camshaft seal insert
KV113B0240 Internal shaft protector
(Rou. 15-01) 16 mm (0.63 in) dia.
Shaft protector
KV113B0400 Connecting compression gauge and glow
(Mot. 1592) plug holex
Compression gauge attachment
MBIB0712E
— Tool for locking sprockets for toothed timing

(Mot. 1606-A) belt
Camshaft pulley holder
E1BIA0053ZZ
— Setting drive belt tension

(Mot. 1638)
Belt tension gauge
MBIB0382E
Commercial Service Tools INFOID:0000000001381460
NISSAN tool number

Tool name
KV113B0030 Crankshaft bearing extractor
(Mot. 11)
Crankshaft bearing remover
MBIB0359E
KV113B0040 Gauge stand used with KV113B0050 (Mot.

(Mot. 251-01) 252-01)
Dial gauge stand set
MBIB0360E
EM-260
PREPARATION
NISSAN tool number
(RENAULT tool No.) Description A
Tool name
KV113B0050 Thrust plate for measuring the protrusion of
(Mot. 252-01) cylinder liners used with KV113B0040 (Mot. EM
Dial gauge stand set 251-01).
MBIB0361E
KV113B0090 Tool for removing valve stem seals D

(Mot. 1335)
Valve seal remover
E
MBIB0370E F
KV113B0180 Tool for installing valve stem seals
(Mot. 1511-01)
Valve seal drift G
H
MBIB0378E
KV113B0200 Cylinder head support

(Mot. 1573) I
Cylinder head stand
MBIB0380E
K
KV113E0010 Spanner for installing and removing injection
(Mot. 1566) tubes
Fuel spill tube spanner
L
M
MBIB0379E
WS39930000 Pressing the tube of liquid gasket

( — )
N
Tube presser
NT052
Manual lift table caddy Removing and installing engine P
ZZA1210D
EM-261
PREPARATION
NISSAN tool number
Tool name
Piston ring expander Removing and installing piston ring
NT030
(Mot. 588) Liner retaining strap
MBIB0364E
(664000) Tool for testing the cylinder head, including: a

Cylinder head test container tray and the various kits suited for each model
of cylinder head (plug, sealing plate, blanking
plate).
MBIB0383E
Torx socket Standard 1/2" (12.7 mm) square drive 8/12 /14
female torx socket.
(Mot. 1505) Tool for belt tension checking with frequency
(Mot. 1715)
Frequency meter
MBIB1423E
Glow plug wrench Articulated wrench for removing and installing

the glow plugs
MBIB0387E
Main bearing wrench Wrench for removing main bearings
MBIB0388E
EM-262
DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [K9K]
ON-VEHICLE MAINTENANCE A
DRIVE BELTS
EM
E1BIA0021ZZ
1. Crankshaft pulley 2. A/C compressor 3. Drive belt

G
4. Generator 5. Drive belt auto-tensioner
Inspection and Adjustment INFOID:0000000001381462 H
INSPECTION
WARNING: I
Be sure to perform when the engine is stopped.
1. Inspect drive belt for cracks, fraying, wear and oil. Replace drive belt if necessary.
2. Manually evaluate the drive belt tension (tension cannot be measured using frequency meter). J
3. Replace drive belt when tension is beyond normal operating limit.
CAUTION:
Auto-tensioner must be replaced with a new one when the belt is replaced. K
ADJUSTMENT
Belt tensioning is not necessary, as it is automatically adjusted by auto-tensioner.
L
CAUTION: M
• Replace any drive belt that has been removed with a new one.
• Auto-tensioner must be replaced with new one when the drive belt is replaced.
• Do not run the engine without the drive belt to avoid damaging the crankshaft pulley.
N
REMOVAL
2. Remove RH front wheel. Refer to WT-6, "Rotation". O
3. Remove right side splash cover.
EM-263
DRIVE BELTS
• Turn drive belt auto-tensioner adjusting bolt clockwise to
release drive belt tension.
MBIB0353E
INSTALLATION
1. Install the drive belt.
CAUTION:
• Make sure drive belt is correctly engaged with the pulley
groove.
• Check for oil and coolant on drive belt and each pulley
groove.
• Certain drive belts have five teeth whereas the air condi-
tioning compressor pulley, power-assisted steering pump
pulley, and generator pulley all have six teeth.In this case,
it is essential to check that inner tooth (O) of the pulleys
remains free when fitting the drive belt.
Never turn the engine in the opposite direction to its nor-
mal operating direction.
MBIB0516E
Use a brush to remove any deposits from the crankshaft
pulley V grooves.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
EM-264
AIR CLEANER FILTER
AIR CLEANER FILTER
A
REMOVAL EM
the inside (B).
2. Pull up the air cleaner cover (1) and remove it (C). C
E
PBIC3557J
3. Remove air cleaner filter (1) and holder (2) assembly from the F
air cleaner case.
G
PBIC3558J I
conditions. Refer to MA-7, "Periodic Maintenance". J
out.
K
M
SMA384C
INSTALLATION
N
2 : Air cleaner filter O

3 : Holder
PBIC3559J
EM-265
Inspection and Adjustment INFOID:0000000001381465
INSPECTION
1. Place the valves of the cylinder concerned at the “end of
exhaust - beginning of intake” position and inspect the clearance
(X).
NOTE:
Dimension (Y) corresponds to the tappet thickness sizes (there
are 25 sizes available).
2. Compare the values recorded with the values specified, then
replace the tappets which are not within tolerance.
Clearance when the : Refer to EM-333, "Cam-

engine is cold shaft". MBIB0333E
ADJUSTMENT
1. The camshaft must be removed to replace the tappets after
determining dimension (Y).
2. Set up the following assembly using dial gauge stand
[KV113B0050 (Mot. 252-01) (commercial service tool) or equiva-
lent tool] and dial gauge, then calibrate the gauge.
MBIB0334E
3. Raise the gauge extension (without modifying the position of the

magnetic support/gauge assembly), then slide in the tappet to
be measured.
Note dimension (Y) and repeat the operation for the tappets
where the valve clearance is not within tolerance.
Select the various thicknesses of the tappet(s). 25 sizes of sin-
gle-piece tappets are available. Refer to EM-333, "Camshaft".
MBIB0335E
EM-266
A
1. Warm up engine thoroughly. Then stop. EM

2. Remove glow plug.
3. Disconnect high-pressure supply pump harness connector to avoid fuel injection during measurement.
4. Connect compression gauge attachment hose [SST: C
KV113B0400 (Mot. 1592)] (A) to the hole for glow plug.
5. Connect compression gauge (B) to attachment hose (A).
6. Turn ignition switch to START for cranking and check compres- D
sion gauge.
Compres- : Refer to EM-333, E

sion pres- "General Specification".
sure
F
7. Perform the same procedure for the other cylinders. E1BIA0052ZZ
• If compression pressure is below minimum value, check valve

clearances and parts associated with combustion chamber (valve, valve seat, piston, piston ring, cylin-
der bore, cylinder head, cylinder head gasket). After checking, measure compression pressure again. G
• If any cylinder has low compression pressure, pour a small amount of engine oil into the glow plug hole
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis- H
• If two adjacent cylinders have respectively low compression pressure and their compression remains I
low even after the addition of engine oil, cylinder head gaskets are leaking. In this case, replace cylinder
head gaskets.
8. Disconnect compression gauge (B) and attachment hose (A). J
10. Start the engine, and make sure that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-1043, "BASIC INSPECTION : Descrip- K
tion".
EM-267
DRIVE BELT AUTO-TENSIONER
< ON-VEHICLE REPAIR > [K9K]
ON-VEHICLE REPAIR
DRIVE BELT AUTO-TENSIONER
E1BIA0020GB
1. Drive belt auto-tensioner 2. Drive belt 3. Multifunction bracket
CAUTION:
• Replace any drive belt that has been removed with a new one.
• Auto-tensioner must be replaced with new one when the drive belt is replaced.
• Do not run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
2. Remove RH front wheel.
3. Remove right side splash cover.
5. Remove drive belt auto-tensioner.
INSTALLATION
1. Install drive belt auto-tensioner.
NOTE:
Align the notch and tighten drive belt auto-tensioner bolt.
40.0 N·m (4.1 kg-m, 30 ft-lb)

2. Install the drive belt. Refer to EM-263, "Removal and Installa-
tion".
3. Release drive belt auto-tensioner, and apply tension to drive
belt.
4. Turn crankshaft pulley clockwise several times to equalize ten- MBIB0558E
sion between each pulley.
EM-268
A
EM
I
AWBIA0118ZZ
1. Air duct (suction) 2. Blow-by hose 3. Air cleaner case J

4. Air cleaner filter 5. Air duct (inlet) 6. Mass air flow sensor
7. O-ring 8. Grommet
A. To turbocharger K
L
REMOVAL
1. Disconnect battery ground cable.
2. Disconnect battery positive cable. M
3. Remove engine cover. Refer to EM-270, "Removal and Installation".
4. Disconnect blow-by hose.
5. Remove air duct (suction) lower clamp and remove air duct (suction). N
6. Remove battery.
7. Disconnect ECM harness connectors and remove ECM and ECM bracket.
O
8. Disconnect mass airflow sensor harness connector.
9. Remove air duct (inlet) by loosening clamp.
10. Remove air cleaner case by sliding the air cleaner case upward.
P
CAUTION:
Slide the air cleaner case carefully so as not to damage it on the air cleaner case and harness
bracket.
INSTALLATION
• Installation is in the reverse order of removal.
EM-269
CHARGE AIR COOLER
CHARGE AIR COOLER
AWBIA0119GB
1. Hose clamp 2. Inlet pipe assembly 3. Air inlet hose

4. Air inlet tube 5. Air inlet hose 6. Charge air cooler
7. Air inlet hose 8. Generator 9. Spacer
10. Air inlet tube 11. Turbocharger boost sensor
: Vehicle front
REMOVAL
2. Remove bumper undercover.
3. Remove engine cover.
EM-270
CHARGE AIR COOLER
4. Remove air inlet hoses.
5. Release the clamp (A) securing the charge air cooler (1) to radi- A
ator (2) and pull to release charge air cooler from the radiator
lower core support (3).
EM
MBIB9031E
H
6. Remove charge air cooler (1) from underbody as shown.
CAUTION:
• Avoid interference between the charge air cooler and con-
denser. I
• When removing charge air cooler, close opening on turbo
charger and throttle with shop cloth or other suitable
material. J
K
MBIB9020E
INSTALLATION
Installation is in the reverse order of removal. L
• Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
• Pay attention to identification mark and direction.
Inspection INFOID:0000000001381473 M

1. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it N
dry.
2. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler in necessary. O
• Be careful not to deform core fins.
EM-271
EGR SYSTEM
EGR SYSTEM
E1BIA0025GB
1. Air inlet tube 2. Engine slinger 3. O-ring

4. Bracket 5. EGR tube 6. Gasket
7. EGR cooler 8. Gasket 9. EGR volume control valve
10. Gasket 11. EGR volume control valve housing 12. Clamp
13. EGR tube 14. Gasket 15. Gasket
16. Electronic throttle control actuator 17. O-ring 18. EGR cooler cover
A. To intake manifold B. To exhaust manifold
REMOVAL
1. Remove battery ground cable.
3. Drain engine coolant. Refer to CO-58, "Draining".
4. Remove lower radiator hose. Refer to CO-62, "Exploded View".
6. Remove air cleaner and air duct assembly. Refer to EM-269, "Removal and Installation".
7. Remove charge air cooler inlet tubes at EGR assembly. Refer to EM-270, "Exploded View".
8. Disconnect EGR volume control valve and electronic throttle control actuator connectors.
9. Disconnect heater hoses from EGR cooler cover.
10. Remove EGR cooler cover.
11. Remove front engine slinger.
12. Remove air inlet tube.
13. Remove RH fender protector. Refer to EXT-22, "Removal and Installation".
EM-272
EGR SYSTEM
14. Remove front driveshaft assembly RH. Refer to FAX-11, "Removal and Installation (Right Side)".
15. Remove electronic throttle control actuator. A
16. Remove driveshaft center bearing bracket. Refer to FAX-11, "Removal and Installation (Right Side)".
17. Remove front exhaust tube. Refer to EX-5, "Component".
EM
18. Remove catalytic converter. Refer to EM-274, "Exploded View".
19. Remove EGR tube.
20. Remove EGR assembly. C
INSTALLATION
D
EM-273
CATALYST
CATALYST
AWBIA0120GB
1. Catalyst 2. Bracket 3. Turbocharger

4. Exhaust manifold 5. EGR unit 6. Gasket
A. To transaxle B. To exhaust front tube ⇐ Engine front
REMOVAL
5. Remove front driveshaft assembly. Refer to FAX-11, "Removal and Installation (Right Side)".
6. Remove driveshaft center bearing bracket. Refer to FAX-11, "Removal and Installation (Right Side)".
8. Remove catalyst bolts and brackets.
9. Remove catalyst.
INSTALLATION

Start engine and raise engine speed to check for exhaust emission leaks.
EM-274
TURBOCHARGER
TURBOCHARGER
A
EM
G
MBIB1418E
1. Washer 2. Turbocharger oil supply tube 3. O-ring

4. Turbocharger 5. Exhaust manifold 6. Gasket
H
7. Turbocharger oil outlet tube 8. Gasket
Removal and Installation INFOID:0000000001381480 I
REMOVAL
1. Remove catalyst. Refer to EM-274, "Removal and Installation". J
2. Remove turbocharger oil supply tube.
NOTE:
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and K
then loosen the nuts to remove.
3. Remove turbocharger oil outlet tube.
NOTE: L
After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and
then loosen the nuts to remove.
4. Remove air duct (suction). Refer to EM-269, "Exploded View". M
5. Disconnect turbocharger vacuum hose.
6. Remove turbocharger from exhaust manifold.
CAUTION: N
Do not disassemble or adjust the turbocharger body.
INSTALLATION
Installation is in the reverse order of removal. O
NOTE:
Apply engine oil to lubricate the turbocharger oil tubes.
P
EM-275
TURBOCHARGER
MBIB1419E
CAUTION:
When the compressor wheel turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary failure:
Suction side : Between turbocharger and air cleaner

Exhaust side : Between turbocharger and catalyst
EM-276
EXHAUST MANIFOLD
EXHAUST MANIFOLD
A
EM
I
AWBIA0120GB
1. Catalyst 2. Bracket 3. Turbocharger J

4. Exhaust manifold 5. EGR unit 6. Gasket
A. To transaxle B. To exhaust front tube ⇐ Engine front
K
REMOVAL L
2. Remove turbocharger assembly. Refer to EM-275, "Removal and Installation".
3. Remove air duct (inlet). Refer to EM-269, "Exploded View". M
4. Remove blow-by tube.
5. Remove air duct (suction). Refer to EM-269, "Exploded View".
6. Remove EGR tube. Refer to EM-272, "Exploded View". N
7. Loosen exhaust manifold nuts in the reverse order as shown.
Then remove exhaust manifold.
CAUTION: O
Be careful not to deform turbocharger piping when removing
the assembly.
P
MBIB1417E
INSTALLATION
EM-277
EXHAUST MANIFOLD
1. Clean the surface of exhaust manifold and cylinder head.
2. Install new gasket to cylinder head.
3. Tighten the exhaust manifold nuts in numerical order as shown.
: 26.0 N·m (2.7 kg-m, 19 ft-lb)

4. Installation is in the reverse order of removal for the remaining
components.
MBIB1417E

Start engine and raise engine speed to check for exhaust emission leaks.
EM-278
GLOW PLUG
GLOW PLUG
A
EM
E1BIA0005GB
1. Glow plug G
: Engine front

H
REMOVAL
CAUTION: I
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect battery ground cable.
2. Remove air duct (inlet). Refer to EM-269, "Exploded View". J
4. Remove charge air cooler tubes and hoses at EGR unit and electronic throttle control actuator. Refer to
EM-270, "Exploded View". K
5. Remove high pressure pipes protection cover. Refer to EM-281, "Exploded View".
6. Disconnect harness connector from glow plug.
L
7. Remove glow plug.
CAUTION:
• When removing or installing, do not use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from M
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
N
1. Remove adhered carbon from glow plug installation hole with a suitable tool.
2. Install glow plug.
O
: 15.0 N·m (1.5 kg-m, 11 ft-lb)
P
EM-279
VACUUM PUMP
VACUUM PUMP
E1BIA0007GB
1. Vacuum pump 2. Gasket

A. To vacuum hose
: Engine front
REMOVAL
2. Remove air duct (inlet). Refer to EM-269, "Exploded View".
3. Remove battery. Refer to PG-6, "Removal and Installation".
4. Remove the air duct (suction). Refer to EM-269, "Exploded View".
5. Remove blow-by hose.
6. Remove electronic throttle control actuator. Refer to EM-272, "Exploded View".
7. Disconnect vacuum hose from vacuum pump.
8. Remove vacuum pump.
INSTALLATION
INSPECTION BEFORE REMOVAL

1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-
tor.
2. Start engine and measure generated vacuum at idle speed.
Standard
: – 86.6 to – 101.3 kPa (– 866 to – 1,013 mbar, – 650 to – 760 mmHg, – 25.59 to – 29.92 inHg)
EM-280
INJECTION TUBE AND FUEL INJECTOR
A
EM
I
E1BIA0018GB
1. Spill hose 2. Injection tube 3. Fuel injector J

4. Heat protection washer 5. Fuel injector bracket 6. Fuel injector bracket spacer
7. Fuel rail stud bolt 8. Fuel rail 9. High pressure pipes protection cover
(lower)
K
10. Injection tube 11. High pressure supply pump 12. High pressure pipes protection cover
(upper)
13. Oil level gauge guide
L
REMOVAL M
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-253, "Precaution for Diesel Equip-
ment". N
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• Never open an injector. If you open an injector by mistake, you will have to change it.
This is because of the manufacturing and installation tolerances and because there is a risk of con- O
taminating the inside of the injector.
• The rod filter of the injector must not be removed.
NOTE: P
It is possible to replace a single injection tube.
1. Disconnect the battery.
2. Remove the air duct (inlet). Refer to EM-269, "Exploded View".
4. Remove charge air cooler hose and pipes. Refer to EM-270, "Exploded View".
5. Remove oil level gauge guide and plug the hole.
EM-281
6. Remove fuel hose shield.
7. Disconnect fuel feed hose.
8. Remove high pressure pipes protection cover (upper).
9. Remove the neck located on the fuel rail.
NOTE:
Undo the nut on the pump side or the injector side, then the nut located on the rail side. Undo the
nuts for each pipe in turn. Move the nut along the pipe keeping the olive in contact with the taper.
10. Remove all the injection tubes.
11. Plug all the holes in the injection circuit.
12. Remove fuel rail.
13. Disconnect fuel return pipe.
14. Remove retaining clip and disconnect the diesel return pipe on
the injector.
15. Plug all the holes of the injection circuit.
E1BIA0049ZZ
16. Disconnect the injector harness connector (1).

17. Remove the injector bracket (2).
18. Remove the injector.
19. Pull off the flame shield washer.
20. Disconnect the fuel pressure sensor.
21. Remove the high pressure pipes protection cover (lower).
MBIB9030E
INSTALLATION
CAUTION:
All the injection tubes removed must be systematically replaced.
1. Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the
wipes recommended for this purpose, dipped in clean solvent.
2. Dry off using a different new wipe.
3. Replace the flame shield washer with a new one.
4. Position the injector.
5. Tighten the mounting bracket bolts.
: 30.0 N·m (3.1 kg-m, 22 ft-lb)

6. Install injection tubes with new one.
7. Finger tighten the nuts.
8. Before fitting the new injection tubes, lightly lubricate the nut threads with the oil from the sachet provided
in the new parts kit.
NOTE:
Fit the pump/rail pipe before the rail/injector tubes.
9. Fit the pump-rail injection tube as follows:
• Remove the protective plugs from the high pressure pump outlet, the high pressure rail inlet and the
pipe.
EM-282
• Insert the injection tube olive into the taper of the high pressure pump outlet,
• Insert the injection tube olive into the taper of the high pressure rail inlet. A
• Finger tighten the nuts of the injection tube starting with the one located on the rail side.
10. Install the rail-injector injection tube.
11. Tighten the injection tube nut. EM
: 24.0 N·m (2.4 kg-m, 18 ft-lb)

C
12. Connect fuel return pipe to injector and install retaining clip.
13. Installation is in the reverse order to removal for the remaining
parts. D
F
E1BIA0055ZZ
EM-283
OIL PAN
OIL PAN
E1BIA0008GB
1. Gasket 2. Oil pan 3. O-ring

4. Drain plug 5. Oil level sensor 6. Clutch housing
7. Crankshaft position sensor
CAUTION:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
REMOVAL
2. Remove oil level indicator.
CAUTION:
Perform when engine is cold.
4. Remove fender protector (RH).
5. Remove front driveshaft assembly (RH). Refer to FAX-11, "Removal and Installation (Right Side)".
6. Remove driveshaft center bearing bracket.
7. Remove rear torque rod (lower). Refer to EM-302, "Exploded View".
8. Remove bolts from the catalyst bracket. Refer to EM-274, "Exploded View".
9. Disconnect and remove oil level sensor.
EM-284
OIL PAN
10. Remove oil pan and transaxle joint bolts.
A
EM
MBIB1039E
D
11. Support the engine bottom of the oil pan with a transmission jack
etc.
E
G
MBIB0575E
12. Remove oil pan bolts in reverse order as shown.

H
MBIB1257E
K
13. Insert seal cutter [SST: KV10111100 (—)] between upper oil pan
and cylinder block. Slide tool by tapping on the side of the tool
with a hammer. L
CAUTION:
Exercise care not to damage mating surface.
14. Remove oil pan. M
N
SEM365EA
INSTALLATION O
• Installation is in the reverse order of removal.
EM-285
OIL PAN
1. Apply liquid gasket as shown.
• Use Genuine Liquid Gasket or equivalent.
MBIB0593E
MBIB0594E
2. Using suitable tool, align the oil pan with the cylinder block.
3. Install oil pan bolts in numerical order as shown.
NOTE:
Wait at least 30 minutes after oil pan is installed before filling
engine with engine oil.
: 14.0 N·m (1.4 kg-m, 10 ft-lb)
MBIB1257E

Clean oil pump assembly if any objects attached.
• Check the engine oil level. Refer to LU-26, "Inspection".
• Start the engine and make sure there are no leaks of engine oil. Refer to LU-26, "Inspection".
EM-286
HIGH PRESSURE SUPPLY PUMP
A
EM
E1BIA0119GB
1. High pressure supply pump protec- 2. Stud bolt 3. High pressure supply pump G
tor
4. Engine cover bracket
H
REMOVAL I
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-253, "Precaution for Diesel Equip-
ment".
J
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• It is strictly forbidden to remove any high pressure supply
pump sprocket marked number 070 575 (see diagram). If the K
pump is being replaced, the pulley must be replaced.
1. Disconnect the battery.
2. Remove air duct (inlet). Refer to EM-269, "Exploded View". L
5. Remove charge air cooler hose and pipes. Refer to EM-270, M
"Exploded View".
6. Remove the RH front tire. Refer to WT-6, "Rotation". MBIB9036E
N
7. Remove fender protector (RH). Refer to EXT-22, "Removal and
Installation".
O
9. Support the engine using suitable tool.
10. Remove the timing belt. Refer to EM-291, "Removal and Installation".
11. Remove the oil level gauge guide and plug the hole. Refer to EM-281, "Exploded View". P
12. Remove high pressure pipes protection cover (upper). Refer to EM-281, "Exploded View".
13. Carefully disconnect:
• The connectors from the flow actuator,
• The connectors from the fuel temperature sensor,
• On the pump, the fuel supply and return pipes.
• The return pipe connecting the injectors with the pump.
14. Remove the injection tube connecting the pump to the rail. Refer to EM-281, "Removal and Installation".
EM-287
15. Plug all the holes of the injection circuit.
16. Remove the three mounting bolts from the high pressure supply pump then remove it.
INSTALLATION
1. Install the pump then position the mounting bolts without tightening them.
2. Before fitting the new injection tube, lightly lubricate the nut threads with the oil from the sachet provided
in the new parts kit.
3. Install the injection tubes according to the following:
• remove the protective plugs.
• insert the injection tube olive into the taper of the high pressure pump outlet.
• insert the injection tube olive into the taper of the high pressure rail inlet.
4. Finger tighten the nuts of the injection tube starting with the one located on the rail side.
5. Tighten the bolts on the high pressure pump.
: 21.0 N·m (2.1 kg-m, 15 ft-lb)

6. Tighten the injection tube nut.
: 24.0 N·m (2.4 kg-m, 18 ft-lb)

7. Install the high pressure supply pump protector.
CAUTION:
When installing the high pressure supply pump protector, follow the steps below.
• Be sure rubber spacer (1) is touching bolt head of high
pressure supply pump (4) as shown.
E1BIA0117ZZ
• Tighten bolt (2) while holding protector towards the high

pressure supply pump.
: 21.0 N·m (2.1 kg-m, 15 ft-lb)
• Tighten nut (3).
: 21.0 N·m (2.1 kg-m, 15 ft-lb)
• Be sure rubber spacer (1) is touching bolt head of high

pressure supply pump (4). E1BIA0118ZZ
8. Installation is in the reverse order to removal.

9. Test the sealing of the high pressure supply pump after it has been repaired (refer to EM-253, "Precaution
for Diesel Equipment").
EM-288
ROCKER COVER
ROCKER COVER
A
EM
E1BIA0006GB
1. Oil filler cap 2. Rocker cover 3. Gasket G

4. Camshaft position sensor
Removal and Installation INFOID:0000000001381498 H
REMOVAL
1. Remove engine cover. I
2. Remove air duct (inlet). Refer to EM-269, "Exploded View".
3. Remove air duct (suction). Refer to EM-269, "Exploded View".
J
4. Remove charge air cooler pipes and hoses. Refer to EM-270, "Exploded View".
5. Disconnect and remove camshaft position sensor.
6. Remove fuel hose shield. K
7. Disconnect electronic throttle control actuator. Refer to EM-272, "Exploded View".
9. Remove high pressure pipes protection cover (upper). L
10. Unclip fuel injector spill hose from rocker cover.
11. Unclip timing belt upper cover.
12. Remove rocker cover. M
NOTE:
Loosen bolts in the reverse order as shown.
N
E1BIA0048ZZ
P
INSTALLATION
1. Install new gasket to rocker cover.
EM-289
ROCKER COVER
2. Apply liquid gasket on locations shown.
Use Genuine Liquid gasket or equivalent.
MBIB0581E
3. Tighten bolts in the numerical order as shown.
: 12.0 N·m (1.2 kg-m, 9 ft-lb)

E1BIA0048ZZ
EM-290
TIMING BELT
TIMING BELT
A
EM
I
E1BIA0022GB
1. Timing belt inner cover 2. Timing belt 3. Camshaft sprocket J

4. Camshaft sprocket stud bolt 5. Timing belt tensioner 6. Timing belt cover
7. Cylinder head suspended bracket 8. Crankshaft pulley 9. Crankshaft sprocket (timing belt)
10. Oil seal 11. Crankshaft cover 12. Gasket K
A. 30.0 N·m (3.1 kg-m, 22 ft-lb) and 86 degrees
B. 120.0 N·m (12 kg-m, 89 ft-lb) and 95 degrees
L
CAUTION:
• Apply new engine oil to parts marked in illustration before installation. M
• Replace any belt that has been removed.
• Never turn the engine in the direction opposite to that of normal operation.
• When replacing the timing belt, be sure to replace the timing belt tensioner. N
• Do not run the engine without the drive belts to avoid damaging the crankshaft pulley.
REMOVAL
1. Remove front wheel RH. Refer to WT-6, "Rotation". O
2. Remove fender protector RH. Refer to EXT-22, "Removal and Installation".
P
6. Remove RH engine torque rod.
7. Remove RH engine mounting support bracket and RH engine mounting insulator.
EM-291
TIMING BELT
8. Remove timing belt cover (upper).
E1BIA0040ZZ
E1BIA0041ZZ
9. Remove cylinder head suspended mounting bracket (1).

10. Remove timing belt cover (lower).
E1BIA0042ZZ
11. Remove the TDC pin plug.
MBIB0392E
12. Rotate the crankshaft clockwise, until the position (A) of the
camshaft pulley is opposite of the position (B) on the cylinder
head.
E1BIA0043ZZ
EM-292
TIMING BELT
13. Insert TDC set pin [SST: KV113B0110 (Mot.1430)] (A) into the
camshaft sprocket and cylinder head hole. A
EM
E1BIA0044ZZ
D
14. Screw in the TDC set pin [SST: KV113 B0130 (Mot. 1439)].
G
MBIB0394E
15. Turn the engine clockwise (timing side) until the crankshaft H
touches the TDC set pin.
MBIB0395E K
16. The pin [SST: KV113B0110 (Mot.1430)] (A) must engage in the
camshaft pulley and cylinder head holes.
L
17. Remove crankshaft position sensor. Refer to EM-284,
"Exploded View".
E1BIA0044ZZ
18. Remove crankshaft pulley (1). O

CAUTION:
Do not remove bolt. Keep loosened bolt in place to protect
removed crankshaft pulley from dropping. P
NOTE:
Insert flat-bladed screwdriver into position of crankshaft position
sensor to hold crankshaft from moving and loosen crankshaft
pulley bolt.
E1BIA0045ZZ
EM-293
TIMING BELT
19. Slacken the timing belt by loosening the bolt of tensioner (1),
then remove timing belt.
E1BIA0046ZZ
INSTALLATION
CAUTION:
It is essential to remove any dirt or grease from the end of the crankshaft, the bore of the crankshaft
sprocket and the bearing faces of the drive belt pulley to prevent any movement between the timing
sprockets and the crankshaft which would risk damaging the engine.
1. Install timing belt tensioner.
NOTE:
Put the timing belt tensioner tab (1) in the cylinder head groove.
2. Insert TDC set pin [SST: KV113B0110 (Mot. 1430)] (A) in the
camshaft pulley and cylinder head holes.
3. Check that high pressure supply pump sprocket mark (2) has
shifted one tooth to the right of vertical axle as shown.
E1BIA0060ZZ
4. Turn crankshaft to set TDC set pin [SST: KV113B0130 (Mot.

1489)] (the crankshaft groove (1) must be facing upwards).
E1BIA0061ZZ
5. Insert and tighten crankshaft pulley bolt with a spacer (1) (which
does not cover the timing sprocket mark).
E1BIA0059ZZ
EM-294
TIMING BELT
6. Insert TDC set pin [SST: KV113B0130 (Mot.1489)] to crankshaft.
A
EM
MBIB0395E
7. Remove one wheel bolt from camshaft sprocket, and then

loosen the other two bolts (1). E
8. Install the timing belt, aligning the marks on the bolt with those
on the camshaft and high pressure supply pump sprockets (19
teeth spaces on the belt between the marks on the camshaft F
and pump sprockets).
E1BIA0062ZZ
H
9. Using a 6 mm (0.24 in) Allen key, move the movable index (F) of
the timing belt tensioner into the position as shown, by turning
the key counterclockwise. I
10. Tighten timing belt tensioner bolt.
J
: 27.0 N·m (2.8 kg-m, 20 ft-lb)
11. Check that the camshaft sprocket bolts are not fully up against
the camshaft sprocket wheel. K
12. Install and tighten camshaft sprocket wheel bolts.
MBIB0509E
: 14.0 N·m (1.4 kg-m, 10 ft-lb) L
13. Remove TDC set pin [SST: KV113B0130 (Mot. 1489)] and TDC set pin [SST: KV113B0110 (Mot. 1430)].
14. Turn the crankshaft two revolutions in a clockwise direction (tim-
M
ing side). Just before the hole (A) of the camshaft pulley is oppo-
site the cylinder head hole (B), insert TDC set pin [SST:
KV113B0130 (Mot. 1489)] into the cylinder block.
15. Then turn the crankshaft slowly and smoothly against TDC set N
pin.
E1BIA0043ZZ
P
EM-295
TIMING BELT
16. Insert TDC set pin [SST: KV113B0110 (Mot. 1430)] (A).
If the pin cannot be inserted, perform the following.
a. Remove TDC set pin [SST: KV113B0130 (Mot. 1489)].
b. Loosen camshaft sprocket wheel bolts.
c. Turn camshaft pulley to adjust.
d. Confirm that the crankshaft sprocket groove is facing upward.
e. Loosen timing belt tensioner bolt.
E1BIA0044ZZ
f. Move the movable index of the drive belt tensioner into the posi-
tion as shown, by turning the key clockwise.
g. Tighten timing belt tensioner bolt.
: 27.0 N·m (2.8 kg-m, 20 ft-lb)

h. Install and tighten camshaft sprocket wheel bolts.
: 14.0 N·m (1.4 kg-m, 10 ft-lb)

MBIB0511E
i. Turn the crankshaft two revolutions in a clockwise direction (tim-
ing side). Just before the hole (A) of the camshaft pulley is opposite the cylinder head hole (B), insert TDC
set pin [SST: KV113B0130 (Mot. 1489)] into the cylinder block.
j. Then turn the crankshaft slowly and smoothly against TDC set pin.
17. Install crankshaft pulley and tighten the bolt (1).
: 120 N·m (12 kg-m, 89 ft-lb)

18. Turn bolt 95 degrees clockwise.
CAUTION:
wrench [SST: KV10112100 ( — )] or protractor. Avoid judg-
19. Remove TDC set pin [SST: KV113B0130 (Mot. 1489)] and TDC
set pin [SST: KV113B0110 (Mot. 1430)]. E1BIA0045ZZ
20. Apply liquid gasket to the thread of TDC pin plug.

21. Install TDC pin plug.
: 20 N·m (2.0 kg-m, 15 ft-lb)

22. Install the cylinder head suspended bracket (1).
: 21 N·m (2.1 kg-m, 15 ft-lb)
E1BIA0042ZZ
EM-296
TIMING BELT
23. Install the timing cover by positioning the tab (M) into the hole
(N) on the inner timing cover. A
EM
MBIB0514E
EM-297
CAMSHAFT
CAMSHAFT
E1BIA0023GB
1. Camshaft sprocket stud bolt 2. Camshaft sprocket 3. Oil seal

4. Camshaft bracket 5. Camshaft 6. Cylinder head suspended bracket
7. Valve lifter 8. Cap 9. Cylinder head
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove front wheel RH. Refer to WT-6, "Rotation".
2. Remove fender protector RH. Refer to EXT-22, "Removal and Installation".
3. Remove rocker cover. Refer to EM-289, "Removal and Installation".
4. Remove electronic throttle control actuator. Refer to EM-272, "Exploded View".
5. Remove vacuum pump. Refer to EM-280, "Removal and Installation".
CAUTION:
Put a piece of wood or something similar as supporting surface to secure a completely stable con-
dition.
8. Remove timing belt. Refer to EM-291, "Removal and Installation".
9. Remove camshaft brackets.
10. Remove camshaft.
INSTALLATION
EM-298
CAMSHAFT
2. Install camshaft. A
3. Install camshaft bracket and tighten bolts in numerical order as
shown.
EM
: 11 N·m (1.1 kg-m, 8 ft-lb)
D
E1BIA0050ZZ
4. Screw the shouldered rod of camshaft seal insert [SST: E

KV113B0230 (Mot. 1632)] onto the stud of the camshaft.
MBIB0430E H
5. For the new seal, put the protector with the seal on the cam-
shaft, taking care not to touch the seal. I
MBIB0431E
L
6. Install the cover (E) and the collar nut (F) of camshaft seal insert
[SST: KV113B0230 (Mot. 1632)].
M
O
MBIB0432E
EM-299
CAMSHAFT
7. Screw the collar nut until the cover touches the cylinder head.
MBIB0433E
8. Install camshaft sprocket and sprocket holder [SST: — (Mot.

1606-A)] (A).
9. Install timing belt. Refer to EM-291, "Removal and Installation".
E1BIA0054ZZ

Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 4 journal of camshaft.
CAUTION:
four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft in one direction and measure the camshaft
runout on dial indicator. (Total indicator reading)
Standard : Refer to EM-333, "Camshaft".

PBIC3177J
Camshaft Cam Height

1. Measure the camshaft cam height with a suitable tool (A).
Standard : Refer to EM-333, "Camshaft".

PBIC3178J
Camshaft End Play
EM-300
CAMSHAFT
1. Install the camshaft.
2. Install the camshaft brackets. A
3. Check the end play.
Standard : Refer to EM-333, "Camshaft". EM
MBIB0420E
D
Valve Lifter
1. Measure outer diameter of valve lifter.
E
Intake and exhaust : Refer to EM-333, "Camshaft"
2. Measure inner diameter of valve lifter hole in cylinder head.
F
3. Calculate the valve lifter clearance.
(Valve lifter clearance) = (Valve lifter hole inner diameter) – (Valve lifter diameter) G

H
EM-301
ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [K9K]
REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
AWBIA0162GB
1. Engine mounting insulator LH 2. Engine mounting frame support LH 3. Engine mounting bracket LH
4. Upper torque rod 5. Engine mounting insulator RH 6. Engine mounting bracket RH (upper)
7. Engine mounting bracket RH (lower) 8. Lower torque rod bracket 9. Lower torque rod
: Vehicle front
WARNING:
• Situate vehicle on a flat and solid surface.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Do not start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the main engine section, follow the procedures in the
applicable sections.
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
• For supporting points for lifting and jacking rear axle, refer to GI-48, "Garage Jack and Safety Stand
and 2-Pole Lift" or GI-49, "Board-On Lift".
REMOVAL
Description of Work
EM-302
ENGINE ASSEMBLY
Remove engine and transaxle assembly from vehicle down ward. Separate engine and transaxle.
Preparation A
Remove the following parts.
• Battery ground cable.
• Engine undercover. EM
• LH and RH front wheels. Refer to WT-6, "Rotation".
• LH and RH fender protectors. Refer to EXT-22, "Removal and Installation".
Engine Room C
1. Drain engine coolant. Refer to CO-58, "Draining".
CAUTION:
Perform when engine is cold. D
2. Remove lower radiator hose. Refer to CO-62, "Exploded View".
3. Drain transaxle fluid. Refer to TM-672, "Draining".
4. Disconnect clutch tube at clutch housing and drain clutch fluid. E
NOTE:
Cover clutch tube ends to prevent contamination.
5. Remove hood. Refer to DLK-214, "Removal and Installation". F
7. Remove battery and battery trap. Refer to PG-6, "Removal and Installation".
8. Disconnect engine room harness from the engine side and position aside. G
9. Remove the air duct (inlet). Refer to EM-269, "Exploded View".
H
12. Remove air cleaner case and air duct (suction). Refer to EM-269, "Removal and Installation".
13. Remove reservoir tank and hoses. Refer to CO-62, "Exploded View". I
14. Remove charge air cooler hoses and tubes. Refer to EM-270, "Exploded View".
15. Remove vacuum hose. Refer to EM-280, "Removal and Installation".
16. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining. J
17. Remove radiator upper hose. Refer to CO-62, "Exploded View".
18. Disconnect heater hoses.
K
19. Disconnect transaxle side harness.
20. Disconnect breather hose transaxle side.
21. Disconnect shift cable and select cable. Refer to TM-674, "Exploded View". L
22. Remove cooling fan. Refer to CO-64, "Removal and Installation".
23. Remove radiator. Refer to CO-62, "Exploded View".
24. Disconnect all the body-side vacuum hoses and air hoses at engine side. M
Vehicle Underbody
1. Remove drive shaft assembly RH and LH. Refer to Removal and Installation.
N
4. Remove A/C compressor and position aside. O
NOTE:
Secure it to body with a rope to avoid putting load on A/C lines.
5. Remove lower torque rod. Refer to EM-302, "Exploded View".
P
Removal
EM-303
ENGINE ASSEMBLY
1. Install engine slingers (1) into front right of cylinder head and
engine slinger (2) into rear left of cylinder head.
2. Remove upper torque rod.
3. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a jack or trestle. Securely support bot-
tom of engine and transaxle.
CAUTION:
Put a piece of wood or something similar at the supporting
surface to secure a stable condition.
4. Remove RH and LH engine mounting bolts.
MBIB9022E
5. Remove engine and transaxle assembly from vehicle downward
by carefully operating supporting tools.
CAUTION:
• During the operation, make sure that no part interferes with body side.
• During the removal operation, always be careful to prevent vehicle from falling off the lift due to
changes in the center of gravity.
• If necessary, support vehicle by setting a jack or equivalent tool at the rear.
Separation Work
CAUTION:
During the operation, secure the engine by placing a piece of wood under the engine oil pan and tran-
saxle and lift the engine using a suitable tool.
1. Remove starter motor.
2. Separate engine and transaxle.
3. Lift the engine with a suitable tool and separate the engine from the transaxle assembly. Refer to EM-302,
"Exploded View".
INSTALLATION
• Do not allow oil to get on mounting insulator. Be careful not to damage mounting insulator.
• When installation directions are specified, install parts according to the direction marks on them referring to
exploded views.
• Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.

• Before starting engine check the levels of coolant, lubricants and oils. Fill to the specified level.
• Before starting engine, bleed air from fuel piping. Refer to EM-287, "Removal and Installation".
• Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, oil, fuel and exhaust
gas.
• Bleed air from passages in pipes and tubes of applicable lines.
EM-304
< DISASSEMBLY AND ASSEMBLY > [K9K]
DISASSEMBLY AND ASSEMBLY A

Setting INFOID:0000000001381507
EM
Before the engine is mounted on the engine sub-attachment, the engine's electrical harness must be removed
and the engine oil drained.
C
1. Remove the generator.
2. Remove the multifunction support.
D
MBIB0355E
3. Remove the coolant inlet pipe on the water pump. G
J
MBIB0356E
4. Place the rods (A), (X), (Y) on the cylinder block.

K
MBIB0357E
EM-305
CYLINDER HEAD
CYLINDER HEAD
E1BIA0024GB
1. Valve lifter 2. Valve collet 3. Valve spring retainer

4. Valve spring 5. Cylinder head bolt 6. Cylinder head
7. Cylinder head gasket 8. Engine slinger 9. Valve
A. 25.0 N·m (2.6 kg-m, 18ft-lb) and 255 degrees
REMOVAL
• Air inlet tube: Refer to EM-272, "Removal and Installation".
• Rocker cover: Refer to EM-289, "Removal and Installation".
• Injection tube and fuel injector: Refer to EM-281, "Removal and Installation".
• High pressure supply pump: Refer to EM-287, "Removal and Installation".
• Exhaust manifold: Refer to EM-277, "Removal and Installation".
• Timing belt: Refer to EM-291, "Removal and Installation".
• Camshaft: Refer to EM-298, "Removal and Installation".
2. Remove cylinder head bolts in reverse order as shown and
remove cylinder head.
E1BIA0047ZZ
EM-306
CYLINDER HEAD
INSTALLATION
1. Position the pistons at mid-stroke. A
2. Install new cylinder head gasket using the centering dowels of the cylinder block.
NOTE:
The gasket faces (cylinder head and rocker cover) must be clean, dry and free from grease (in par- EM
ticular, remove finger marks).
3. Install cylinder head and tighten cylinder head bolts in the
numerical order as shown. C
: 25.0 N·m (2.6 kg-m, 18 ft-lb)

D
4. Turn all bolts 255 degrees clockwise (angle tightening) in the
CAUTION:
Check and confirm the tightening angle by using the angle E
ment by visual inspection without the tool. E1BIA0047ZZ
5. Install in the reverse order of removal after this step. F
G
DISASSEMBLY
1. Place the cylinder head on cylinder head stand [KV113B0200
(Mot. 1573) (commercial service tool) or equivalent tool]. H
CAUTION:
Pay strict attention to the rules regarding cleanliness. Refer
to EM-253, "Precaution for Diesel Equipment". I
MBIB0406E
K
2. Remove high pressure supply pump and related parts. Refer to EM-281, "Removal and Installation".
3. Remove the injectors and glow plugs. Refer to EM-281, "Removal and Installation" and EM-279,
"Removal and Installation". L
4. Remove the vacuum pump and water outlet and thermostat assembly. Refer to EM-280, "Removal and
Installation" and CO-68, "Removal and Installation".
5. Remove the front engine slinger, EGR assembly, air inlet pipe and exhaust manifold. Refer to EM-272, M
"Removal and Installation" and EM-277, "Removal and Installation".
6. Remove the camshaft sprocket. Refer to EM-291, "Removal and Installation".
7. Remove the camshaft brackets. Refer to EM-298, "Removal and Installation". N
8. Remove the tappets, noting their position.
MBIB0415E
EM-307
CYLINDER HEAD
9. Compress the valve springs using the valve lifter.
Remove the keys, upper cups and springs.
MBIB0416E
NOTE:
Before removing the valves and the valve stem seals, it is
vital to measure position “H” of one of the old seals in rela-
tion to the cylinder head using valve seal drift [KV113B0180
(Mot. 1511-01) (commercial service tool) or equivalent tool].
MBIB0417E
10. Install the push rod (A) of valve seal drift [KV113B0180 (Mot.
1511-01) (commercial service tool) or equivalent tool] on the
valve stem seal.
NOTE:
The inner diameter of the push rod must be identical to that
of the valve. In addition, the bottom of the push rod must
come into contact with the metal upper section of the valve
stem seal.
MBIB0418E
11. Install the guide tube (B) over the push rod until the guide tube
comes into contact with the cylinder head, locking the push rod
with the knurled wheel.
12. Remove the guide tube assembly plus push rod, being careful
not to loosen the knurled wheel.
13. Remove the valves and valve guide seals using the valve seal
remover [KV113B0090 (Mot. 1335) (commercial service tool) or
equivalent tool].
MBIB0419E
ASSEMBLY
EM-308
CYLINDER HEAD
1. Install new valves and grind them gently into their respective
seats. Clean all the parts thoroughly, mark them for identification A
purposes, then carry out the refitting operation.
Lubricate the inside of the valve guide.
• It is imperative to fit the valve stem seals using valve seal drift
EM
[KV113B0180 (Mot. 1511-01) (commercial service tool) or
equivalent tool].
NOTE:
Do not lubricate the valve stem seals before fitting them. C
2. Place the valve in the cylinder head.
MBIB0421E
D
3. Place the barrel of valve seal drift [KV113B0180 (Mot. 1511-01)
(commercial service tool) or equivalent tool] over the valve stem
(the inner diameter of the barrel must be identical to the diame-
E
ter of the valve stem).
G
MBIB0422E
4. Keep the valve pressed against its seat. H

5. Place the valve stem seal (not lubricated) over the tool barrel.
MBIB0423E K
6. Push the valve stem seal past the tool barrel, then withdraw the
barrel. L
MBIB0424E
EM-309
CYLINDER HEAD
7. Place the guide tube plus push rod assembly on the valve stem
seal.
8. Push the valve stem seal down by tapping the top of the sleeve
with the palm of your hand until the guide tube touches the cylin-
der head.
9. Repeat these operations for all the valves.
MBIB0425E
10. Install the valve springs and upper cups using valve spring com-
pressor.
11. Install the keys using tweezers.
12. Install in the reverse order of removal after this step.
MBIB0416E
Cleaning INFOID:0000000001381511
• It is very important not to scratch the gasket faces of any aluminium components.
• Use suitable tool to dissolve any part of the seal which remains stuck to the metal surface.
• Apply the dissolving product to the part to be cleaned, wait approximately 10 minutes, then remove it using a
wooden spatula.
• Wear gloves while carrying out this operation.
• Do not allow this dissolving product to drip on to the paintwork.
• Great care should be taken when performing this operation, to prevent foreign objects from entering
the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover)
and the oil return pipes.
• Failure to follow these instructions could lead to the blocking of the oilways, resulting in rapid and
serious damage to the engine.

Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-330, "Inspec-
tion".
CAUTION:
EM-310
CYLINDER HEAD
Use utmost care not to allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions A
using straightedge and feeler gauge.
Limit : Refer to EM-335, "Cylinder Head". EM

• If it exceeds the limit, replace cylinder head.
Cylinder Head Height C

Measure the height of cylinder head (H).
Standard : Refer to EM-335, "Cylinder Head". D
F
E1BIA0063ZZ
Valve protrusion
Check the valve protrusion using dial gauge stand set [KV113B0040 G
(Mot. 251-01) (commercial service tool) or equivalent tool] and dial
gauge stand set [KV113B0050 (Mot. 252-01) (commercial service
tool) or equivalent tool] as shown. H
Standard : −0.07 to 0.07 mm (−0.0028 to 0.0028 in)

I
J
MBIB0426E
INSPECTION AFTER DISASSEMBLY

Valve K
Measure the valves as follows.
• Stem diameter (d)
L
Intake : Refer to EM-335, "Cylinder Head"
Exhaust : Refer to EM-335, "Cylinder Head"
M
• Face angle (α)

N
E1BIA0064ZZ
• Head diameter (D)
O
• Valve length (L) P

• Valve margin (T)
EM-311
CYLINDER HEAD

Valve Seat
Measure the valve seats as follows.
• Seat angle (α)

• Contacting width (X)

E1BIA0066ZZ
• Seat outer diameter (D):

• Cylinder head seat recess diameter (D)

1. Measure diameter of valve stem with micrometer.
2. Measure inner diameter of valve guide with inside micrometer.
3. Calculate the valve guide clearance.
(Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter)
Intake : 0.020 - 0.050 mm (0.0008 - 0.0020 in)

Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
• If it exceeds the limit, replace and/or valve guide.
SEM938C
Valve Spring
Measure the valve spring as follows.
• Free height
Intake and exhaust : Refer to EM-335, "Cylinder Head"

• Length under load

• Full pressed height
Intake and exhaust : Refer to EM-335, "Cylinder Head" SEM113
• Wire diameter

• Inner diameter

• Outer diameter
EM-312
CYLINDER HEAD
Intake and exhaust : Refer to EM-335, "Cylinder Head" A

• Squareness
Intake and exhaust : Refer to EM-335, "Cylinder Head" EM
EM-313
CYLINDER BLOCK
CYLINDER BLOCK
E1BIA0017GB
1. Oil seal 2. Crankshaft cover 3. Gasket

4. Cylinder block 5. Oil seal 6 TDC pin plug
7. Top ring 8. Second ring 9. Oil ring
10. Piston 11. Piston pin 12. Snap ring
13. Connecting rod 14. Crankshaft pulley bolt 15. Crankshaft pulley
Crankshaft sprocket (oil pump drive
16. Crankshaft sprocket (timing belt) 17. 18. Crankshaft
chain)
19. Pilot bushing 20. Flywheel 21. Reinforcement plate
B. 20.0 N·m (2.0 kg-m, 15 ft-lb) and 45 degrees
C. 120.0 N·m (12 kg-m, 89 ft-lb) and 95 degrees
D. 20.0 N·m (2.0 kg-m, 15 ft-lb) and 36 degrees
DISASSEMBLY
EM-314
CYLINDER BLOCK
1. Install the ring gear stopper [SST: KV113B0060 (Mot. 582-01)].
2. Remove the clutch housing. A
EM
MBIB0397E
D
3. Remove the flywheel.
G
MBIB0439E
4. Remove the oil pan bolt in reverse order as shown.

H
MBIB1257E
K
5. Remove the oil level sensor.
6. Remove the oil pump.
L
N
MBIB0442E
7. Remove the crankshaft cover. O

8. Remove the water pump.
MBIB0443E
EM-315
CYLINDER BLOCK
9. Remove the oil pump chain.
10. Remove the oil pump drive sprocket.
MBIB0444E
WARNING:
Do not use a sharp point to mark the bearing caps in rela-
tion to their connecting rods to avoid starting a crack in the
rod. Use a permanent marker pen.
11. Remove the big end cap bolts and the connecting rod/piston
assemblies.
NOTE:
It is essential to mark the position of the main bearing cap,
as the category may be different for each bearing.
12. Remove the main bearing caps.
13. Remove the crankshaft.
MBIB0341E
14. Remove the oil pressure switch, the knock sensor and oil filter
bracket connecting bolt.
MBIB0445E
15. Remove the oil cooler connecting bolt.
MBIB0446E
EM-316
CYLINDER BLOCK
16. To remove the oil jets (A), they must be drilled with a 7 mm (0.28
in) diameter drill. This is necessary in order to remove the spring A
stop (B) and the spring (C).
EM
MBIB0447E
D
NOTE:
Do not remove the ball (D) to prevent from entering the
cooling circuit. E
MBIB0448E
H
17. Remove the using a suitable brush.
K
MBIB0449E
18. Screw oil jet remover [SST: KV113B0120 (Mot. 1485-01)] in the L
drilled out jets using a 6 mm (0.24 in) Allen key which must slide
into the tool.
MBIB0450E
O
EM-317
CYLINDER BLOCK
19. Screw sliding hammer [SST: KV113B0020 (Emb. 880)] onto oil
jet remover [SST: KV113B0120 (Mot. 1485-01)] and remove the
oil jet.
MBIB0451E
20. To remove the piston pin, remove the snap ring using a screwdriver, then release the pin.
Removing the Piston Pins
NOTE:
It is imperative to mark the connecting rod to match it to its piston, because the piston height classes
in the same engine may be different (see Technical Specifications section).
ASSEMBLY
1. The oil jets must be installed using oil jet remover plate [SST: KV113B0170 (Mot. 1494)].
2. Install oil jets for NO. 1 and NO. 3 cylinders with the following procedure.
a. Install plate (A) of oil jet remover plate [SST: KV113B0170 (Mot. 1494)] onto the cylinder block (as shown)
without tightening the two bolts (C).
b. Position the guide rod (B) in the plate (A) and the end of the guide rod in the hole of the oil jet to center the
plate (A).
c. Tighten the two bolts (C).
d. Remove the guide rod.
e. Install the push rod instead of the guide rod, then insert the oil jet
into the push rod.
NOTE:
Check that the oil jet is correctly oriented with the end of
the jet (D) directed towards the center of the cylinder.
MBIB0453E
f. With a hammer, tap the push rod until the shoulder (E) of the
push rod comes into contact with the plate (A).
MBIB0454E
3. Install oil jets for NO. 1 and NO.4 cylinders with the following procedure.
EM-318
CYLINDER BLOCK
a. Fit plate (A) of oil jet remover plate [SST: KV113B0170 (Mot.
1494)] onto the cylinder block (as shown) without tightening the A
two bolts (C).
EM
MBIB0455E
D
b. Position the guide rod (B) in the plate (A) and the end of the guide rod in the hole of the oil jet to center the
plate (A).
c. Tighten the two bolts (C). E
d. Remove the guide rod.
e. Position the push rod instead of the guide rod, then insert the oil
jet into the push rod. F
NOTE:
Check that the oil jet is correctly oriented with the end of
the jet (D) directed towards the center of the cylinder.
G
MBIB0453E
I
f. With a hammer, tap the push rod until the shoulder (E) of the
push rod comes into contact with the plate (A).
J
L
MBIB0456E
4. Check orientation of the oil jets (see diagram below).

M
A Orientation of the oil jets of No. 2 and No. 4 cylinders

B Orientation of the oil jets of No. 1 and No. 3 cylinders N
5. Clean the cylinder block and crankshaft by passing a wire
through the lubrication channels.
6. Install oil level gauge guide tube. O
MBIB0457E
P
7. Select main bearing with the following procedure.
EM-319
CYLINDER BLOCK
a. Identify the category of crankshaft main journal diameter (A) with
checking the marking of crankshaft as shown.
NOTE:
The marking has 5 digits. Left end is the diameter category of
No. 1 bearing (flywheel side) and right end is the diameter cate-
gory of No. 5 bearing (Sprocket side).
Journal diameter category

Journal diameter category mark
[Diameter mm (in)]
D1
A, G, K, R, W
[47.990 - 47.997 (1.8894 - 1.8896)] MBIB0344E
D2
B, H, L, S, Y
[47.997 - 48.003 (1.8896 - 1.8899)]
D3
C, J, O, T, Z
[48.003 - 48.010 (1.8899 - 1.8902)]
b. Identify the category of main bearing journal inner diameter on
the cylinder block (A) with measuring the length between cylin-
der block top surface and drilled hole (B).
Category marking
Position of (B)
[Inner diameter (A) mm (in)]
1 or Blue
33 mm (1.30 in)
[51.936 - 51.942 (2.0447 - 2.0450)]
2 or Red
43 mm (1.69 in)
[51.942 - 51.949 (2.0450 - 2.0452)]
MBIB0346E
MBIB0345E
c. Select main bearing category by referring to the table.
Category of main
Category of crank-
bearing journal in- Main bearing category
shaft main journal
ner diameter on [Thickness mm (in)]
diameter
the cylinder block
C1 (Yellow)
D1
[1.949 - 1.955 (0.0767 - 0.0770)]
C2 (Blue)
1 or Blue D2
[1.946 - 1.952 (0.0766 - 0.0769)]
C3 (Black)
D3
[1.943 - 1.949 (0.0765 - 0.0767)]
EM-320
CYLINDER BLOCK
Category of main
Category of crank-
bearing journal in- Main bearing category A
shaft main journal
ner diameter on [Thickness mm (in)]
diameter
the cylinder block
C4 (Red) EM
D1
[1.953 - 1.959 (0.0769 - 0.0771)]
C1 (Yellow)
2 or Red D2
[1.949 - 1.955 (0.0767 - 0.0770)]
C
C2 (Blue)
D3
[1.946 - 1.952 (0.0766 - 0.0769)]
8. Install main bearing with the following procedure. D
a. Position the grooved main bearing on the cylinder block.
G
MBIB0348E
b. Install the smooth bearing cap on the bearings. H
MBIB0349E
K
c. Position bearing insert [SST: KV113B0160 (Mot. 1493-01)] on
the cylinder block.
L
MBIB0472E
d. Install the bearing cap in bearing insert [SST: KV113B0160 (Mot. O

1493-01)], then press at (A) until the bearing cap is touching at
(B) with bearing insert.
P
MBIB0473E
EM-321
CYLINDER BLOCK
e. Position bearing insert [SST: KV113B0160 (Mot. 1493-01)] on
the bearing cap.
MBIB0474E
f. Install the main bearing in bearing insert [SST: KV113B0160

(Mot. 1493-01)], then press at (A) until the main bearing is
touching at (B) with bearing insert.
g. Lubricate the main bearing with engine oil.
h. Install the crankshaft.
i. Install the lateral shims on bearing No. 3, putting the grooves on
the crankshaft side.
MBIB0475E
j. Degrease the gasket faces (of the cylinder block and bearing
No. 1). They should be clean, dry and free from grease (in par-
ticular, remove finger marks).
k. Lay two beads of liquid sealant with a width of 4 mm (0.16 in) on
bearing No. 1 of the cylinder block.
MBIB0478E
l. Install the main bearing caps on bearing cap No. 1 (these are
numbered from 1 - 5 and these numbers should be positioned
opposite the water pump). Then tighten the bolts to a torque of
25 N·m (2.6 kg-m, 18 ft-lb) plus an angle tightening of 47
degrees.
: 25.0 N·m (2.6 kg-m, 18 ft-lb)

m. Turn all bolts 47 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle MBIB0476E
n. Check the lateral play. Refer to EM-330, "Inspection".
9. Install connecting rod bearing with the following procedure.
EM-322
CYLINDER BLOCK
The connecting rod bearing are installed using bearing assem-
bling set [SST: KV113B0140 (Mot. 1492)] and bearing assem- A
bling adapter [SST: KV113B0150 (Mot. 1492-03)].
EM
MBIB0461E
G
MBIB0352E
a. Slide the connecting rod bearing support (A) of bearing assem-

H
bling adapter [SST: KV113B0150 (Mot. 1492-03)] (positioning
the engraved mark (B) as shown)] into the groove (C) of the
base of bearing assembling set [SST: KV113B0140 (Mot.
1492)]. I
MBIB0462E
K
b. Install the guide (D) of bearing assembling adapter [SST:
KV113B0150 (Mot. 1492-03)] onto the base (as shown).
L
N
MBIB0463E
c. Lay the body of the connecting rod on the base of the tool (as O
shown in the diagram). Check that the lower part (E) of the small
end is touching the centering pin and push the guide (G) in the
direction of the arrow.
P
MBIB0464E
EM-323
CYLINDER BLOCK
d. Lay the connecting rod bearing [with a width of 20.625 mm
(0.8120 in)] (F) on the connecting rod bearing support, then
push it in the direction of the arrow (as shown).
MBIB0465E
e. Bring the connecting rod support up against the base of the con-
necting rod body.
f. Remove the connecting rod body support and repeat the opera-
tion for the remaining connecting rod bodies.
MBIB0466E
g. Position the connecting rod bearing support either on the

engraved mark (C) if the width of the connecting rod bearing is
equal to 20.625 mm (0.8120 in).
h. Position the connecting rod bearing support either on the
engraved mark (D) if the width of the connecting rod bearing is
equal to 17.625 mm (0.6939 in).
MBIB0467E
i. Install the connecting rod cap as shown.
MBIB0468E
j. Push the guide (in the direction of the arrow) until the connecting
rod cap is in contact with the pins (I) on the base of the tool.
MBIB0469E
EM-324
CYLINDER BLOCK
k. Install the connecting rod bearing (H) on the bearing support,
then push it in the direction of the arrow (as shown). A
EM
MBIB0470E
D
l. Bring the connecting rod bearing support up against the base of
the connecting rod cap.
m. Remove the connecting rod bearing support and repeat the E
operation for the remaining connecting rod caps.
G
MBIB0471E
10. Assemble connecting rod and piston with the following procedure. H
a. The pistons have a mark engraved on their heads indicating the engine rear side.
• Oil the piston pin.
• Check that the piston pins rotate correctly in the new piston and in the matching connecting rod. I
b. Point the mark (A) engraved on the top of the piston upwards
and the flat (B) of the big end downwards as shown.
J
L
MBIB0342E
c. Position the opening (C) of the snap rings opposite the removal
and fitting channel (D). M
d. Install snap ring.
• Rings set to their original adjustment must be free within their
channels. N
• Ensure the snap rings are fitted the correct way, with the word
TOP pointing upwards.
O
MBIB0343E
P
EM-325
CYLINDER BLOCK
e. Ensure the break in each piston ring is correctly oriented as
shown.
f. Apply new engine oil to the pistons.
g. Install the connecting rod/piston assemblies into the cylinder
block using the ring, being careful to fit them the right way round
(mark towards the flywheel).
h. Install the connecting rods onto the oiled crankshaft pins of the
crankshaft.
i. Install the connecting rod caps, ensuring they are correctly
matched. MBIB0339E
j. Tighten the connecting rod cap bolts.
: 20.0 N·m (2.0 kg-m, 15 ft-lb)

k. Turn all bolts 45 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle wrench [SST: KV10112100 ( — )] or pro-
tractor. Avoid judgment by visual inspection without the tool.
l. Inspect that the big end lateral play. Refer to EM-330, "Inspection".
11. Install the oil pump sprocket and chain.
12. Tighten oil pump mounting bolts.
: 25.0 N·m (2.6 kg-m, 18 ft-lb)

13. Install water pump, Refer to CO-66, "Removal and Installation".
NOTE:
The gasket faces (cylinder block, crankshaft cover and water
pump) must be clean, dry and free from grease (in particular,
remove finger marks).
MBIB0442E
14. Install crankshaft cover oil seal with a new one.
15. Install the crankshaft cover in the numerical order as shown.
: 11.0 N·m (1.1 kg-m, 8 ft-lb)
E1BIA0051ZZ
16. Apply two beads (B) of liquid gasket, with a diameter of 5 mm

(0.20 in).
Apply two points (C) of liquid gasket, with a diameter of 5 mm
(0.20 in) at the intersection of the crankshaft cover and the cylin-
der block.
MBIB0483E
EM-326
CYLINDER BLOCK
17. Apply two beads (B) of liquid gasket, with a diameter of 5 mm
(0.20 in). A
18. Install the oil pan Refer to EM-284, "Removal and Installation".
EM
MBIB0484E
D
19. Crankshaft elastomer seal, timing side.
20. Screw the threaded rod (A) of front oil seal drift set [SST:
KV113B0220 (Mot. 1586)] into the crankshaft. E
G
MBIB0487E
21. Position the spacer (B) of front oil seal drift set [SST: H
KV113B0220 (Mot. 1586)] on the crankshaft.
MBIB0488E K
22. Install the protector complete with the seal onto the spacer, tak-
ing care not to touch the seal. L
MBIB0489E
O
23. Install the cover (A) and the nut (B) (putting the threaded part
(C) of the nut on the side away from the engine) of front oil seal
drift set [SST: KV113B0220 (Mot. 1586)].
P
MBIB0490E
EM-327
CYLINDER BLOCK
24. Tighten the nut until the cover touches the spacer.
MBIB0491E
MBIB0492E
25. Remove the nut, the cover, the protector and the threaded rod.
MBIB0493E
26. Crankshaft elastomer seal, flywheel side.

27. Install front oil seal drift set [SST: KV113B0210 (Mot. 1585)] on
the crankshaft, securing it with bolts (F).
MBIB0494E
EM-328
CYLINDER BLOCK
28. Put the protector complete with the seal on front oil seal drift set
[SST: KV113B0210 (Mot. 1585)], being careful not to touch the A
seal.
EM
MBIB0495E
D
29. Install the cover (G) and nut (H) (putting the threaded part (I) of
the nut on the side away from the engine) of front oil seal drift
set [SST: KV113B0210 (Mot. 1585)].
E
G
MBIB0496E
30. Tighten the nut until the cover touches the cylinder block.
H
MBIB0497E
K
MBIB0498E
EM-329
CYLINDER BLOCK
31. Remove the nut, the cover, the protector and the threaded rod.
MBIB0499E
32. Install ring gear stopper [SST: KV113B0060 (Mot. 582-01)] and
tighten flywheel bolts with new one.
: 20.0 N·m (2.0 kg-m, 15 ft-lb)

33. Turn all bolts 36 degrees clockwise (angle tightening).
CAUTION:
34. Install the clutch housing. Refer to TM-680, "Exploded View". MBIB0500E
35. Remove ring gear stopper [SST: KV113B0060 (Mot. 582-01)].

CYLINDER BLOCK TOP SURFACE DISTORTION

other contamination.
CAUTION:
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and feeler
gauge (B).

PBIC3250J
PISTON PROTRUSION
1. Clean the piston head.
2. Turn the crankshaft one turn in its operating direction to bring piston No. 1 close to TDC.
3. Install dial gauge stand set [KV113B0050 (Mot. 252-01) (com-
mercial service tool) or equivalent tool] on the piston.
4. Install dial gauge stand set [KV113B0040 (Mot. 251-01) (com-
mercial service tool) or equivalent tool] equipped with a gauge
on dial gauge stand set [KV113B0050 (Mot. 252-01) (commer-
cial service tool) or equivalent tool], and find TDC.
NOTE:
All measurements must be carried out along the longitudinal
axis of the engine, in order to eliminate any errors due to tilting
of the piston.
WARNING: MBIB0480E
EM-330
CYLINDER BLOCK
The gauge follower must not be in the valve clearance.
5. Inspect the piston protrusion. A

EM
CRANKSHAFT LATERAL PLAY
1. Install crankshaft.
2. Inspect the lateral play. C

D
MBIB0477E F
CONNECTING ROD BIG END LONGITUDINAL PLAY

1. Install crankshaft. G
2. Install piston and connecting rod assembly.
3. Inspect that the big end lateral play.
H
MBIB0479E
K
PISTON DIAMETER
Measure the piston diameter.
The piston diameter (A) must be measured at height (a) = 56 mm
(2.205 in). L

M
SEM882E
O
PISTON RING THICKNESS
Measure piston ring thickness with micrometer.
P
• The piston rings are supplied ready adjusted.
EM-331
CYLINDER BLOCK
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge (A).

• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
PBIC3280J
PISTON RING END GAP

• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).

• If the measured value exceeds the limit, replace piston ring.
PBIC3267J

Use micrometer to measure crankshaft main journal diameter.
FEM114

Use micrometer to measure crankshaft pin journal diameter.
PBIC0127E
EM-332
< SERVICE DATA AND SPECIFICATIONS (SDS) [K9K]
SERVICE DATA AND SPECIFICATIONS (SDS) A

General Specification INFOID:0000000001381516
EM
C
Displacement cm3 (cu in) 1.461 (89.15)

Bore and stroke mm (in) 76 x 80.5 (2.99 x 3.17) D
Valve arrangement SOHC
E
Compression 2
Oil 1
Number of main bearings 5 F
Maximum pressure must be at least 1,800
Compression pressure kPa (bar, kg/cm2, psi) (18, 18.36, 261) G
Valve timing I
PBIC0187E
a b c d e f
K
200° 191° -9° 20° -7° 27°
Drive Belt INFOID:0000000001381517 L
DRIVE BELT
M
Tension of drive belt Auto adjustment by auto-tensioner
Camshaft INFOID:0000000001381518 N
CAMSHAFT
Unit: mm (in) O
Items Standard
No. 1, 2, 3, 4, 5 25.04 - 25.06 (0.9858 - 0.9866)
Camshaft bracket inner diameter P
No. 6 28.04 - 28.06 (1.1039 - 1.1047)
No. 1, 2, 3, 4, 5 24.979 - 25.000 (0.9834 - 0.9843)
No. 6 27.979 - 28.000 (1.1015 - 1.1024)
Camshaft end play 0.080 - 0.178 (0.0031 - 0.0070)
Camshaft runout Less than 0.05 (0.0020)
EM-333
Items Standard
Intake 43.985 - 44.045 (1.7317 - 1.7341)
Exhaust 44.565 - 44.625 (1.7545 - 1.7569)
SEM671
VALVE LIFTER
Unit: mm (in)
Items Standard
Valve lifter outer diameter 34.965 - 34.985 (1.3767 - 1.3774)
Valve lifter hole diameter 35.000 - 35.040 (1.3780 - 1.3795)
VALVE CLEARANCE
Unit: mm (in)
Items Cold
Intake 0.125 - 0.250 (0.0049 - 0.0098)
Exhaust 0.325 - 0.450 (0.0128 - 0.0177)
AVAILABLE VALVE LIFTER

Unit: mm (in)
Part number Thickness
13229BN700 7.550 (0.2972)
13229BN701 7.575 (0.2982)
13229BN702 7.600 (0.2992)
13229BN703 7.625 (0.3002)
13229BN704 7.650 (0.3012)
13229BN705 7.675 (0.3022)
13229BN706 7.700 (0.3031)
13229BN707 7.725 (0.3041)
13229BN708 7.750 (0.3051)
13229BN709 7.775 (0.3061)
13229BN710 7.800 (0.3071)
13229BN711 7.825 (0.3081)
13229BN712 7.850 (0.3091)
13229BN713 7.875 (0.3100)
13229BN714 7.900 (0.3110)
13229BN715 7.925 (0.3120)
13229BN716 7.950 (0.3130)
13229BN717 7.975 (0.3140)
EM-334
Part number Thickness
A
13229BN718 8.000 (0.3150)
13229BN719 8.025 (0.3159)
13229BN720 8.050 (0.3169) EM
13229BN721 8.075 (0.3179)
13229BN722 8.100 (0.3189)
13229BN723 8.125 (0.3199) C
13229BN724 8.150 (0.3209)
Cylinder Head INFOID:0000000001381519

D
CYLINDER HEAD
Unit: mm (in) E
Items Standard
Cylinder head gasket thickness 0.68 - 0.74 (0.0269 - 0.0291)
F
Head surface distortion Less than 0.05 (0.002)
Normal cylinder head height “H” 127 (5.000)
G
J
E1BIA0063ZZ
VALVE DIMENSIONS
K
Items Standard
Intake 33.38 - 33.62 (1.314 - 1.324)
Valve head diameter “D” mm (in) L
Exhaust 28.88 - 29.12 (1.137 - 1.146)
Intake 100.74 - 101.16 (3.9661 - 3.9827)
Valve length “L” mm (in)
Exhaust 100.54 - 100.96 (3.9583 - 3.9748) M
5.969 - 5.985 (0.2350 - 0.2356)
Intake
Measuring point (X1) is 41 (1.61)
Valve stem diameter “d” mm (in)
5.955 - 5.971 (0.2344 - 0.2351) N
Exhaust
Measuring point (X1) is 41 (1.61)
Valve seat angle “α” degree 45°00′ (45.00°)
Valve margin “T” mm (in) 1.0 (0.039) O
EM-335
Items Standard
Intake 8.0 (0.315)
Valve lift mm (in)
Exhaust 8.6 (0.339)
E1BIA0064ZZ
VALVE GUIDE
Items Standard
Length 40.35 - 40.65 (1.5886 - 1.6004)
Outer diameter 10.956 - 11.062 (0.4313 - 0.4355)
Valve guide mm (in)
Inner diameter (Finished
6.000 - 6.018 (0.2362 - 0.2369)
size)
Cylinder head valve guide hole diameter mm (in) 11.0 (0.4431)
Intake 0.020 - 0.050 (0.0008 - 0.0020)
Valve guide clearance mm (in)
Exhaust 0.030 - 0.063 (0.0012 - 0.0025)
Intake 14.0 (0.5512)
Projection length “A” mm (in)
Exhaust 14.2 (0.5591)
Valve guide inclination angle “a” degree 90°00′ (90.00°)
E1BIA0065ZZ
VALVE SEAT
Items Standard
Intake 34.444 - 34.474 (1.3561 - 1.3572)
Cylinder head seat recess diameter “D” mm (in)
Exhaust 29.955 - 29.985 (1.1793 - 1.1805)
Intake 34.534 - 34.550 (1.3596 - 1.3602)
Valve seat outer diameter “D” mm (in)
Exhaust 30.035 - 30.048 (1.1825 - 1.1830)
Angle “α” degree 89°30′ (89.50°)
Contacting width “X” mm (in) 1.8 (0.071)
Intake 4.61 - 4.69 (0.1815 - 0.1846)
Valve seat height “H” mm (in)
Exhaust 5.63 - 5.71 (0.2217 - 0.2248)
EM-336
Items Standard
A
Intake 6.0 (0.236)
Cylinder head seat recess depth “H” mm (in)
Exhaust 7.0 (0.276)
EM
E
E1BIA0066ZZ
VALVE SPRING
F
Items Standard
Free height mm (in) 43.31 (1.7051)
G
218 - 242 (22.2 - 24.7, 49.0 - 54.4) at 33.80 (1.3307)
Pressure N (kg, lb) at height mm (in)
477 - 523 (48.7 - 53.3, 107.2 - 117.6) at 24.80 (0.9764)
Spring squareness mm (in) 1.2 (0.047) H
Full pressed height mm (in) 23.40 (0.9213)
Diameter of wire mm (in) 3.45 (0.1358)
Outer diameter at the top of spring mm (in) 20.8 - 21.2 (0.8189 - 0.8346)
I
Outer diameter at the bottom of spring mm (in) 25.5 - 25.9 (1.0039 - 1.0197)
Inner diameter at the top of spring mm (in) 13.9 - 14.3 (0.5472 - 0.5630) J
Inner diameter at the bottom of spring mm (in) 18.6 - 19.0 (0.7323 - 0.7480)
Cylinder Block INFOID:0000000001381520

K
CYLINDER BLOCK
Unit: mm (in)
L
Items Standard
Cylinder block top surface clearance Less than 0.05 (0.002)
M
PISTON MARKING
MBIB0337E
1 Direction of fitting of the piston mark towards the flywheel

2 Height between the piston pin and the top of the piston (see table below).
EM-337
3 Used by the supplier only
6 Piston axis of symmetry
7 Piston pin hole axis
8 Offset between the hole axis (7) and the piston's axis of symmetry (6) is 0.3 mm (0.012 in)
PISTON
Unit: mm (in)
Items Standard
Piston skirt diameter “A” mm (in) 75.938 - 75.952 (2.9897 - 2.9902)
“a” dimension mm (in) 56.0 (2.205)
Category J 41.605 - 41.646 (1.6380 - 1.6396)
Category K 41.647 - 41.688 (1.6396 - 1.6413)
Piston pin hole diameter mm (in) Category L 41.689 - 41.730 (1.6413 - 1.6429)
Category M 41.731 - 41.772 (1.6429 - 1.6446)
Category N 41.773 - 41.814 (1.6446 - 1.6462)
“b” dimension mm (in) 26.0 (1.024)
Capacity of combustion chamber m (Imp fl oz) 19.71 - 20.21 (0.67 - 0.71)
Piston protrusion mm (in) 0.030 - 0.288 (0.0012 - 0.113)
SEM882E
PISTON RING
Unit: mm (in)
Items Standard
Top 1.97 - 1.99 (0.0776 - 0.0783)
Thickness 2nd 1.97 - 1.99 (0.0776 - 0.0783)
Oil ring 2.47 - 2.49 (0.0972 - 0.0980)
Top 0.10 - 0.12 (0.0039 - 0.0047)
Side clearance 2nd 0.08 - 0.10 (0.0031 - 0.0039)
Oil ring 0.03 - 0.05 (0.0012 - 0.0020)
Top 0.20 - 0.35 (0.0079 - 0.0138)
Piston ring end gap 2nd 0.70 - 0.90 (0.0276 - 0.0354)
Oil ring 0.25 - 0.50 (0.0098 - 0.0197)
PISTON PIN
Unit: mm (in)
Items Standard
Length 59.7 - 60.0 (2.350 - 2.362)
Piston pin outer diameter 25.995 - 26.000 (1.0234 - 1.0236)
EM-338
CONNECTING ROD
Unit: mm (in) A
Items Standard
Center distance 133.75 (5.266)
EM
Connecting rod small end diameter (with bush) 26.013 - 26.025 (1.0241 - 1.0246)
Connecting rod big end diameter 47.610 - 47.627 (1.8744 - 1.8751)
Big end longitudinal play 0.205 - 0.467 (0.0081 - 0.0184) C
Big end radial play 0.010 - 0.064 (0.004 - 0.025)
CRANKSHAFT D
Unit: mm (in)
Items Standard
Main journal diameter “Dm” 47.99 - 48.01 (1.8894 - 1.8902) E
Pin journal diameter “Dp” 43.96 - 43.98 (1.7307 - 1.7315)
Maximum run-out allowed on the flywheel bearing face of the flywheel 0.6 (0.024)
F
Lateral play (without lateral shim) 0.045 - 0.252 (0.0018 - 0.0099)
Lateral play (with lateral shim) 0.045 - 0.852 (0.0018 - 0.0335)
Journal radial play 0.010 - 0.054 (0.0004 - 0.0021) G
E1BIA0067ZZ
K
Turbocharger INFOID:0000000001381521
Items Standard L
Regulation value operating vacuum kPa (bar, kg/cm2, psi) 50 (0.5, 0.51, 7.3)
Valve rod moving length mm (in) 1.7 (0.067)
M
EM-339

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ENGINE

SYMPTOM DIAGNOSIS ............................... 5 SPARK PLUG ................................................... 19

PREPARATION ..................................................11 FUEL INJECTOR AND FUEL TUBE ................ 35

CYLINDER HEAD .............................................. 80 PRECAUTIONS ................................................ 134

1. Locate the area where noise occurs.

Operating condition of engine

Piston to piston pin oil

• Drain coolant when engine is cooled.

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

Tool number : KV10112100 (BT-8653-A)

screwdriver is used, be careful not to damage the mating sur-

LIQUID GASKET APPLICATION PROCEDURE

4. Apply the sealant without breaks to the specified location using

Tool number WS39930000 ( – )

• If the sealant protrudes, wipe it off immediately. N

KV10116200 Disassembling and assembling valve mecha-

KV10117100 Loosening or tightening heated oxygen sen-

KV10107902 Removing valve oil seal M

KV11103000 Removing crankshaft pulley

Quick connector release Removing fuel tube quick connectors in en-

1. Press stand: ST13030020 Installing and removing piston pin

KV11105210 Fixing drive plate and flywheel

Commercial Service Tools INFOID:0000000001381383

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring F

Valve guide reamer 1: Reaming valve guide inner hole

Oxygen sensor thread cleaner Reconditioning the exhaust system threads M

Manual lift table caddy Removing and installing engine

Tube presser Pressing the tube of liquid gasket

Idler pulley lock nut : 34.8 N·m (3.5 kg-m, 26 ft-lb)

Removal and Installation INFOID:0000000001381386

2. Remove drive belt.

Idler pulley lock nut : 4.4 N·m (0.45 kg-m, 39 in-lb)

Idler pulley lock nut : 34.8 N·m (3.5 kg-m, 26 ft-lb) C

INSPECTION AFTER REMOVAL

2 : Air cleaner filter

1. Ignition coil 2. Spark plug

INSPECTION AFTER REMOVAL

Spark plug (Standard type): Refer to MA-29, "SPARK PLUG : In-

Cleaner air Less than 588 kPa (6 kg/cm2, 85 psi)

• Checking and adjusting plug gap is not required between

Plug type : Platinum tipped

B : White paint mark (Not use for service)

• If they do not face outside, rotate crankshaft pulley once more

• By referring to the figure, measure the valve clearances at O

Measurement po- EXH × ×

B : White paint mark (Not use for service)

• By referring to the figure, measure the valve clearance at loca-

A : No. 4 cylinder compression TDC

3. If out of standard, perform adjustment procedure.

Valve lifter thickness calculation: t = t1 + (C1– C2)

1. Warm up engine thoroughly. Then, stop it.

• Use the adapter whose picking up end inserted to spark plug

Compression Pressure: Refer to EM-122, "General Specification".

Removal and Installation INFOID:0000000001381394

: 4.4 N·m (0.45 kg-m, 39 in-lb)

3. Installation is in the reverse order of removal.

1. Air cleaner filter 2. Mass air flow sensor 3. O-ring J

INSPECTION AFTER REMOVAL