Engine Mechanical: Section

ENGINE
EM
A
EM
SECTION
ENGINE MECHANICAL C
E
CONTENTS
PRECAUTION ............................................... 3 Removal and Installation .........................................15 F
PRECAUTIONS ................................................... 3 SPARK PLUG ................................................... 16

Precaution for Supplemental Restraint System Exploded View .........................................................16
G
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation .........................................16
SIONER" ................................................................... 3
Precaution for Procedure without Cowl Top Cover...... 3
CAMSHAFT VALVE CLEARANCE .................. 18
Valve Clearance ......................................................18 H
Precaution for Drain Coolant and Engine Oil ............ 3
Precaution for Disconnecting Fuel Piping ................. 3 COMPRESSION PRESSURE ........................... 22
Precaution for Removal and Disassembly ................ 3 On-Vehicle Service ..................................................22
Precaution for Inspection, Repair and Replace- I
ment .......................................................................... 4 REMOVAL AND INSTALLATION ............... 23
Precaution for Assembly and Installation .................. 4
Parts Requiring Angular Tightening .......................... 4 ENGINE ROOM COVER ................................... 23 J
Precaution for Liquid Gasket ..................................... 4 Exploded View .........................................................23
Removal and Installation .........................................23
PREPARATION ............................................ 6
AIR CLEANER AND AIR DUCT ....................... 24 K
PREPARATION ................................................... 6 Exploded View .........................................................24
Special Service Tool ................................................. 6 Removal and Installation .........................................24
Commercial Service Tool .......................................... 7 L
INTAKE MANIFOLD COLLECTOR .................. 26
SYSTEM DESCRIPTION ............................. 10 Exploded View .........................................................26
Removal and Installation .........................................26
NOISE, VIBRATION, AND HARSHNESS M
(NVH) TROUBLESHOOTING ............................10 INTAKE MANIFOLD ......................................... 29
NVH Troubleshooting - Engine Noise ..................... 10 Exploded View .........................................................29
Use the Chart Below to Help You Find the Cause Removal and Installation .........................................29 N
of the Symptom ....................................................... 11
EXHAUST MANIFOLD AND THREE WAY
PERIODIC MAINTENANCE ......................... 12 CATALYST ........................................................ 31
Exploded View .........................................................31 O
DRIVE BELT .......................................................12 Removal and Installation (bank 2) ...........................31
Exploded View ........................................................ 12 Removal and Installation (bank 1) ...........................33
Checking Drive Belt ................................................. 12 P
Tension Adjustment ................................................ 12 OIL PAN AND OIL STRAINER ......................... 36
Removal and Installation ......................................... 12 Exploded View .........................................................36
Removal and Installation of Drive Belt Auto-ten- Removal and Installation (Lower Oil Pan) ...............36
sioner ...................................................................... 14 Removal and Installation (Upper Oil Pan) ...............37
AIR CLEANER FILTER ......................................15 IGNITION COIL ................................................. 42

Exploded View ........................................................ 15 Exploded View .........................................................42
Revision: April 2016 EM-1 2016 QX60

Removal and Installation LH ................................... 42 Inspection After Disassembly .................................. 99
Removal and Installation RH .................................. 42
ENGINE MOUNT .............................................. 104
ROCKER COVER .............................................. 43
Exploded View ........................................................ 43 ENGINE MOUNT (FRONT) ..................................... 104
Removal and Installation (LH) ................................ 44 ENGINE MOUNT (FRONT) : Removal and Instal-
Removal and Installation (RH) ................................ 46 lation ..................................................................... 104
FUEL INJECTOR AND FUEL TUBE ................. 49 UNIT REMOVAL AND INSTALLATION ... 107
Exploded View ........................................................ 49
ENGINE ASSEMBLY ....................................... 107
Removal and Installation ........................................ 49
Inspection ............................................................... 53 FWD ......................................................................... 107
FWD : Exploded View ........................................... 107
VALVE TIMING CONTROL ............................... 54 FWD : Removal and Installation ........................... 107
Exploded View ........................................................ 54
Valve Timing Control Solenoid Valves (Bank 1) ..... 55 AWD ........................................................................ 111
Valve Timing Control Solenoid Valves (Bank 2) ..... 56 AWD : Exploded View ........................................... 111
AWD : Removal and Installation ........................... 112
FRONT TIMING CHAIN CASE .......................... 57
Exploded View ........................................................ 57 UNIT DISASSEMBLY AND ASSEMBLY .. 116
CYLINDER BLOCK .......................................... 116
TIMING CHAIN .................................................. 66 Exploded View ...................................................... 116
Exploded View ........................................................ 66 Disassembly and Assembly .................................. 117
Removal and Installation ........................................ 67 Inspection .............................................................. 126
Dowel Pin Alignment ............................................. 136
REAR TIMING CHAIN CASE ............................ 75
Exploded View ........................................................ 75 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ........................................ 75 (SDS) ......................................................... 138
CAMSHAFT ....................................................... 80 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 80
(SDS) ................................................................ 138
General Specification ........................................... 138
Inspection After Removal ....................................... 85
Drive Belt .............................................................. 138
Inspection after Installation ..................................... 88
Spark Plug ............................................................ 139
OIL SEAL ........................................................... 90 Intake Manifold ...................................................... 139
Removal and Installation of Valve Oil Seal ............. 90 Exhaust Manifold .................................................. 139
Removal and Installation of Front Oil Seal ............. 90 Camshaft ............................................................... 139
Removal and Installation of Rear Oil Seal .............. 92 Cylinder Head ...................................................... 141
Cylinder Block ...................................................... 144
CYLINDER HEAD .............................................. 94 Main Bearing ........................................................ 147
Exploded View ........................................................ 94 Connecting Rod Bearing ..................................... 148
Removal and Installation ........................................ 94 Drive Plate ............................................................ 149
Disassembly and Assembly .................................... 97

PRECAUTIONS
< PRECAUTION >
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000013506508
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. This system includes dual stage front air bag modules. The SRS system may only deploy
one front air bag, depending on the severity of a collision and whether the front passenger seat is occupied.
Information necessary to service the system safely is included in the SR and SB section of this Service Man- D
ual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in E
the event of a collision which would result in air bag inflation, it is recommended that all mainte-
nance and repair be performed by an authorized NISSAN/INFINITI dealer.
• Improper repair, including incorrect removal and installation of the SRS, can lead to personal injury
F
caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module,
see the SR section.
• 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- G
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
H
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly I
causing serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery or batteries, and wait at least three minutes before performing any service. J
Precaution for Procedure without Cowl Top Cover INFOID:0000000012856607
When performing the procedure after removing cowl top cover, cover K
the lower end of windshield with urethane, etc to prevent damage to
windshield.
L
PIIB3706J N
Precaution for Drain Coolant and Engine Oil INFOID:0000000012856608
• Drain engine coolant and engine oil after the engine has cooled completely. O
Precaution for Disconnecting Fuel Piping INFOID:0000000012856609
• Before starting work, make sure no fire or spark producing items are in the work area. P
• Release fuel pressure before disassembly.
• After disconnecting pipes, plug openings to stop fuel leaks.
Precaution for Removal and Disassembly INFOID:0000000012856610
• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.

PRECAUTIONS
< PRECAUTION >
• 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:0000000012856611
• Thoroughly inspect parts before repairing or replacing them, even if they are new. Replace as necessary.
Precaution for Assembly and Installation INFOID:0000000012856612
• Use torque wrench to tighten bolts or nuts to specification.

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Dowel pins are used in several critical parts for correct alignment. When replacing and reassembling parts
with dowel pins, check that dowel pins are installed in their original positions.
• Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining coolant.
• Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped).
Then make sure that there are no leaks at fuel line connections.
• After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for
leaks.
Parts Requiring Angular Tightening INFOID:0000000012856613
• Use an angle wrench for the final tightening of the following engine parts:
- Cylinder head bolts
- 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)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000012856614
REMOVAL OF LIQUID GASKET

CAUTION:
Do not damage the mating surfaces.
• After removing the bolts and nuts, separate the mating surface and
remove the old liquid gasket using Tool.
Tool number : KV10111100 (J-37228)

• In areas where the Tool is difficult to use, use a plastic hammer to
lightly tap (1) the Tool where the liquid gasket is applied. Use a
plastic hammer to slide (2) the Tool by tapping on the side.
WBIA0566E
LIQUID GASKET APPLICATION PROCEDURE

PRECAUTIONS
< PRECAUTION >
1. Using suitable tool (A), remove old liquid gasket adhering to the
liquid gasket application surface and the mating surface. A
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur- EM
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
C
JPBIA0053ZZ
D
3. Attach the liquid gasket tube to the suitable tool.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-22, "Recommended Chemical Products and Sealants". E
4. Apply the liquid gasket without gaps to the specified location
with the specified dimensions.
F
G
EMA0622D
• If there is a groove for the liquid gasket application, apply the H

liquid gasket to the groove.
• Normally apply the liquid gasket on the inside edge of the bolt
holes. Also apply to the outside edge of the bolt holes when I
specified in the procedure.
• Within five minutes of liquid gasket application, install the mat-
ing component.
J
• If the liquid gasket protrudes, wipe it off immediately.
• Do not retighten bolts after the installation.
• Wait 30 minutes or more after installation before refilling the
engine with engine oil or engine coolant. K
SEM159F
CAUTION:
If there are more specific instructions in the procedures contained in this manual concerning liquid
gasket application, observe them. L

PREPARATION
< PREPARATION >
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000012856615
The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.)
Tool name
KV10116200 Disassembling valve mechanism
(J-26336-A) Part (1) is a component of KV10116200 (J-
Valve spring compressor 26336-A), but part (2) is not.
1. KV10115900
(J-26336-20)
Attachment
2. KV10109220
( — )
Adapter PBIC1650E
KV10107902 Removing valve oil seal

(J-38959)
Valve oil seal puller
S-NT011
KV10115600 Installing valve oil seal

(J-38958) Use side A.
Valve oil seal drift a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
S-NT603
EM03470000 Installing piston assembly into cylinder bore

(J-8037)
Piston ring compressor
S-NT044
ST16610001 Removing crankshaft pilot bushing

(J-23907)
Pilot bushing puller
NT045
KV10111100 Removing steel oil pan and rear timing chain

(J-37228) case
Seal cutter
NT046

PREPARATION
< PREPARATION >
Tool number Description
(TechMate No.) A
Tool name
16441 6N210 Removing fuel tube quick connectors in en-
(J-45488) gine room EM
Quick connector release (Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
PBIC0198E
KV10112100 Tightening bolts for cylinder head, main bear- D

(BT-8653-A) ing cap and connecting rod cap
Angle wrench
E
AWBIA1043ZZ F
KV991J0050 Loosening or tightening air fuel ratio A/F sen-
(J-44626) sor
Air fuel sensor Socket a: 22 mm (0.87 in) G
H
LBIA0444E
KV10114400 Loosening or tightening rear heated oxygen

(J-38365) sensor I
Heated oxygen sensor wrench a: 22 mm (0.87 in)
NT636
K
— Removing and installing crankshaft pulley
(J-50288)
Ring gear stopper
L
M
ALBIA0675ZZ
— Installing rear main seal

(J-47128)
N
Seal installer
LBIA0452E
Commercial Service Tool INFOID:0000000012856616

P

PREPARATION
< PREPARATION >
(TechMate No.) Description
Tool name
(J-47242) Removing engine and transaxle assembly
Engine support table
WBIA0658E
( — ) Loosening nuts, screws and bolts

Power tool
PIIB1407E
( — ) Removing and installing spark plug

Spark plug wrench
PBIC2982E
( — ) Finishing valve seat dimensions

Valve seat cutter set
NT048
( — ) Removing and installing piston ring

Piston ring expander
NT030
( — ) Removing and installing valve guide

Valve guide drift Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
NT015
( — ) Reaming valve guide 1 or hole for oversize

Valve guide reamer valve guide 2
Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
NT016

PREPARATION
< PREPARATION >
(TechMate No.) Description
Tool name A
(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.) EM
a: J-43897-18 (18 mm dia.) for zirconia ox-
ygen sensor
b: J-43897-12 (12 mm dia.) for titania oxy-
gen sensor C
AEM488
( — ) Lubricating oxygen sensor thread cleaning

Anti-seize lubricant (Permatex 133AR tool when reconditioning exhaust system D
or equivalent meeting MIL specifica- threads
tion MIL-A-907)
E
AEM489
F
( — ) Pressing the tube of liquid gasket
Tube presser
H
S-NT052

NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
< SYSTEM DESCRIPTION >
SYSTEM DESCRIPTION
NVH Troubleshooting - Engine Noise INFOID:0000000012856617
AWBIA1176GB
1. Camshaft bearing noise 2. Piston pin noise 3. Piston slap noise

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

< SYSTEM DESCRIPTION >
Timing chain and chain
7. 8. Drive belt noise (Sticking/Slipping) 9. Tappet noise
tensioner noise A
A. Valve B. Valve mechanism C. Rotation mechanism
D. Drive belt E. Timing chain
EM
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000012856618
1. Locate the area where noise occurs. C

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

Location Type of Before After When Source of Refer- E
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet F
C A — A B — Valve clearance EM-18
gine clicking noise
Rocker
cover Camshaft Camshaft journal clear-
Cylinder Rattle C A — A B C bearing ance EM-80
G
head noise Camshaft runout
Piston and piston pin

Slap or Piston pin clearance H
— A — B B — EM-22
knock noise Connecting rod bushing
clearance
Piston-to-bore clear-
Crank- ance I
shaft pul- Piston ring side clear-
Slap or Piston
ley A — — B B A ance EM-117
rap slap noise
Cylinder Piston ring end gap
J
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod clearance (Small end) K
Knock A B C B B B EM-117
bearing Connecting rod bearing
noise clearance (Big end)
Main bear-
Main bearing oil clear- L
Knock A B — A B C ance EM-117
ing noise
Crankshaft runout
Front of Timing
Timing chain cracks M
engine chain and
Tapping or and wear
Timing A A — B B B chain ten- EM-66
ticking Timing chain tensioner
chain cov- sioner
operation
er noise N
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing
ping) EM-12 O
Front of
Drive belts Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
P
Water
Squall
A B — B A B pump Water pump operation CO-19
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

DRIVE BELT
< PERIODIC MAINTENANCE >
PERIODIC MAINTENANCE
DRIVE BELT
Exploded View INFOID:0000000012856619
AWBIA1225GB
1. Drive belt auto-tensioner 2. Generator 3. A/C compressor

4. Drive belt 5. Crankshaft pulley A. Indicator
B. Range when new drive belt is installed C. Possible use range D. View D
Engine front
Checking Drive Belt INFOID:0000000012856620
WARNING:
Inspect and check the drive belt with the engine off.
1. Visually check entire drive belt for wear, damage or cracks.
2. Check that the drive belt auto-tensioner indicator is within the possible use range.
NOTE:
• When new drive belt is installed, the drive belt auto-tensioner indicator should be within the new drive
belt range.
• Check the drive belt auto-tensioner indicator when the engine is cold.
3. If the drive belt auto-tensioner indicator is out of the possible use range or belt is damaged, replace drive
belt.
Tension Adjustment INFOID:0000000012856621
• Drive belt tension is automatically adjusted by the drive belt auto-tensioner.

• Drive belt tension is not manually adjustable.
Removal and Installation INFOID:0000000012856622
REMOVAL
1. Remove the front wheel and tire (RH) using a power tool. Refer to WT-52, "Adjustment".
2. Remove the fender protector side cover (RH). Refer to EXT-28, "FENDER PROTECTOR : Exploded
View".

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

the rear of drive belt auto-tensioner into retaining boss to lock drive belt auto-tensioner pulley.
NOTE:
Leave drive belt auto-tensioner pulley arm locked until belt is installed. E
5. Remove drive belt from crankshaft pulley and then remove it from the other pulleys.
INSTALLATION
1. Install the drive belt onto all of the pulleys. F
CAUTION:
Confirm belt is completely set on the pulleys.
2. Release drive belt auto-tensioner, and apply tension to drive belt. G
WARNING:
Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes
off. H
CAUTION:
Do not loosen the drive belt auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned
counterclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including
I
pulley.)
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm drive belt auto-tensioner indicator is within the possible use range. Refer to EM-12, "Checking J
Drive Belt".
5. Install the fender protector side cover (RH). Refer to EXT-28, "FENDER PROTECTOR : Exploded View".
6. Install the front wheel and tire (RH). Refer to WT-52, "Adjustment". K

DRIVE BELT
Removal and Installation of Drive Belt Auto-tensioner INFOID:0000000012856623
AWBIA1220GB
1. Drive belt auto-tensioner
REMOVAL
1. Remove the drive belt. Refer to EM-12, "Removal and Installation".
2. Remove the drive belt auto-tensioner.
CAUTION:
Do not loosen the drive belt auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned coun-
terclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including pulley).
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• If there is damage greater than peeled paint, replace drive belt auto-tensioner.
• Do not swap the pulley between the new and old drive belt auto-tensioner.
• The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.

AIR CLEANER FILTER
AIR CLEANER FILTER
A
EM
I
AWBIA1624ZZ
1. Air duct hose and resonator assembly 2. Front air duct 3. Grommet J
4. Air cleaner case (lower) 5. Grommets 6. Air cleaner case mounting bracket
7. Bracket 8. Air cleaner filter 9. Air cleaner case (upper)
10. Mass air flow sensor A. Air cleaner case side To electric throttle control actuator K
clips

L
REMOVAL
CAUTION:
It is not necessary to remove the front air duct to replace the air cleaner filter. M
NOTE:
Replace the air cleaner filter per the periodic maintenance schedule or as necessary. Refer to MA-10, "FOR
USA AND CANADA : Introduction of Periodic Maintenance" (USA and Canada) or MA-13, "FOR MEXICO : N
Introduction of Periodic Maintenance" (Mexico).
1. Unhook air cleaner case side clips and lift air cleaner case (upper).
2. Remove the air cleaner filter. O
INSTALLATION
P

SPARK PLUG
SPARK PLUG
AWBIA1226GB
1. Ignition coil 2. Spark plug 3. Rocker cover (RH)

4. Rocker cover (LH)
REMOVAL
1. Remove the ignition coil. Refer to EM-42, "Removal and Installation LH" and EM-42, "Removal and Instal-
lation RH".
2. Remove the spark plug using a suitable tool.
PBIC2982E
INSPECTION AFTER REMOVAL

SPARK PLUG
Use the standard type spark plug for normal condition.
A
Spark plug : Refer to EM-139, "Spark Plug".
CAUTION:
• Do not drop or shock spark plug. Discard spark plug if EM
dropped.
• Do not use a wire brush for cleaning.
• If plug is covered with carbon, a spark plug cleaner may be C
used.
Cleaner air pressure : less than 588 kPa (6 kg/cm2,

SMA773C
D
85 psi)
Cleaning time : less than 20 seconds
• Spark plug gap adjustment is not required between replacement E
intervals.
• Measure spark plug gap. When it exceeds the limit, replace spark
plug even if it is within the specified replacement mileage. Refer to F
MA-10, "FOR USA AND CANADA : Introduction of Periodic Main-
tenance" (For United States and Canada) or MA-13, "FOR MEX-
ICO : Introduction of Periodic Maintenance" (For Mexico).
G
SMA806CA
H
INSTALLATION
I
Make DENSO
Standard type* FXE22HR11
J
Gap (nominal) 1.1 mm (0.043 in)
*: Always check with the Parts Department for the latest parts information.
K

CAMSHAFT VALVE CLEARANCE
Valve Clearance INFOID:0000000012856628
CHECKING
CAUTION:
Check valve clearance while engine is cold and not running.
NOTE:
Perform valve clearance inspection after removal, installation or replacement of camshaft or valve parts, or as
necessary.
1. Remove the air duct with air cleaner case, collectors, hoses, wires, harnesses, and connectors. Refer to
EM-24, "Removal and Installation".
2. Remove the intake manifold collector. Refer to EM-26, "Removal and Installation".
3. Remove the ignition coils and spark plugs. Refer to EM-42, "Exploded View".
4. Remove the rocker covers. Refer to EM-43, "Exploded View".
5. Set No.1 cylinder at TDC on its compression stroke.
SEM713A
a. Align pointer with TDC mark (A) on crankshaft pulley.
AWBIA1219GB
b. Check that the valve lifters on No.1 cylinder are loose and valve
lifters on No.4 are tight. If not, turn the crankshaft one full revolu-
tion (360°) and align as shown.
SEM418G

6. Check only the valves as shown.
A
Crank Position Valve No. 1 Valve No. 2 Valve No. 3 Valve No. 6
No. 1 TDC Intake Exhaust Exhaust Intake
EM
G
SEM893E
a. Using a feeler gauge, measure the clearance between the valve

lifter and camshaft. H
Valve clearance : Refer to EM-138,

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

specification. They will be used later to determine the required
J
replacement lifter size.
SEM139D
K
N
KBIA0185E
7. Turn crankshaft 240°.

8. Set No.3 cylinder at TDC on its compression stroke. O

9. Check only those valves as shown.
No. 3 TDC Intake Intake Exhaust Exhaust
SEM894E
10. Turn the crankshaft 240° and align as above.

11. Set No.5 cylinder at TDC on its compression stroke.
12. Check only those valves as shown.
No. 5 TDC Exhaust Intake Intake Exhaust
SEM958E
13. Perform adjustment if the measured values are out of the specification range.
14. Installation of components is in the reverse order of removal.
VALVE ADJUSTING
CAUTION:
Adjust valve clearance while engine is cold.
NOTE:
• Perform adjustment by selecting the correct head thickness of the valve lifter (adjusting shims are not used).

• The specified valve lifter thickness dimension is measured at room temperature.
• Use specifications for hot engine for hot engine condition to confirm valve clearances. A
1. Remove the camshaft.
2. Remove the valve lifter that was measured as being outside the standard specifications.
3. Measure the center thickness of the removed lifter with a EM
micrometer as shown.
SEM754G
E
4. Use the equation below to calculate the replacement valve lifter thickness.
F
Valve lifter thickness calculation: (C1 – C2) + t1=t
C1 = measured valve clearance
C2 = standard valve clearance G
t1 = thickness of the removed lifter
t = thickness of the replacement lifter
H
a. The thickness of the new valve lifter can be identified by the
stamp mark (A) on the reverse side (inside the lifter).
NOTE:
I
Available thicknesses of the valve lifters (B) are: 7.88 - 8.40 mm
(0.3102 - 0.3307 in), in 0.02 mm (0.0008 in) increments. Refer to
EM-139, "Camshaft"
J
K
JPBIA0170ZZ
5. Install the selected replacement valve lifter. L

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

COMPRESSION PRESSURE
COMPRESSION PRESSURE
On-Vehicle Service INFOID:0000000012856629
CHECKING COMPRESSION PRESSURE

1. Run the engine until it reaches normal operating temperature.
2. Turn the ignition switch to OFF.
3. Release fuel pressure and leave the fuel pump electrically disconnected. Refer to EC-168, "Work Proce-
dure" (For United States and Canada) or EC-707, "Work Procedure" (For Mexico).
4. Remove all six spark plugs. Refer to EM-16, "Removal and Installation".
5. Attach a compression tester to No. 1 cylinder.
SBIA0533E
6. Depress accelerator pedal fully to keep the electric throttle control actuator butterfly-valve wide open to
maximize air intake flow.
7. Crank the engine and record the highest gauge indication.
CAUTION:
Always use a fully charged battery to obtain specified engine speed.
8. Repeat the test for each cylinder (steps 5 - 7).
Unit: kPa (kg/cm2, psi) /rpm
Standard Minimum Differential limit between cylinders

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

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

I
CAUTION:
Do not damage or scratch engine room cover when installing or removing.
J
REMOVAL
1. Remove front air duct. Refer to EM-24, "Removal and Installation".
2. Remove engine room cover bolts. K
3. Remove engine room cover.
INSTALLATION
L

AIR CLEANER AND AIR DUCT
AWBIA1624ZZ
1. Air duct hose and resonator assembly 2. Front air duct 3. Grommet
4. Air cleaner case (lower) 5. Grommets 6. Air cleaner case mounting bracket
7. Bracket 8. Air cleaner filter 9. Air cleaner case (upper)
10. Mass air flow sensor A. Air cleaner case side To electric throttle control actuator
clips
REMOVAL
1. Remove front air duct.
2. Disconnect the tube clamp at the electric throttle control actuator and at the air duct hose and resonator
assembly.
3. Disconnect the blow-by hose. Refer to EM-43, "Exploded View"
4. Remove air duct hose and resonator assembly.
5. Disconnect the harness connector from mass air flow sensor.
6. Remove mass air flow sensor from air cleaner case (upper) (if necessary).
CAUTION:
Handle mass air flow sensor with care.
• Do not shock it.
• Do not disassemble it.
• Do not touch its sensor.
7. Disconnect the transaxle air breather hose. Refer to TM-203, "Removal and Installation"
8. Remove bolts and pull air cleaner case (lower) upward to remove from the grommets.
9. Remove air cleaner assembly.

Inspect air cleaner case (upper), air cleaner case (lower), front air duct, air duct and resonator assembly for
cracks or tears. Replace as necessary. A
INSTALLATION
EM

INTAKE MANIFOLD COLLECTOR
AWBIA1625ZZ
1. Intake manifold collector 2. Intake manifold collec- 3. Electric throttle control actuator
tor gasket
4. Electric throttle control actuator gasket
WARNING:
Do not drain the engine coolant when the engine is hot to avoid the danger of being scalded.
CAUTION:
• Do not remove the power valves.
• Cover engine openings to avoid the entry of any foreign material.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
1. Disconnect the negative battery terminal. Refer to PG-147, "Exploded View".
2. Remove the cowl top cover and the cowl top extension. Refer to EXT-25, "Exploded View".

3. Remove the engine room cover. Refer to EM-23, "Removal and Installation".
4. Remove the air cleaner case (upper), air cleaner case (lower), and air duct and resonator assembly. Refer A
to EM-24, "Removal and Installation".
5. Disconnect the power brake booster vacuum hose.
6. Disconnect the harness connector from engine mount control valve solenoid. Refer to EC-583, "Electronic EM
Controlled Engine Mount".
7. Disconnect the harness connector from VIAS control solenoid valve. Refer to EC-583, "Electronic Con-
trolled Engine Mount". C
8. Disconnect the PCV hose.
9. Disconnect the harness connector from electric throttle control actuator electrical.
10. Disconnect the EVAP canister purge volume control solenoid valve hose. D
11. Remove the electric throttle control actuator bolts and remove
the electric throttle control actuator and position aside. Loose
bolts in reverse order as shown. E
CAUTION:
• Handle carefully to avoid any shock to the electric throttle
control actuator. F
• Do not disassemble the electric throttle control actuator.
G
AWBIA2709ZZ
12. Remove the VIAS control solenoid valve (if necessary). H

13. Remove the EVAP canister purge volume control solenoid valve.
14. Loosen the intake manifold collector bolts and nuts, and then
remove the intake manifold collector and gasket. Loose bolts I
and nuts in reverse order as shown.
ALBIA0240ZZ
L
INSTALLATION
• Tighten intake manifold collector bolts and nuts in the order as M
shown.
CAUTION:
Do not reuse intake manifold collector gasket. N
ALBIA0240ZZ
P

• Tighten electric throttle control actuator bolts in the order as
shown.
CAUTION:
Do not reuse electric throttle control actuator gasket.
AWBIA2709ZZ
NOTE:
After installation, re-calibrate the electric throttle control actuator as follows:
1. Perform the ″Throttle Valve Closed Position Learning″ when harness connector of the electric throttle con-
trol actuator is disconnected. Refer to EC-702, "Description".
2. Perform the ″Idle Air Volume Learning″ when the electric throttle control actuator is replaced. Refer to EC-
703, "Description".
3. Perform the ″Accelerator Pedal Released Position Learning″ when the electric throttle control actuator is
replaced. Refer to EC-703, "Description".

INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
I
ALBIA0231ZZ
1. Intake manifold 2. Intake manifold gasket A. Refer to INSTALLATION J
K
REMOVAL
WARNING:
Do not drain the engine coolant when the engine is hot to avoid the danger of being scalded. L
1. Remove the fuel injectors and fuel tube as a unit from the intake manifold. Refer to EM-49, "Removal and
Installation".
2. Remove the engine mount control valve solenoid hose. M
3. Remove VIAS control solenoid valve vacuum hoses.
4. Remove the EVAP canister purge volume control solenoid valve vacuum pipes and hoses.
5. Remove the vacuum gallery. N
6. Remove the electric throttle control actuator coolant hoses.
7. Remove the intake manifold and gaskets. Loose bolts and nuts
in reverse order as shown. O
CAUTION:
Cover the engine openings to avoid the entry of foreign
materials.
P
ALBIA0233ZZ

INTAKE MANIFOLD
Surface Distortion
• Using straightedge and feeler gauge, inspect the surface distortion
of the intake manifold. Refer to EM-29, "Removal and Installation".
Standard : 0.1 mm (0.004 in)
WBIA0052E
INSTALLATION
CAUTION:
• Do not reuse gaskets.
• Install the gaskets with the painted surface facing the intake manifold side.
• Install intake manifold studs (if removed) and tighten to specification.
Intake manifold studs : 10.8 N·m (1.1 kg-m, 8 ft-lb)

• Install intake manifold bolts and nuts in two steps in the numerical
order as shown.
Step 1 : 7.4 N·m (0.75 kg-m, 65 in-lb)

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

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

EXHAUST MANIFOLD AND THREE WAY CATALYST
A
EM
L
AWBIA1206GB
1. Gasket 2. Exhaust manifold (bank 1) 3. Exhaust manifold cover (bank 1) M

4. Air fuel ratio sensor 1 (bank 1) 5. Ring gasket 6. Three way catalyst (bank 1)
7. Three way catalyst support (bank 1) 8. Heated oxygen sensor 2 (bank 1) 9. Three way catalyst (bank 2)
10. Three way catalyst support (bank 2) 11. Heated oxygen sensor 2 (bank 2) 12. Ring gasket N
13. Exhaust manifold (bank 2) 14. Exhaust manifold cover (bank 2) 15. Air fuel ratio sensor 1 (bank 2)
A. To oil pan (upper) B. Upper mark
O
Removal and Installation (bank 2) INFOID:0000000012856639
REMOVAL
P
WARNING:
• Perform the work when the exhaust system has completely cooled down.
• When removing the front and rear engine through bolts and nuts, lift the engine up slightly for safety.
NOTE:
ing.

1. Remove the air cleaner case (upper), air cleaner case (lower), and air duct hose and resonator assembly.
Refer to EM-24, "Removal and Installation".
2. Remove the battery and battery tray assembly. Refer to PG-149, "Removal and Installation".
3. Remove the front wheels and tires using power tool. Refer to WT-52, "Adjustment".
4. Remove the front under cover. Refer to EXT-30, "Exploded View".
5. Remove the fender protector side covers (LH and RH). Refer to EXT-28, "FENDER PROTECTOR :
Exploded View".
6. Remove the radiator assembly. Refer to CO-15, "Removal and Installation".
7. Remove the engine cooling fan shroud and motor assembly. Refer to CO-17, "Removal and Installation".
8. Remove the front exhaust tube. Refer to EX-5, "Exploded View".
9. Support the engine with a suitable tool.
10. Remove the engine mount bracket (front). Refer to EM-107, "FWD : Exploded View" (FWD) or EM-111,
"AWD : Exploded View" (AWD).
11. Remove the three way catalyst support brackets (bank 2).
12. Remove heated oxygen sensor 2 (bank 2), air fuel ratio (A/F) sensor 1 (bank 2).
a. Disconnect the harness connector from each sensor, and remove the harness from the bracket and mid-
dle clamp.
b. Remove both heated oxygen sensor and air fuel ratio (A/F) sensor using Tool.
Tool numbers : KV10114400 (J-38365)

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

Surface Distortion
• Use a reliable straightedge and feeler gauge to check the flatness
of the exhaust manifold mating surfaces.
Limit : 0.3 mm (0.012 in)

• Replace the exhaust manifold if the measurement exceeds specifi-
cations.
PBIC1173E
INSTALLATION

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

EM
2. Install the exhaust manifold gasket in the direction shown.
CAUTION:
Do not reuse exhaust manifold gasket.
C
(A) : Bank 1
(B) : Triangle press
(C) : Bank 2 D
: Engine front
PBIC4954E
F
3. Install the exhaust manifold (LH) nuts and tighten to specifica-
tion in the order shown.
G
: Engine front
NOTE:
Number 7 and 8 are tightened a second time. H
I
AWBIA1208GB
CAUTION:
J
• Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust manifold
threads using the oxygen sensor thread cleaner tool and apply anti-seize lubricant.
Oxygen sensor thread cleaner : — (J-43897-12) K

: — (J-43897-18)
• Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause
damage. L

: KV991J0050 (J-44626) M
Removal and Installation (bank 1) INFOID:0000000012856640
N
REMOVAL
WARNING:
• Perform the work when the exhaust system has completely cooled down. O
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill- P
ing.
1. Remove the cowl top grille and the lower cowl top extension. Refer to EXT-25, "Exploded View".
2. Remove the front wheel and tire (RH) (AWD models only) using a power tool. Refer to WT-52, "Adjust-
ment".
3. Remove the front under cover. Refer to EXT-30, "Exploded View".
4. Remove the fender protector side cover (RH) (AWD models only). Refer to EXT-28, "FENDER PROTEC-
TOR : Exploded View".
5. Remove transmission air breather hose. Refer to TM-203, "Exploded View".
6. Remove the front exhaust tube, hanger and heat insulator. Refer to EX-5, "Exploded View".
7. Remove the propeller shaft and propeller shaft center bearing (AWD models only). Refer to RAX-9,
"Removal and Installation".
8. Remove the front axle shaft (RH) (AWD models only). Refer to FAX-17, "Removal and Installation (RH)".
9. Remove the three way catalyst support brackets (bank 1).
10. Remove heated oxygen sensor 2 (bank 1), air fuel ratio (A/F) sensor 1 (bank 1).
a. Disconnect the harness connector from each sensor, and remove the harness from the bracket and mid-
dle clamp.
b. Remove both heated oxygen sensors and air fuel ratio (A/F) sensors using Tool.

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

Surface Distortion
• Use a reliable straightedge and feeler gauge to check the flatness
of the exhaust manifold mating surfaces.
Limit : 0.3 mm (0.012 in)

• Replace the exhaust manifold if the measurement exceeds specifi-
cations.
PBIC1173E
INSTALLATION
1. Install the studs in the exhaust manifold (if removed) and tighten to specification.
Exhaust manifold studs : 15.4 N·m (1.6 kg-m, 11 ft-lb)

2. Install the exhaust manifold gasket in the direction shown.
CAUTION:

Do not reuse exhaust manifold gasket.
A
(A) : Bank 1
(B) : Triangle press
(C) : Bank 2 EM
: Engine front
PBIC4954E
D
3. Install the exhaust manifold (bank 1) nuts and tighten to specifi-
cation in the order shown.
: Engine front
E
NOTE:
Number 7 and 8 are tightened a second time.
F
G
AWBIA1209GB
CAUTION: H
• Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust mani-
fold threads using the oxygen sensor thread cleaner tool and apply anti-seize lubricant.
Oxygen sensor thread cleaner : — (J-43897-12) I

: — (J-43897-18)
• Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause
J
damage.

K
: KV991J0050 (J-44626)

OIL PAN AND OIL STRAINER
AWBIA1628ZZ
1. O-ring 2. Front cover gasket and rear oil 3. Oil pressure switch
seal retainer gasket
4. Oil cooler gasket 5. Oil cooler 6. Oil cooler connection
7. Oil filter 8. Lower oil pan 9. Oil strainer
10. Rear plate cover 11. Crankshaft position sensor 12. O-ring
(POS)
13. Upper oil pan
Removal and Installation (Lower Oil Pan) INFOID:0000000012856642
REMOVAL
WARNING:
Do not remove the oil pan until the exhaust system and cooling system have completely cooled off.
1. Drain the engine oil. Refer to LU-9, "Changing Engine Oil".
2. Loosen the lower oil pan bolts in reverse order as shown.
AWBIA1211GB
3. Remove the lower oil pan.

CAUTION:
Do not damage the mating surfaces. A
• After removing the bolts, separate the mating surface and
EM
Tool number : KV10111100 (J-37228)
• In areas where the Tool is difficult to use, use a plastic hammer
to lightly tap (1) the Tool where the liquid gasket is applied. C
Use a plastic hammer to slide (2) the Tool by tapping on the
side.
D
WBIA0566E
4. Remove the old sealant from the bolt holes and threads.
E
Clean debris from the oil strainer.
INSTALLATION F
1. Apply a continuous bead of sealant to the lower oil pan.
• Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-
22, "Recommended Chemical Products and Sealants". G
• Be sure the sealant is 4.5 - 5.5 mm (0.177 - 0.217 in) wide.
CAUTION:
• Installation should be done within 5 minutes after apply- H
ing liquid gasket.
• Do not fill the engine with engine oil for at least 30 min-
utes after the components are installed to allow the seal-
ant to cure. I
SEM159F
2. Install the lower oil pan. Tighten the lower oil pan bolts in order J
as shown.
CAUTION:
• Installation should be done within 5 minutes after apply- K
ing liquid gasket.
ant to cure. L
3. Refill the engine with oil. Refer to LU-9, "Changing Engine Oil".
AWBIA1211GB
M

1. Inspect the engine oil level. Refer to LU-8, "Inspection". N
2. Start the engine and check for leaks. Refer to LU-8, "Inspection". Repair as necessary.
Removal and Installation (Upper Oil Pan) INFOID:0000000012856643
O
REMOVAL
WARNING:
P
• Do not remove the pan until the exhaust system and cooling system have completely cooled off.
CAUTION:
When removing the upper oil pan from the engine, first remove the crankshaft position sensor (POS).
Be careful not to damage sensor edges or signal plate teeth.
NOTE:
ing.

1. Remove the engine from the vehicle. Refer to EM-107, "FWD : Removal and Installation" (FWD models)
or EM-112, "AWD : Removal and Installation" (AWD models).
2. Remove the oil dipstick.
3. Remove the drive belt. Refer to EM-12, "Removal and Installation".
4. Disconnect the harness connector from A/C compressor.
5. Remove the A/C compressor bolts and remove the A/C compressor. Refer to HA-30, "COMPRESSOR :
Removal and Installation".
6. Remove water pipe bolts. Refer to LU-15, "Removal and Installation"
7. Remove water hoses from the engine oil cooler. Refer to LU-15, "Removal and Installation"
8. Remove the oil filter and engine oil cooler from the upper oil pan. Refer to LU-15, "Removal and Installa-
tion".
9. Remove the oil pressure switch, and the crankshaft position sensor (POS) from the upper oil pan.
10. Remove the lower oil pan. Refer to EM-36, "Removal and Installation (Lower Oil Pan)".
11. Remove the oil strainer.
12. Remove the upper oil pan.
a. Loosen the bolts in the reverse order shown.
AWBIA1212GB
b. Insert a suitable tool into the notch (1) of the upper oil pan as
shown.
c. Pry off the upper oil pan by moving the tool up and down (2) as
shown.
SEM155F
13. Remove the O-ring seals from the bottom of the cylinder block
and oil pump housing. Use new O-rings for installation.
CAUTION:
Do not reuse O-rings.
WBIA0327E

14. Remove front cover gasket and rear oil seal retainer gasket.
A
EM
WBIA0328E
D
15. If re-installing the original oil pan, remove the old sealant from
the mating surfaces using a scraper.
• Also remove the old sealant from mating surface of the cylin- E
der block.
• Remove the old sealant from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when clean- F
ing off the old sealant.
G
MEM108A
INSPECTION AFTER REMOVAL H

Clean debris from oil strainer.
INSTALLATION
1. Install oil strainer and tighten bolt to specified torque. Refer to EM-36, "Exploded View". I
2. Apply Genuine Silicone RTV Sealant or equivalent to the front
cover gasket and the rear oil seal retainer gasket as shown.
Refer to GI-22, "Recommended Chemical Products and Seal- J
ants".
CAUTION:
• Installation should be done within 5 minutes after apply-
K
ing liquid gasket.
ant to cure. L
SEM964E
3. Install the front cover gasket and rear oil seal retainer gasket as M
shown.
CAUTION:
Do not reuse front cover gasket or rear oil seal retainer gas-
N
ket.
WBIA0328E P

4. Apply a bead of sealant to the cylinder block mating surface of
the upper oil pan as shown.
CAUTION:
ing liquid gasket.
ant to cure.
NOTE:
• Apply liquid gasket to the outside of bolt holes 5, 6, 10, 11 and
12.
SEM185FA
• Apply liquid gasket to the inside of the other bolt holes.
a. Be sure the sealant is applied 4.0 - 5.0 mm (0.157 - 0.197 in) as shown. Increase the bead to 4.5 - 5.5 mm
(0.177 - 0.217 in) at the four places indicated.
b. Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-
22, "Recommended Chemical Products and Sealants".
SEM159F
5. Install new O-rings on the cylinder block and oil pump body.
CAUTION:
WBIA0327E
6. Install the upper oil pan.

• Tighten bolts (1) and (2) to specification within five minutes of
applying the liquid gasket.
• Tighten the remaining upper oil pan bolts to specification in the
order shown.
CAUTION:
ing liquid gasket.
ant to cure.
AWBIA1212GB
7. Install the lower oil pan. Refer to EM-36, "Removal and Installation (Lower Oil Pan)".
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If there is less than
required quantity, fill to the specified level. Refer to MA-16, "FOR USA AND CANADA : Fluids and Lubri-
cants" (United States and Canada) or MA-17, "FOR MEXICO : Fluids and Lubricants" (Mexico).
• Use procedure below to check for fuel leaks.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leaks
at connection points.
• Start engine. With engine speed increased, check again for fuel leaks at connection points.
• Run engine to check for unusual noise and vibration. A
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
EM
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leaks of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system. C
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-
ified level, if necessary.
• Summary of the inspection items: D
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leaks Level
E
Engine oil Level Leaks Level
Leaks Level/Leaks Leaks
Transaxle fluid CVT Models
Level/Leaks Leaks Level/Leaks F
Other oils and fluids* Level Leaks Level
Fuel Leaks Leaks Leaks
G
Exhaust gas — Leaks —
*Power steering fluid, brake fluid, etc.
H

IGNITION COIL
IGNITION COIL
AWBIA1226GB
1. Ignition coil 2. Spark plug 3. Rocker cover (RH)

4. Rocker cover (LH)
Removal and Installation LH INFOID:0000000012856645
REMOVAL
1. Remove engine room cover. Refer to EM-23, "Removal and Installation".
2. Disconnect the harness connector from ignition coil.
3. Remove the ignition coil.
CAUTION:
Do not shock ignition coil.
INSTALLATION
Removal and Installation RH INFOID:0000000012856646
REMOVAL
2. Disconnect the harness connector from ignition coil.
3. Remove the ignition coil.
CAUTION:
Do not shock ignition coil.
INSTALLATION

ROCKER COVER
ROCKER COVER
A
For United States and Canada EM
I
AWBIA0856GB
1. Camshaft position sensor (LH) 2. O-ring 3. Camshaft position sensor (RH) J

4. O-ring 5. Rocker cover (RH) 6. Rocker cover gasket (RH)
7. Rocker cover gasket (LH) 8. Rocker cover (LH) A. Refer to INSTALLATION
Engine front K

ROCKER COVER
For Mexico
AWBIA1231GB
1. Camshaft position sensor (LH) 2. O-ring 3. Camshaft position sensor (RH)

4. O-ring 5. Rocker cover (RH) 6. Rocker cover gasket (RH)
7. Rocker cover gasket (LH) 8. Rocker cover (LH) A. Follow installation procedure
Engine front
Removal and Installation (LH) INFOID:0000000012856648
REMOVAL
2. Remove blow by hose from rocker cover.
3. Remove camshaft position sensor.
CAUTION:
• Handle carefully to avoid dropping and shocks.
• Do not disassemble camshaft position sensor.
• Do not allow metal powder to adhere to magnetic part at
sensor tip (A).
• Do not place sensor in a location where they are exposed
to magnetism.
ALBIA0258ZZ
4. Unclip the camshaft position sensor harness retainers.

5. Remove the ignition coils. Refer to EM-42, "Removal and Installation LH".
CAUTION:
Do not shock ignition coils.
6. Remove rocker cover bolts from cylinder head in the reverse order shown.
• For United States and Canada

ROCKER COVER
: Engine front A
EM
AWBIA0703ZZ
D
• For Mexico
: Engine front E
AWBIA1213GB
H
7. Remove the rocker cover and gasket.
INSTALLATION I
CAUTION:
• Do not reuse gasket. J
• Blow by hose clamps should be installed facing upwards.
• Install press fit hoses so that the white mark faces the rib of the connector.
• Apply sealant to the areas on the front corners using a suitable
K
tool.
• Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-22,
"Recommended Chemical Products and Sealants".
CAUTION: L
• Installation should be done within 5 minutes after applying
liquid gasket.
• Do not fill the engine with engine oil for at least 30 minutes M
after the components are installed to allow the sealant to
cure.
PBIC2474E
• Tighten the rocker cover bolts to specification in two steps in order shown.

ROCKER COVER
For United States and Canada
: Engine front
Rocker cover bolts

Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)
AWBIA0703ZZ
For Mexico
: Engine front
Rocker cover bolts

Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)
AWBIA1213GB
Removal and Installation (RH) INFOID:0000000012856649
REMOVAL
2. Remove the front air duct and air duct hose and resonator assembly. Refer to EM-24, "Removal and
Installation".
4. Remove camshaft position sensors.
CAUTION:
• Do not disassemble.
• Do not allow metal powder to adhere to magnetic part at
sensor tip (A).
• Do not place sensors in a location where they are
exposed to magnetism.
ALBIA0258ZZ
5. Disconnect the PCV hose from the rocker cover.

6. Remove ignition coils. Refer to EM-42, "Removal and Installation RH".
CAUTION:
Do not shock ignition coils.
7. Remove rocker cover bolts from cylinder head in the reverse order shown.

ROCKER COVER
• For United states and Canada
A
: Engine front
EM
AWBIA0705ZZ
D
• For Mexico
: Engine front E
G
AWBIA1214GB
8. Remove the rocker cover and gasket.

H
INSTALLATION
CAUTION: I
• Do not reuse gasket.
• Blow by hose clamps should be installed facing upwards.
• Install press fit hoses so that the white mark faces the rib of the connector.
• Apply sealant to the areas on the front corners using a suitable J
tool.
• Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-22,
"Recommended Chemical Products and Sealants". K
CAUTION:
• Installation should be done within 5 minutes after applying
liquid gasket.
• Do not fill the engine with engine oil for at least 30 minutes L
after the components are installed to allow the sealant to
cure.
M
PBIC2474E
• Tighten the rocker cover bolts in two steps in order as shown.

ROCKER COVER
For United states and Canada
: Engine front
Rocker cover bolts

Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)
AWBIA0705ZZ
For Mexico
: Engine front
Rocker cover bolts

Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)
AWBIA1214GB

FUEL INJECTOR AND FUEL TUBE
A
EM
J
AWBIA1215GB
1. Fuel feed hose 2. Quick connector cap 3. Fuel tube K

4. O-ring 5. Fuel damper 6. Fuel damper cap
7. Clip 8. O-ring (black) 9. Fuel injector
10. O-ring (green) A. Refer to installation L
M
REMOVAL
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop. N
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
• Do not drain engine coolant when engine is hot to avoid the danger of being scalded.
CAUTION: O
Do not remove or disassemble parts unless instructed.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill- P
ing.
2. Release the fuel pressure. Refer to EC-168, "Work Procedure" (For United States and Canada) or EC-
707, "Work Procedure" (For Mexico).
3. Disconnect the battery negative terminal. Refer to PG-147, "Exploded View".
4. Remove intake manifold collector. Refer to EM-26, "Removal and Installation".

5. When separating fuel feed hose and fuel tube connection, disconnect quick connector using Tool as fol-
lows:
a. Remove quick connector cap from quick connector.
b. Disconnect quick connector from fuel tube as follows:
CAUTION:
Disconnect quick connector by using the special service tool, not by prying out retainer tabs.
i. With the sleeve side (B) of Tool (A) facing toward the quick connector, install the Tool (A) onto fuel tube.
ii. Insert the Tool (A) into quick connector (2) until sleeve (B) con-
tacts and goes no further. Hold Tool (A) in that position.
(C) : Insert and retain
Tool number (A) : 16441 6N210 (J-45488)

CAUTION:
Inserting Tool (A) with excess force will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
JPBIA0033ZZ
iii. Draw and pull out quick connector straight from fuel tube (1).
CAUTION:
• Pull quick connector (E) holding position (D) as shown.
• Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Keep parts away from heat source. Be especially careful when welding is performed around
them.
• Do not expose parts to battery electrolyte or other acids.
• Do not bend or twist connection between quick connector and fuel feed hose (with damper) dur-
ing installation/removal.
• To keep the connecting portion clean and to avoid dam-
age and foreign materials, cover them completely with
plastic bags (A) or something similar.
JPBIA0035ZZ
6. Disconnect harness connector from fuel injector.

7. Loosen bolts in reverse order as shown, and remove fuel tube
and fuel injector assembly.
: Engine front
CAUTION:
Do not tilt fuel tube or remaining fuel in pipes may flow out
from pipes.
JPBIA1715ZZ
8. Remove fuel injector from fuel tube as follows:

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

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

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

(4) : O-ring (green)
• Insert clip so that protrusion (E) of fuel injector matches cutout
(C) of clip.
CAUTION:
• Do not reuse clip. Replace it with new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (A) of fuel tube matches
cutout (B) of clip.
• Check that fuel tube flange (G) is securely fixed in flange
groove (D) on clip.
CAUTION:
Do not pressure-fit with excessive force.
Reference value : 147 N (15.0 kg, 33.0 lb)

JPBIA1959ZZ
c. Check that installation is complete by checking that fuel injector does not rotate or come off.
• Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.
4. Install fuel tube and fuel injector assembly to intake manifold.
CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.
• Tighten bolts in two steps in numerical order as shown.
: Engine front
1st step : 10.1 N·m (1.0 kg-m, 7 ft-lb)

2nd step : 22.0 N·m (2.2 kg-m, 16 ft-lb)
JPBIA1715ZZ
5. Connect fuel injector harness.

6. Install intake manifold collector. Refer to EM-26, "Removal and Installation".
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:
a. Check no foreign substances are on the fuel tube or quick connector and that they are not damaged.
b. Apply a light coating of new engine oil around fuel tube from tip end to spool end.
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector (1) to fuel tube until top spool (2) is
completely inside quick connector, and 2nd level spool (3)
exposes right below quick connector.
(B) : Installed condition

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

• Insert until you hear a “click” sound and actually feel the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next step. A
d. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does
not come out from fuel tube.
e. Install quick connector cap (3) to quick connector. EM
(1) : Fuel feed hose

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

F
Inspection INFOID:0000000012856652
INSPECTION AFTER INSTALLATION G

Check For Fuel Leaks
1. Turn ignition switch “ON” with the engine stopped. With fuel pressure applied to fuel piping, check for fuel H
leaks at connection points. Repair as necessary.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again for fuel leaks at connection points. Repair as I
necessary.
WARNING:
Do not touch the engine immediately after stopped, as the engine becomes extremely hot. J

VALVE TIMING CONTROL
AWBIA2227ZZ
1. Front timing chain case 2. Valve timing control cover gas- 3. O-ring
ket (bank 1)
4. O-ring 5. Intake valve timing intermediate 6. Exhaust valve timing control sole-
lock control solenoid valve (bank noid valve (bank 1)
1)
7. Intake valve timing control sole- 8. Valve timing control cover (bank 9. Valve timing control cover (bank
noid valve (bank 1) 1) 2)
10. Intake valve timing control sole- 11. Exhaust valve timing control so- 12. Intake valve timing intermediate
noid (bank 2) lenoid (bank 2) lock control solenoid valve (bank
2)
13. Valve timing control cover gas- A. Refer to INSTALLATION
ket (bank 2)

For Mexico
A
EM
AWBIA1635ZZ
K
1. Front timing chain case 2. Intake valve timing control 3. Intake valve timing control cover (bank 1)
cover gasket (bank 1) L
4. Intake valve timing control cov- 5. Intake valve timing control 6. Intake valve timing control solenoid valve
er O-ring (bank 1) solenoid valve O-ring (bank (bank 1)
1)
M
7. Intake valve timing control cov- 8. Intake valve timing control 9. Intake valve timing control solenoid valve
er O-ring (bank 2) solenoid valve O-ring (bank (bank 2)
2)
10. Intake valve timing control cov- 11. Intake valve timing control A. Refer to EM-57 N
er (bank 2) cover gasket (bank 2)
B. Refer to EM-57 C. Refer to EM-57 Engine front
O
Valve Timing Control Solenoid Valves (Bank 1) INFOID:0000000012856654
REMOVAL P
1. Disconnect battery negative terminal. Refer to PG-151, "Exploded View".
2. Remove core support cover. Refer to DLK-249, "Exploded View".
3. Remove front air duct. Refer to EM-24, "Exploded View".
4. Remove cowl top. Refer to EXT-25, "Exploded View".
5. Remove strut tower brace.
6. Remove reservoir tank. Refer to CO-15, "Exploded View".

7. Remove power steering oil pump (if necessary). Refer to ST-58, "Removal and Installation".
8. Support engine (1) and transaxle (2) using suitable jack (A).
CAUTION:
• Position a suitable jack under the engine and transaxle
assembly as shown.
• Do not damage the front exhaust tube or transaxle oil pan
with the jack.
ALBIA0894GB
9. Remove upper torque rod, engine mounting insulator (RH), and engine mounting bracket (RH). Refer to
EM-107, "FWD : Exploded View" (FWD) or EM-111, "AWD : Exploded View" (AWD).
10. Disconnect the harness connector from intake valve timing intermediate lock control solenoid valve (bank
1). (For United States and Canada)
11. Disconnect the harness connector from exhaust valve timing control solenoid valve (bank 1). (For United
States and Canada)
12. Disconnect the harness connector from intake valve timing control solenoid valve (bank 1).
13. Remove intake valve timing intermediate lock control solenoid valve (bank 1) and exhaust valve timing
control solenoid valve (bank 1) from valve timing control cover (bank 1). (For United States and Canada)
CAUTION:
14. Remove intake valve timing control solenoid valve (bank 1) from valve timing control cover (bank 1).
CAUTION:
INSTALLATION
CAUTION:
• Lubricate O-rings with clean engine oil prior to installation.
Valve Timing Control Solenoid Valves (Bank 2) INFOID:0000000012856655
REMOVAL
1. Remove power steering oil pump. Refer to ST-58, "Removal and Installation".
2. Disconnect the harness connector from intake valve timing intermediate lock control solenoid valve (bank
2). (For United States and Canada)
3. Disconnect the harness connector from exhaust valve timing control solenoid valve (bank 2). (For United
States and Canada)
4. Disconnect the harness connector from intake valve timing control solenoid valve (bank 2).
5. Remove intake valve timing intermediate lock control solenoid valve (bank 2) and exhaust valve timing
control solenoid valve (bank 2) from valve timing control cover (bank 2). (For United States and Canada)
CAUTION:
6. Remove intake valve timing control solenoid valve (bank 2) from valve timing control cover (bank 2).
CAUTION:
INSTALLATION
CAUTION:
• Lubricate O-rings with clean engine oil prior to installation.

FRONT TIMING CHAIN CASE
A
EM
I
AWBIA2623ZZ
1. Engine assembly 2. Front timing chain case oil filter 3. Water pump cover J
4. Crankshaft pulley 5. Front oil seal 6. Front timing chain case
7. O-ring A. To valve timing control cover (bank 1/ B. Refer to INSTALLATION
bank 2). Refer to EM-54, "Exploded
K
View".
Front
L
NOTE:
• This section describes the procedure for removal/installation of the front timing chain case in vehicle and M
without removing the oil pan (upper). Remove the engine prior to following this procedure if the engine is to
be removed to facilitate other repairs.
• To remove the rear timing chain case, remove the engine from the vehicle. Refer to EM-75, "Removal and
N
Installation"
• Refer to EM-66, "Exploded View" for component parts location.
• When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from
spilling. O
REMOVAL
P
2. Remove cowl top and cowl top lower panel extension. Refer to EXT-25, "Removal and Installation".
3. Drain the engine oil. Refer to LU-9, "Changing Engine Oil".
4. Disconnect coolant reservoir hose from the radiator and remove coolant reservoir.
5. Remove the radiator. Refer to CO-15, "Removal and Installation".
6. Remove the radiator shroud and cooling fan assembly. Refer to CO-17, "Removal and Installation".
7. Remove battery tray and bracket. Refer to PG-149, "Removal and Installation".

8. Remove the electric power steering oil pump motor assembly and bracket. Refer to ST-58, "Removal and
Installation".
9. Remove rocker covers.Refer to EM-43, "Exploded View".
10. If removing the timing chains, obtain compression TDC of No. 1
cylinder as follows:
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator (A).
AWBIA1219GB
b. Check that intake and exhaust camshaft lobes on No. 1 cylinder

(RH of engine) are located as shown.
• If not, turn the crankshaft one revolution (360°) and align as
shown.
NOTE:
The graphic shows the RH bank of the engine. The camshaft
lobes on the LH bank are clocked differently.
SEM418G
11. Remove the water pump. Refer to CO-19, "Removal and Installation".
12. Lock the drive plate using Tool.
Tool number : — (J-50288)

CAUTION:
Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when setting the
Tool.
13. Remove the crankshaft pulley as follows:
a. Loosen crankshaft pulley bolt and locate bolt seating surface at 10 mm (0.39 in) from its original position.
b. Position a suitable tool at recess hole of crankshaft pulley to
remove crankshaft pulley.
CAUTION:
Do not use a puller claw on the outer diameter of the crank-
shaft pulley.
EMQ0477D
14. Remove the generator and generator bracket. Refer to CHG-24, "Removal and Installation".
15. Support the engine with suitable tool and remove the engine mounting insulator (RH), engine mounting
insulator (Front) and engine mounting insulator (Rear). Refer to EM-107, "FWD : Exploded View" (FWD)
or EM-111, "AWD : Exploded View" (AWD).
16. Disconnect the oil pressure switch harness connector.
17. Remove the lower oil pan. Refer to EM-36, "Removal and Installation (Lower Oil Pan)".
18. Remove engine mounting bracket (front). Refer to EM-107, "FWD : Exploded View" (FWD) or EM-111,
"AWD : Exploded View" (AWD).
19. Disconnect the intake valve timing control solenoid valve harness connectors (bank1/bank2).
20. Disconnect the intake timing intermediate lock control solenoid valve harness connectors and the exhaust
valve timing control solenoid valve harness connectors (bank1/bank2). A
21. Remove the intake valve timing control cover [(bank1) A] and intake valve timing control cover [(bank 2)
B].
• For USA and Canada EM
Loosen the intake valve timing control cover RH and intake
valve timing control cover LH bolts in the reverse order as
shown.
CAUTION: C
The shaft in the intake valve timing control cover is
inserted into the center hole of the intake camshaft
sprocket. Remove the intake valve timing control cover by D
pulling straight out until the intake valve timing control
cover disengages from the camshaft sprocket.
(A) : Bank 1 (RH)

E
(B) : Bank 2 (LH)
(C) : Dowel pin hole
F
H
AWBIA2335ZZ
• For Mexico I
Loosen the intake valve timing control cover [(bank1) A] and
intake valve timing control cover [(bank 2) B] bolts in the
reverse order as shown. J
CAUTION:
The shaft in the intake valve timing control cover is
inserted into the center hole of the intake camshaft
sprocket. Remove the intake valve timing control cover by K
pulling straight out until the intake valve timing control
cover disengages from the camshaft sprocket.
L
(A) : Bank 1 (RH)
(B) : Bank 2 (LH)
(C) : Dowel pin hole M
AWBIA1234GB

22. Remove the front timing chain case.
a. Loosen the front timing chain case bolts in the reverse order
shown.
JPBIA1640ZZ
b. Insert the appropriate size tool into the notch (A) at the top of the
front timing chain case as shown.
c. Pry off the case by moving the suitable tool (B) as shown.
• Cut liquid gasket for removal using Tool.
CAUTION:
• Do not use a screwdriver or similar tool.
• After removal, handle carefully so it does not bend or
warp under a load.
ALBIA0251ZZ
23. Remove O-rings (1) from rear timing chain case.
(A) : Bank 1 (RH)

(B) : Bank 2 (LH)
CAUTION:
Use new O-rings for installation.
JPBIA1111ZZ
24. Remove the front oil seal from the front timing chain case using
a suitable tool.
CAUTION:
Do not damage the front cover.
SEM829E
25. Remove all old liquid gasket from all the bolt holes and bolts.
CAUTION:
Do not damage the threads or mating surfaces.
SEM161F

26. Use a scraper to remove all of the old liquid gasket from the
front timing chain case and opposite mating surfaces. A
CAUTION:
EM
SEM428G
D
27. Remove front timing chain case oil filters (if necessary).
INSTALLATION
E
1. Install front timing chain case oil filter (2) (if necessary).
CAUTION:
• Insert front timing chain case oil filter (2) into the front
timing chain case (1) to specified distance (A). F
• Ensure oil filter mesh remains intact during insertion into
the front timing chain case (1).
• Ensure oil filter mesh does not protrude from front timing G
chain case (1).
(A) : 1.0 - 1.5 mm (0.039 - 0.059 in) H

ALBIA1316ZZ
2. Install dowel pins (right and left) into front timing chain case up
to a point close to taper in order to shorten protrusion length. I
NOTE:
Be sure to place the dowel pins in original hole locations in the
front timing chain case. J
PBIC1101E
L
3. Install the new front oil seal on the front timing chain case. Apply
new engine oil to the oil seal edges.
CAUTION: M
Do not reuse the front oil seal.
NOTE:
Install it so that each seal lip is oriented as shown. N
O
SEM715A

a. Install the new front oil seal so that it becomes flush with the
face of front timing chain case using suitable tool.
CAUTION:
Press fit straight and avoid causing burrs or tilting the oil
seal.
NOTE:
Make sure the garter spring is in position and seal lip is not
inverted.
PBIC0790E
4. Install new O-rings (1) on rear timing chain case.
(A) : Bank 1 (RH)

(B) : Bank 2 (LH)
CAUTION:
JPBIA1111ZZ
5. Apply liquid gasket to front timing chain case as shown.

• Use Genuine Silicone RTV Sealant or equivalent. Refer to GI-
22, "Recommended Chemical Products and Sealants".
• Before installation, wipe off the protruding liquid gasket.
• (C): 2.6 - 3.6 mm (0.102 - 0.142 in) diameter.
CAUTION:
ing liquid gasket.
utes after the components are installed to allow the liquid
gasket to cure.
ALBIA0252ZZ
6. Install the front timing chain case by aligning the dowel pin on the rear timing chain case with the dowel
pin hole in front timing chain case.

7. Loosely install the front timing chain case bolts.
A
Bolt position Bolt diameter
1, 2 : 8 mm (0.31 in)
EM
3 – 22 : 6 mm (0.24 in)
8. Tighten the front timing chain case bolts in the order shown.
• Retighten the front timing chain case bolts in the order shown. C
Bolt position Tightening specification
JPBIA1640ZZ
1, 2 : 28.4 N·m (2.9 kg-m, 21 ft-lb) D
3 – 22 : 12.7 N·m (1.3 kg-m, 9 ft-lb)
9. Install intake valve timing control cover (bank 1) and intake valve timing control cover (bank 2).
E
a. Install new seal rings in shaft grooves.
CAUTION:
• When replacing seal rings, replace all rings with new ones on both intake valve timing control
cover RH and intake valve timing control cover LH. F
b. Install intake valve timing control cover (bank 1) and intake valve timing control cover (bank 2) with new G
gaskets to front timing chain case.
CAUTION:
Ensure the seal ring remains in the shaft groove.
H
c. Being careful not to move seal ring from the installation groove, align the dowel pins on the front timing
chain case with the holes to install valve timing control covers.
d. Tighten bolts in the numerical order as shown (For USA and
Canada). I
Intake valve timing 11.3 N·m (1.2 kg-m, 8 ft-lb)

control cover bolts J
(A) : Bank 1 (RH)

(B) : Bank 2 (LH) K
O
AWBIA2335ZZ

e. Tighten bolts in the numerical order as shown (For Mexico).
Intake valve timing 11.3 N·m (1.2 kg-m, 8 ft-lb)

control cover bolts
(A) : Bank 1 (RH)

(B) : Bank 2 (LH)
AWBIA1234GB
10. Install the water pump. Refer to CO-19, "Removal and Installation".
11. Install crankshaft pulley and tighten the bolt in two steps.
• Lubricate thread and seat surface of the bolt with new engine oil.
• For the second step, angle tighten using Tool.
CAUTION:
• Do not damage the front oil seal when inserting crankshaft pulley.
• Use only brass or plastic hammer if tapping on the crankshaft pulley.
• Do not hammer on pulley grooves.
Step 1 : 44.1 N·m (4.5 kg-m, 33 ft-lb)

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

12. Remove the Tool to unlock the drive plate.

CAUTION:
Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when removing
the Tool.
13. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-16, "FOR USA AND CANADA : Fluids and Lubricants" (United
States and Canada) or MA-17, "FOR MEXICO : Fluids and Lubricants" (Mexico).
• 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:

may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop A
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
EM
• Bleed air from passages in lines and hoses, such as in cooling system.
• Summary of the inspection items: C

Engine coolant Level Leakage Level D
Engine oil Level Leakage Level
Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage

transaxle fluid
E
M/T Models Level/Leakage Leakage Level/Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage F
Exhaust gas — Leakage —
G

TIMING CHAIN
TIMING CHAIN
AWBIA2795ZZ
1. Timing chain tensioner (secondary) 2. Internal chain guide 3. Timing chain tensioner (secondary)
(bank 2) (bank 1)
4. Camshaft sprocket (EXH) (bank 1) 5. Timing chain (secondary) 6. Timing chain (primary)
7. Camshaft sprocket (INT) (bank 1) 8. Slack guide 9. Timing chain tensioner (primary)
10. Crankshaft sprocket 11. Camshaft sprocket (INT) 12. Timing chain (secondary)
(bank 2)
13. Camshaft sprocket (EXH) (bank 2) 14. Tension guide

TIMING CHAIN
For Mexico
A
EM
H
AWBIA1637ZZ
1. Timing chain tensioner (secondary) 2. Internal chain guide 3. Timing chain tensioner (secondary)
(bank 2) (bank 1) I
4. Camshaft sprocket (EXH) (bank 1) 5. Timing chain (secondary) 6. Timing chain (primary)
7. Camshaft sprocket (INT) (bank 1) 8. Slack guide 9. Timing chain tensioner (primary)
10. Crankshaft sprocket 11. Camshaft sprocket (INT) 12. Timing chain (secondary) J
(bank 2)
13. Camshaft sprocket (EXH) (bank 2) 14. Tension guide
K
CAUTION:
• After removing timing chains, do not turn the crankshaft and camshaft separately or the valves will L
strike the pistons.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil. M
• Apply new engine oil to bolt threads and seat surfaces when installing camshaft sprockets, camshaft
brackets, and crankshaft pulley.
REMOVAL N
1. Remove front timing chain case. Refer to EM-57, "Removal and Installation".
3. Remove the spark plugs. Refer to EM-16, "Removal and Installation". O
4. Place paint marks on the timing chain and sprockets to indicate the correct position of the components for
installation.
5. Disconnect the harness connectors from camshaft position sensor. P
6. Remove the rocker covers. Refer to EM-44, "Removal and Installation (LH)" and EM-46, "Removal and
Installation (RH)".
7. Remove the timing chain tensioner (primary).

TIMING CHAIN
a. Pull lever down and release plunger stopper tab. Plunger stop-
per tab can be pushed up to release (coaxial structure with
lever).
SEM732G
b. Insert stopper pin into timing chain tensioner (primary) body hole
to hold lever, and keep the tab released. An Allen wrench [1.2
mm (0.047 in)] is used for a stopper pin as an example.
c. Insert plunger into tensioner body by pressing the slack guide.
d. Keep the slack guide pressed and hold it by pushing the stopper
pin through the lever hole and body hole.
e. Remove the bolts and remove the timing chain tensioner (pri-
mary).
SEM733G
8. Remove internal chain guide, tension guide and slack guide.

NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
PBIC2266E
9. Remove timing chain (primary) and crankshaft sprocket.

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

TIMING CHAIN
a. Attach a suitable stopper pin (B) to the bank 1 (A) and bank 2
(C) timing chain tensioners (secondary) (1). A
NOTE:
• Use approximately 0.5 mm (0.02 in) diameter hard metal pin
as a stopper pin.
EM
• Removal of camshaft bracket (No. 1) is required prior to
removing the timing chain tensioner (secondary).
JPBIA1727ZZ
D
b. Remove camshaft sprockets (INT and EXH) bolts.
• Secure the hexagonal portion of camshaft using a wrench to
loosen bolts.
E
CAUTION:
Do not loosen bolts using anything other than the cam-
shaft hexagonal portion. Do not apply tension to the tim-
ing chain. F
KBIA1698J
H
c. Remove timing chain (secondary) together with camshaft sprockets.
• Turn camshaft slightly to keep the chain tight when removing the timing chain (secondary).
• Insert 0.5 mm (0.020 in) thick metal or resin plate between tim-
ing chain and timing chain tensioner plunger (guide) (E). I
Remove timing chain (secondary) (2) together with camshaft
sprockets with timing chain loose from guide groove.
J
(1) : Timing chain tensioner (secondary)
(A) : Bank 1
(B) : View B
K
(C) : Stopper pin
(D) : Plate
JPBIA2527ZZ
(F) : Timing chain tensioner (body)
L
CAUTION:
Be careful of plunger coming off when removing timing chain (secondary). The plunger of timing
chain tensioner (secondary) moves during operation, which could cause the stopper pin to fall M
out.
• Bank 1 shown.
d. Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing
chain (secondary). N
CAUTION:
• Handle camshaft sprocket (INT) carefully to avoid any
shock to camshaft sprocket. O
• Do not disassemble. [Do not loosen bolts (A) as shown].
PBIC2980E
INSPECTION
TIMING CHAIN
Check for cracks and any excessive wear of the timing chain. Replace the timing chain as necessary.
INSTALLATION
WBIA0280E
1. Internal chain guide 2. Camshaft sprocket (INT) 3. Mating mark (pink link) (green link
for USA and CANADA)
4. Mating mark (punched) 5. Timing chain tensioner (secondary) 6. Mating mark (orange link)
7. Timing chain (secondary) 8. Camshaft sprocket (EXH) 9. Tension guide
10. Water pump 11. Crankshaft sprocket 12. Mating mark (notched)
13. Timing chain (primary) 14. Slack guide 15. Timing chain tensioner (primary)
16. Mating mark (back side) 17. Crankshaft key
NOTE:
This illustration shows the relationship between the mating mark on each timing chain and on the correspond-
ing sprocket with the components installed.
1. Install timing chain tensioners (secondary) with a new O-ring and the stopper pin attached.
CAUTION:
Do not reuse O-ring.
2. Check that dowel pin (A) and crankshaft key (1) are located as
shown. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown, for the
placement of cam nose, it is generally accepted camshaft is
placed in the same direction.
Camshaft dowel pin : At cylinder head upper face

side in each bank
Crankshaft key : At cylinder head side of bank 1
AWBIA1221GB
3. Install timing chain (secondary) and camshaft sprockets (INT
and EXH) as follows:
CAUTION:

TIMING CHAIN
Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions
repeatedly during the installation process. A
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin (A).
EM
D
JPBIA0095ZZ
b. Install timing chain (secondary) (1) and camshaft sprockets (INT E

and EXH).
(A) : Camshaft sprocket (INT) back face

F
(B) : Orange link
(C) : Mating mark (Circle)
(D) : Camshaft sprocket (EXH) back face
G
(E) : Mating mark (2 circles on front face)
(F) : Dowel pin groove
(G) : Mating mark (2 oblongs on front face)
H
(H) : Mating mark (Oblong)
(I) : Dowel pin hole
NOTE: I
Figure shows bank 1 (rear view).
• Align the mating marks on timing chain (secondary) (orange
link) with the ones on camshaft sprockets (INT and EXH)
(punched), and install them. J
NOTE:
• Mating marks for camshaft sprocket (INT) are on the back
side of camshaft sprocket (secondary). K
• There are two types of mating mark, circle and oblong types.
They should be used for the bank 1 and bank 2, respectively. JPBIA1726ZZ
L
Bank 1 : Use circle type.
Bank 2 : Use oblong type.
• Align dowel pin on camshafts with the groove or hole on sprockets, and install them. M
• On the intake side, align dowel pin on the camshaft front end with dowel pin hole on the back side of
camshaft sprocket, and install them.
• On the exhaust side, align dowel pin on camshaft front end with dowel pin groove on camshaft sprocket,
N
and install them.
• In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine
adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
• Bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to O
prevent the dislocation of dowel pins.

TIMING CHAIN
• It may be difficult to visually check the dislocation of mating
marks during and after installation. To make the matching eas-
ier, make a mating mark (A) on the top of sprocket teeth and
its extended line in advance with paint.
(B) : Mating mark (orange link)
JPBIA2260ZZ
4. After confirming the mating marks are aligned, tighten the cam-
shaft sprocket bolts.
• Secure the camshaft using a wrench at the hexagonal portion
to tighten the bolts.
KBIA1698J
5. Pull stopper pins (B) out from timing chain tensioners (second-
ary) (1).
(A) : Bank 1
(C) : Bank 2
JPBIA1727ZZ
6. Install the crankshaft sprocket on the crankshaft.

• Make sure the mating marks on the crankshaft sprocket face
the front of the engine.
SEM929E

TIMING CHAIN
7. Install the timing chain (primary).
• Install timing chain (primary) so the mating mark (punched) (B) A
on camshaft sprocket (C) is aligned with the pink link (A) on
the timing chain, while the mating mark (notched) (E) on the
crankshaft sprocket (D) is aligned with the orange one (F) on
EM
the timing chain, as shown.
• When it is difficult to align mating marks of the timing chain
(primary) with each sprocket, gradually turn the camshaft
using a wrench on the hexagonal portion to align it with the C
mating marks.
• During alignment, be careful to prevent dislocation of mating
mark alignments of the secondary timing chains. D
(G) : Water pump
NOTE: E
For USA and CANADA, link (A) is green link.
G
WBIA0721E
8. Install the internal chain guide (1) and slack guide (2). H
(3) : Tension guide
N
JPBIA1104ZZ
CAUTION: O

TIMING CHAIN
Do not over tighten slack guide bolt (2). It is normal for a
gap (A) to exist under the bolt seat when bolt is tightened to
specification.
(1) : Slack guide

(3) : Cylinder block
JPBIA0117ZZ
9. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin (E) through hole of lever into
tensioner body hole (B).
• The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition. JPBIA0118ZZ
NOTE:
Illustration shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper
pin.
e. Install timing chain tensioner (primary) (1).
• Remove any dirt and foreign materials completely from the
back and the mounting surfaces of timing chain tensioner (pri-
mary).
f. Pull out stopper pin (A) after installing, and then release plunger.
JPBIA0119ZZ
10. Reconfirm that the matching marks on the sprockets and the timing chain have not slipped out of align-
ment.
11. Install the front timing chain case. Refer to EM-57, "Removal and Installation".
12. Install the rocker covers. Refer to EM-44, "Removal and Installation (LH)" and EM-46, "Removal and
Installation (RH)".
13. Install the spark plugs. Refer to EM-16, "Removal and Installation".
14. Install the intake manifold collector. Refer to EM-26, "Removal and Installation".

REAR TIMING CHAIN CASE
A
EM
I
AWBIA2622ZZ
1. O-ring 2. Blind plug 3. Rear timing chain case J

4. Cylinder block 5. O-ring 6. O-ring
A. Refer to INSTALLATION Engine front
K
CAUTION:
L
• After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will
strike the pistons.
• Before removing the upper oil pan, remove the crankshaft position sensor (POS).
• Be careful not to damage sensor edges. M
REMOVAL
1. Remove the engine assembly. Refer to EM-107, "FWD : Removal and Installation" (FWD) or EM-112,
N
"AWD : Removal and Installation" (AWD).
2. Remove upper oil pan. Refer to EM-37, "Removal and Installation (Upper Oil Pan)".
3. Remove the front timing chain case. Refer to EM-57, "Exploded View".
O
4. Remove the timing chains (primary) and (secondary). Refer to EM-67, "Removal and Installation".

5. Remove the rear timing chain case.
CAUTION:
• Do not remove the plate metal cover for the oil passage.
• After removing the chain case, do not apply any load to
the case that might bend it.
KBIA1307E
a. Loosen and remove the rear timing chain case bolts in the reverse order shown.
AWBIA0710ZZ
b. Cut the sealant using Tool and remove the rear timing chain case.
CAUTION:
• After removing the bolts, separate the mating surface and
Tool number : KV10111100 (J-37228)

• Tap the seal cutter to insert it (1).
• In areas where the Tool is difficult to use, lightly tap to slide it
(2).
WBIA0566E

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

PBIC2680E
3. Align the rear timing chain case and water pump assembly with the dowel pins (RH and LH) on the cylin-
der block and install the case. Make sure the O-rings stay in place during installation.
a. Tighten the bolts in the numerical order as shown. There are two bolt lengths used. Follow the chart below
for proper bolt length specifications.
AWBIA0710ZZ

Bolt length Bolt position Torque specification A

20 mm (0.79 in) 1, 2, 3, 6, 7, 8, 9, 10 12.7 N·m (1.3 kg-m, 9 ft-lb)
16 mm (0.63 in) All except the 12.7 N·m (1.3 kg-m, 9 ft-lb)
EM
above
b. After all bolts are initially tightened, retighten them to the specification in the numerical order as shown.
NOTE:
C
If liquid gasket protrudes, wipe it off immediately.
4. Install the timing chains (primary and secondary). Refer to EM-67, "Removal and Installation".
5. Install the front timing chain case. Refer to EM-57, "Removal and Installation". D
6. Install the upper oil pan. Refer to EM-37, "Removal and Installation (Upper Oil Pan)".
7. Install the engine assembly. Refer to EM-107, "FWD : Removal and Installation" (FWD) or EM-112, "AWD
: Removal and Installation" (AWD). E

CAMSHAFT
CAMSHAFT
AWBIA1178GB
1. Camshaft position sensor bracket (RH) 2. Camshaft brackets 3. No. 1 camshaft bracket (RH)
4. Camshaft (EXH) (RH) 5. Camshaft (INT) (RH) 6. Cylinder head (RH)
7. Cylinder head (LH) 8. Camshaft (EXH) (LH) 9. Camshaft (INT) (LH)
10. No. 1 camshaft bracket (LH) 11. Camshaft brackets 12. Camshaft position sensor bracket (LH)
A. Follow installation procedure
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove the timing chains (primary and secondary). Refer to EM-67, "Removal and Installation".

CAMSHAFT
2. Remove camshaft position brackets (RH shown, LH similar).
A
EM
ALBIA0259ZZ
D
3. Remove the intake and exhaust camshaft brackets and the cam-
shafts.
• Mark the camshafts, camshaft brackets, and bolts so they are E
placed in the same position and direction for installation.
• Equally loosen the camshaft bracket bolts in several steps in
the numerical order as shown.
F
G
SEM856E
SEM857E K
4. Remove valve lifters (if necessary).
NOTE:
Identify installation positions to ensure proper installation. L
5. Remove secondary timing chain tensioner (1) from cylinder
head.
• Remove secondary tensioner with its stopper pin attached. M
NOTE:
Stopper pin was attached when secondary timing chain was
removed.
N
O
AWBIA1238GB
INSTALLATION
P

CAMSHAFT
1. Before installation, remove any old Silicone RTV Sealant from
component mating surfaces using a scraper.
• Remove the old Silicone RTV Sealant from the bolt holes and
threads.
• Do not scratch or damage the mating surfaces.
SEM161F
2. Before installing the front cam bracket, remove the old Silicone
RTV Sealant from the mating surface using a scraper.
• Do not scratch or damage the mating surface.
SEM892E
3. Turn the crankshaft until No. 1 piston is set at TDC on the com-
pression stroke.
• The crankshaft key should line up with the right bank cylinder
center line as shown.
SEM532G
4. Install camshaft chain tensioners (1) on both sides of cylinder

head. Refer to EM-57, "Removal and Installation".
AWBIA1238GB
5. Install valve lifter (if removed).

NOTE:
Install them in original positions.

CAMSHAFT
6. Install exhaust and intake camshafts and camshaft brackets.
• Intake camshaft has a drill mark on camshaft sprocket mount- A
ing flange.
EM
SEM652F
D
• Follow your identification marks made during removal or follow
the identification marks that are present on the new camshafts
components for proper placement and direction of the compo- E
nents.
ID mark Paint marks F

Bank INT/EXH Drill mark
(A) M1 (E) M2 (F) M3 (D)
INT 1A Yes Pink No Light blue
RH (B) G
EXH 1C No No Light Blue Light blue
AWBIA1352ZZ
INT 1B Yes Pink No Light blue
LH (C)
EXH 1D No No Light Blue Light blue H
• Position the camshaft dowel pins (A) as shown.
K
AWBIA1221GB

CAMSHAFT
7. Before installing camshaft brackets, apply liquid gasket to mat-
ing surface of No. 1 camshaft bracket.
• Use Genuine Silicone RTV Sealant or equivalent. Refer to
GI-22, "Recommended Chemical Products and Sealants".
CAUTION:
ing liquid gasket.
utes after the components are installed to allow the liq-
uid gasket to cure.
SEM446G
• Before installation, wipe off any protruding liquid gasket. Refer

to EM-4, "Precaution for Liquid Gasket".
PBIC0915E
• Install camshaft brackets in their original positions and direc-

tion. Align the stamp marks as shown.
• If checking and adjusting any part of valve assembly or
camshaft, check valve clearance according to the refer-
ence data. Refer to EM-18, "Valve Clearance".
Valve clearance (cold) Intake : 0.26 - 0.34 mm

(0.010 - 0.013 in)
Valve clearance (cold) Exhaust : 0.29 - 0.37 mm
(0.011 - 0.015 in)
SEM564G

CAMSHAFT
• Tighten the camshaft brackets in three steps, in numerical A

order shown.
Tighten No. 7 - 10, then EM

(1) 1.96 N·m (0.2 kg-m, 17 in-lb) tighten No. 1 - 6 in the nu-
merical order shown.
Tighten No. 1 - 10 in the nu- C
(2) 5.88 N·m (0.6 kg-m, 52 in-lb)
Tighten No. 1 - 10 in the nu-
(3) 10.41 N·m (1.10 kg-m, 8 ft-lb) SEM885EA
D
SEM886EA
H
8. Measure difference in levels between front end faces of No. 1
camshaft bracket and cylinder head.
I
Standard : – 0.14 to 0.14mm (– 0.0055 to 0.0055 in)
• If measurement is outside the specified range, re-install cam-
shaft and camshaft bracket. J
K
EMQ0044D
9. Install camshaft position sensors (PHASE) (RH and LH bank.) L

10. Install the timing chains. Refer to EM-67, "Removal and Installation".
Inspection After Removal INFOID:0000000012856664

M
INSPECTION
N
Camshaft Visual Check
Check camshaft for scratches and wear. Replace if necessary.
Camshaft Runout O

CAMSHAFT
1. Put V-block on precise flat bed and support No. 2 and No. 4 jour-
nal of camshaft as shown.
2. Set dial gauges vertically to No. 3 journal as shown.
3. Turn camshaft in one direction slowly by hand measure the cam-
shaft runout on the dial gauges.
• Runout is the largest indicator reading after one full revolution.
Camshaft Runout
Standard : Less than 0.02 mm (0.0008 in)
Limit : 0.05 mm (0.0020 in) PBIC0929E
4. If actual runout exceeds the limit, replace the camshaft.

Camshaft Lobe Height
1. Measure camshaft lobe height as shown. Refer to EM-139,
"Camshaft".
2. If wear has reduced the camshaft lobe height below specifica-
tions, replace the camshaft.
SEM549A
Camshaft Journal Clearance

Outer Diameter of Camshaft Journal
• Measure outer diameter of camshaft journal as shown.
Standard outer diameter : 25.935 - 25.955 mm

No.1 (1.0211 - 1.0218 in)
Standard outer diameter : 23.445 - 23.465 mm
No.2, 3, 4 (0.9230 - 0.9238 in)
SEM012A
Inner Diameter of Camshaft Bracket

1. Tighten camshaft bracket bolt with specified torque.
2. Using inside micrometer, measure inner diameter (A) of cam-
shaft bracket.
Standard inner diameter : 26.000 - 26.021 mm

No.1 (1.0236 - 1.0244 in)
Standard inner diameter : 23.500 - 23.521 mm
No.2, 3, 4 (0.9252 - 0.9260 in)
SEM862E
Calculation of Camshaft Journal Clearance

(Journal clearance) = (inner diameter of camshaft bracket) – (outer diameter of camshaft journal)

CAMSHAFT
Standard : 0.045 - 0.086 mm (0.0018 - 0.0034 in) A

No.1
Standard : 0.035 - 0.076 mm (0.0014 - 0.0030 in)
No.2, 3, 4 EM
Limit : 0.15 mm (0.0059 in)
• When out of the specified range, replace either or both camshaft and cylinder head.
NOTICE: C
Inner diameter of camshaft bracket is manufactured together with cylinder head. Replace the whole cylinder
head assembly.
Camshaft End Play D
1. Install the camshaft in the cylinder head.
2. Install dial gauge in thrust direction on front end of camshaft. E
Measure end play when camshaft is moved forward/backward
(in direction to axis) as shown.
Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in) F

Limit : 0.24 mm (0.0094 in)
• If out of the specified range, replace with new camshaft and mea- G
sure again.
• If out of the specified range again, replace with new cylinder head.
SEM864E
H
Camshaft Sprocket Runout
1. Put V-block on precise flat bed and support No. 2 and No. 4 jour-
nal of camshaft as shown. I
2. Install camshaft sprocket on camshaft.
3. Measure camshaft sprocket runout.
J
Runout : Less than 0.15 mm (0.0059 in)
4. If sprocket runout exceeds the limit, replace camshaft sprocket.
K
PBIC0930E
L
Valve Lifter
• Check if the surface of the valve lifter has any excessive wear or
cracks replace as necessary.
M
O
KBIA0182E
Valve Lifter Clearance P

Outer Diameter of Valve Lifter

CAMSHAFT
• Measure the outer diameter of the valve lifter. Refer to EM-139,
"Camshaft".
• If out of the specified range, replace the valve lifter.
JEM798G
Valve Lifter Bore Diameter

• Using inside micrometer, measure diameter of valve lifter bore of
cylinder head. Refer to EM-139, "Camshaft".
• If out of the specified range, replace the cylinder head assembly.
SEM867E
Calculation of Valve Lifter Clearance

• (Valve lifter clearance) = (valve lifter bore diameter) – (valve lifter outer diameter) Refer to EM-139, "Cam-
shaft".
• If out of specified range, replace either or both valve lifter and cylinder head assembly.
Inspection after Installation INFOID:0000000012856665
INSPECTION OF CAMSHAFT SPROCKET (INT) OIL GROOVE

WARNING:
Check when engine is cold so as to prevent burns from any splashing engine oil.
CAUTION:
Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT and it
is directed according to inspection procedure of EC section. Refer to EC-729, "Diagnosis Procedure".
1. Check engine oil level. Refer to LU-8, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release fuel pressure. Refer to EC-168, "Work Procedure" (For United States and Canada) or EC-707,
"Work Procedure" (For Mexico).
b. Disconnect ignition coil and injector harness connectors if practical.
3. Remove intake valve timing control solenoid valve.
4. Crank engine, and then make sure that engine oil comes out
from intake valve timing control cover oil hole. End cranking
after checking.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pul-
ley, and crankshaft pulley, etc.).
CAUTION:
• Engine oil may squirt from intake valve timing control
solenoid valve installation hole during cranking. Use a
shop cloth to prevent engine oil from splashing on
worker, engine components and vehicle. KBIA2686E

CAMSHAFT
• Do not allow engine oil to get on rubber components such as drive belts or engine mount insula-
tors. Immediately wipe off any splashed engine oil. A
5. Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from intake valve timing control cover oil hole.
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), EM
and then check each oil groove for clogging.
• Clean oil groove if necessary.
7. After inspection, installation of the remaining components is in the reverse order of removal. C

OIL SEAL
OIL SEAL
Removal and Installation of Valve Oil Seal INFOID:0000000012856666
REMOVAL
1. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping
into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring the front cover with the timing chain.
2. Remove camshaft relating to valve oil seal to be removed. Refer to EM-80, "Removal and Installation".
3. Remove valve lifters. Refer to EM-80, "Removal and Installation".
4. Remove valve collet, valve spring retainer and valve spring
using Tool.
CAUTION:
Do not damage valve lifter bore.
Tool numbers : KV10116200 (J-26336-A)

: KV10115900 (J-26336-20)
: KV10109220 ( — )
• Compress valve spring using Tool, attachment and adapter.
Remove valve collet with magnet hand. WBIA0578E
5. Remove valve oil seal using Tool.
Tool number : KV10107902 (J-38959)
WBIA0489E
INSTALLATION
1. Apply new engine oil to new valve oil seal joint surface and seal lip.
2. Press in valve oil seal to height (H) using Tool to specified
height.
Tool number : KV10115600 (J-38958)

NOTE:
Dimension (H): height measured before valve spring seat instal-
lation.
Intake and exhaust (H) : 14.3 - 14.9 mm (0.563 - 0.587 in)

3. Installation of the remaining components is in the reverse order WBIA0490E
of removal.
Removal and Installation of Front Oil Seal INFOID:0000000012856667
REMOVAL
1. Remove drive belt. Refer to EM-12, "Removal and Installation".
2. Lock the drive plate using Tool.

OIL SEAL
Tool number : — (J-50288) A

CAUTION:
Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when setting the
Tool. EM
3. Remove the crankshaft pulley as follows:
a. Loosen crankshaft pulley and locate bolt seating surface at 10 mm (0.39 in) from its original position.
b. Position a pulley puller at recess hole of crankshaft pulley to C
remove crankshaft pulley.
CAUTION:
Do not use a puller claw on the outer diameter of the crank- D
shaft pulley.
EMQ0477D
F
4. Remove front oil seal from front cover using a suitable tool.
CAUTION: G
Be careful not to damage front cover or crankshaft.
WBIA0680E
J
INSTALLATION
1. Apply new engine oil to new oil seal and install.
• Install new oil seal in the direction as shown. K
CAUTION:
• Do not reuse front oil seal.
• Press fit straight and avoid causing burrs or tilting the oil L
seal.
SEM715A
N
• Press-fit oil seal until it becomes flush with the timing chain case
end face, using suitable tool.
• Make sure the garter spring in the oil seal is in position and seal lip O
is not inverted.
PBIC0790E
2. Install crankshaft pulley and tighten the bolt in two steps.

OIL SEAL
• Lubricate thread and seat surface of the bolt with new engine oil.
• For the second step angle tighten using Tool.
CAUTION:
• Do not damage the front oil seal when inserting crankshaft pulley.
• Use only brass or plastic hammer if tapping on the crankshaft pulley.
• Do not hammer on pulley grooves.
Step 1 : 44.1 N·m (4.5 kg-m, 33 ft-lb)

Step 2 : 90°(+0°/-6°) degrees clockwise

3. Remove the Tool to unlock the drive plate.

CAUTION:
Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when removing
the Tool.
Removal and Installation of Rear Oil Seal INFOID:0000000012856668
REMOVAL
1. Remove the upper oil pan. Refer to EM-37, "Removal and Installation (Upper Oil Pan)".
2. Remove drive plate. Refer to EM-136, "Dowel Pin Alignment".
3. Remove rear oil seal retainer using Tool.
Tool Number : KV10111100 (J-37228)

CAUTION:
• Be careful not to damage mating surface.
• If rear oil retainer is removed, replace it with a new one
NOTE:
Rear oil seal and retainer form a single part and are replaced as
an assembly.
SEM830E
INSTALLATION
1. Remove old liquid gasket material from mating surface of cylinder block and oil pan using a suitable
scraper.
2. Install the rear oil seal retainer using Tool (A).
CAUTION:
Do not reuse rear oil seal retainer.
Tool number (A) : — (J-47128)

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

OIL SEAL
d. Apply sealant to rear oil seal retainer as shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to A
CAUTION:
EM
ing liquid gasket.
utes after the components are installed to allow the liquid
gasket to cure. C
AWBIA0028ZZ
D
e. Lubricate the sealing surface of the new rear main seal with new engine oil.
f. Slide the new rear main seal (1) over the Tool (A) and onto the
crankshaft. E
g. Loosen the wing nut and push the threaded rod into the handle
to remove the Tool (A).
h. Tighten the rear oil seal retainer bolts to specification. F
Rear oil seal retainer bolts : 8.8 N.m (0.9 kg-m, 78 in-
lb)
G
ALBIA0653ZZ
H
CAUTION:
• When replacing an engine or transaxle you must make sure the dowels are installed correctly
during re-assembly. I
• Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of
drivetrain components.
J

CYLINDER HEAD
CYLINDER HEAD
ALBIA0260ZZ
1. Cylinder head bolt 2. Cylinder head 3. Cylinder head gasket

4. Engine block A. Follow installation procedure
REMOVAL
1. Remove the engine from the vehicle. Refer to EM-107, "FWD : Removal and Installation" (FWD) or EM-
112, "AWD : Removal and Installation" (AWD).
2. Remove the rear timing chain case. Refer to EM-75, "Removal and Installation".
3. Remove the intake manifold. Refer to EM-29, "Removal and Installation".
4. Remove the exhaust manifolds. Refer to EM-31, "Exploded View".
5. Remove the intake and exhaust camshafts. Refer to EM-80, "Removal and Installation".
6. Remove the coolant outlet housing. Refer to CO-26, "Removal and Installation".
7. Remove the cylinder head bolts (RH and LH).
• The bolts should be loosened gradually in three stages.
• Loosen the bolts in the reverse order as shown.
SEM877EA

CYLINDER HEAD
EM
SEM878EA
8. Remove cylinder heads and gaskets. D

• Discard the cylinder head gaskets and use new gaskets for
installation.
E
G
SEM863E
INSTALLATION
1. Turn the crankshaft until No. 1 piston is set at TDC on the com- H
pression stroke.
• The crankshaft key should line up with the RH cylinder center
line as shown.
I
SEM532G K
2. Install new cylinder head gaskets.

CAUTION: L
• Do not reuse gaskets.
• Do not rotate crankshaft and camshaft separately or
valves will strike piston heads. M
SEM445G
O
3. Inspect the cylinder head bolts before installing the cylinder heads.
CAUTION:
P

CYLINDER HEAD
• Cylinder head bolts are tightened by degree rotation tight-
ening method. Whenever the size difference between d1
and d2 exceeds the limit, replace the bolts with new ones.
Limit (d1 - d2) : 0.11 mm (0.0043 in)

• Lubricate threads and seat surfaces of the bolts with new
engine oil.
SEM957E
4. Install the cylinder heads on the cylinder block. Tighten the cylin-
der head bolts in the five steps in the numerical order as shown
using Tool.
Tool Number : KV10112100 (BT-8653-A)

• Tightening procedure:
SEM879EA
Cylinder head bolts

Step a : 98.1 N·m (10 kg-m, 72 ft-lb) in order
Step b : Loosen in the reverse order of tightening
Step c : 39.2 N·m (4.0 kg-m, 29 ft-lb) in order
Step d : 103° degrees rotation clockwise in order
Step e : 103° degrees rotation clockwise in order
SEM877EA
SEM878EA

CYLINDER HEAD
Disassembly and Assembly INFOID:0000000012856671
EM
N
ALBIA0261ZZ
1. Valve collet 2. Valve spring retainer 3. Valve spring O

4. Valve oil seal 5. Valve spring seat 6. Valve guide
7. Cylinder head 8. Valve seat (EXH) 9. Valve seat (INT)
10. Valve (EXH) 11. Valve (INT) P
CAUTION:
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
• Apply new engine oil to threads and seat surface when installing cylinder head, camshaft sprocket,
crankshaft pulley, and camshaft bracket.
• Attach tags to valve lifters so as not to mix them up.

CYLINDER HEAD
DISASSEMBLY
1. Remove spark plug.
2. Remove valve lifter.
• Identify installation positions and store them without mixing them up.
3. Remove valve collet.
• Compress valve spring and remove valve collet with magnet
hand using Tool.
CAUTION:
Tool numbers : KV10109220 ( — )

: KV10116200 (J-26336-A)
: KV10115900 (J-26336-20)
WBIA0578E
4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side and remove valve.
• Identify installation positions, and store them without mixing them up.
6. Remove valve oil seals using Tool.
Tool number : KV10107902 (J-38959)
WBIA0489E
7. Remove valve seat (if necessary). Refer to EM-99, "Inspection After Disassembly".
8. Remove valve guide (if necessary). Refer to EM-99, "Inspection After Disassembly".
9. Remove spark plug tube (if necessary).
• Using pair of pliers, pull spark plug tube out of cylinder head.
CAUTION:
• Take care not to damage cylinder head.
• Once removed, spark plug tube will be deformed and cannot be reused. Do not remove it unless
absolutely necessary.
ASSEMBLY
1. Install valve guide (if removed). Refer to EM-99, "Inspection After Disassembly".
2. Install valve seat (if removed). Refer to EM-99, "Inspection After Disassembly".
3. Install valve oil seals using Tool.
Tool number : KV10115600 (J-38958)
Height (H) (Without valve spring seat installed)

Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install valve spring seat.
5. Install valves.
• Install it in the original position.
WBIA0490E
NOTE:
Larger diameter valves are for intake side.

CYLINDER HEAD
6. Install valve spring (uneven pitch type) with narrow pitch end
(paint mark) to cylinder head side (valve spring seat side). A
EM
SEM085D
D
7. Install valve spring retainer.
8. Install valve collet.
• Compress valve spring using Tool, attachment and adapter. E
Install valve collet with magnet hand.
CAUTION:
• Tap valve stem edge lightly with plastic hammer after installa- F
tion to check its installed condition.
Tool numbers : KV10109220 ( — ) G

: KV10116200 (J-26336-A)
: KV10115900 (J-26336-20) WBIA0578E
H
9. Install valve lifter.
• Install it in the original position.
10. Install spark plug tube. I
• Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. J
Use Genuine High Strength Locking Sealant or equivalent. Refer to GI-22, "Recommended Chemi-
cal Products and Sealants".
c. Press-fit spark plug tube so that its height (H) is as specified in K
using suitable tool.
Press-fit height (H) : 38.2 +0.9/- 0.5 mm (1.5 +0.035

L
/ -0.020 in)
CAUTION:
• When press-fitting, take care not to deform spark plug M
tube.
• After press-fitting, wipe off liquid gasket protruding onto
cylinder-head upper face.
11. Install spark plug. Refer to EM-16, "Removal and Installation".
PBIC2638E N
Inspection After Disassembly INFOID:0000000012856672
O
CYLINDER HEAD DISTORTION
Clean the surface of the cylinder head. Use a reliable straightedge and feeler gauge to check the flatness of
cylinder head surface. P

CYLINDER HEAD
Check along six positions as shown.
Head surface distortion

Limit : 0.1 mm (0.004 in)
Standard : Less than 0.03 mm
(0.0012 in)
If it exceeds the limit, replace the cylinder head.
The limit for cylinder head resurfacing is determined by the cyl-
inder block resurfacing.
SEM861E
Resurfacing Limit
Amount of cylinder head resurfacing is (A).
Amount of cylinder block resurfacing is (B).
The maximum limit : A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates freely by hand. If resistance is felt, cylinder head
must be replaced.
Nominal cylinder head height : 126.3 - 126.5 mm (4.972 - 4.980 in)
VALVE GUIDE CLEARANCE

1. Measure valve deflection as shown. (Valve and valve guide
mostly wear in this direction.)
Valve deflection limit (dial gauge reading)

Intake : 0.24 mm (0.0094 in)
Exhaust : 0.28 mm (0.0110 in)
SEM178F
2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diameter.
Refer to EM-141, "Cylinder Head".
b. Check that clearance is within specification.
(Valve guide clearance) = (Valve guide inner diameter) - (Valve
stem diameter)
Valve to valve guide clearance standard

Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.040 - 0.073 mm (0.0016 - 0.0029 in) SEM938C
Valve to valve guide clearance limit

Intake : 0.08 mm (0.0031 in)
Exhaust : 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.

CYLINDER HEAD
1. To remove valve guide, heat cylinder head to 110 - 130°C (230 -
266°F) by soaking in heated oil. A
WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned. EM
SEM008A
D
2. Drive out the valve guide with a press [under a 20 kN (2.2 US
ton) pressure] or hammer and suitable tool.
E
G
SEM931C
3. Ream cylinder head valve guide hole. H
Valve guide hole diameter : 10.175 - 10.196 mm

(for service parts), intake (0.4006 - 0.4014 in) I
and exhaust
K
SEM932C
4. Heat cylinder head to 110 - 130°C (230 - 266°F) by soaking in

heated oil and press new valve guide from camshaft side into L
the cylinder head to the dimensions as shown.
Projection (L) : 12.6 - 12.8 mm (0.496 - 0.504 in) M

WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned. N
SEM950E
O

CYLINDER HEAD
5. Using a valve guide reamer, apply a reamer finish to the valve
guide.
Intake and exhaust : 6.000 - 6.018 mm

finished size (0.2362 - 0.2369 in)
SEM932C
VALVE SEAT CONTACT

• After confirming that the dimensions of valve guides and valves are
within specifications, perform this procedure.
• Apply prussian blue onto contacting surface of valve seat to check
the condition of the valve contact on the surface.
• Check if the contact area band is continuous all around the circum-
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

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.
2. Ream cylinder head recess for service valve seat.
Oversize : 0.5 mm (0.020 in)

Intake : 38.500 - 38.516 mm
(1.5157 - 1.5164 in)
Exhaust : 32.100 - 32.116 mm
(1.2638 - 1.2644 in) SEM795A
Be sure to ream in circles concentric to the valve guide cen-

ter.
This will enable valve seat to fit correctly.
3. Heat cylinder head to 110 - 130°C (230 - 266°F) by soaking in heated oil.
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified dimensions. Refer to EM-141, "Cylinder Head".
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle (α) : 45° 15' - 45° 45' de-

grees/minutes
Contacting width (W) for intake : 1.18 - 1.22 mm
(0.0465 - 0.0480 in)
Contacting width (W) for exhaust : 1.38 - 1.42 mm
(0.0543 - 0.0559 in)
SEM892B

CYLINDER HEAD
8. Use a depth gauge to measure the distance between the mount-
ing surface of the cylinder head spring seat and the valve stem A
end. If the distance is shorter than specified, repeat step 5 to
adjust it. If it is longer, replace the valve seat with a new one.
EM
Valve seat resurface limit (L) : 41.16 - 41.76 mm
intake (1.6205 - 1.6441 in)
Valve seat resurface limit (L) : 41.09 - 41.69 mm C
exhaust (1.6177 - 1.6413 in)
SEM621F
D
VALVE SPRING SQUARENESS
Set try square along the side of valve spring and rotate the spring.
Measure the maximum clearance between the top face of spring and
try square. E
Out-of-square limit : Less than 2.0 mm (0.079 in)

F
PBIC0080E
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD H

Check valve spring pressure at specified spring height.
Standard : 166 - 188 N (16.9 - 19.2 kg, 37.3 - 42.3 lb) at I

height 37.0 mm (1.457 in)
Limit : 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb) at
height 27.2 mm (1.071 in) J
If it is not within specifications, replace the spring.
K
SEM113

ENGINE MOUNT
ENGINE MOUNT
ENGINE MOUNT (FRONT)
ENGINE MOUNT (FRONT) : Removal and Installation INFOID:0000000012856673
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
CAUTION:
• Always work safely.
• Do not start work until the engine and exhaust system are cooled completely.
• Refer to the applicable sections for warnings, cautions, notes, and instructions if necessary proce-
dures are not included in this section.
NOTE:
ing.
REMOVAL
1. Remove the air cleaner case (upper), air cleaner case (lower), front air duct, and air duct hose and reso-
nator assembly. Refer to EM-24, "Removal and Installation".
2. Remove the battery and battery tray assembly. Refer to PG-149, "Removal and Installation".
3. Remove the front under cover. Refer to EXT-30, "Removal and Installation".
4. Remove the fender protector side covers (RH/LH). Refer to EXT-28, "FENDER PROTECTOR : Exploded
View".
5. Partially remove the fender protectors (RH/LH). Refer to EXT-28, "FENDER PROTECTOR : Removal and
Installation".
6. Remove the radiator assembly. Refer to CO-15, "Removal and Installation".
7. Remove the engine cooling fan shroud and motor assembly. Refer to CO-17, "Removal and Installation".
8. Remove the exhaust manifold heat shield (LH). Refer to EM-31, "Exploded View".
9. Support the engine with a suitable tool.
10. Disconnect the engine mount insulator (front) vacuum hose.
11. Remove the engine mount insulator (front) nut (A).
AWBIA1241GB
12. Loosen the engine mount bracket (front) bolts in the reverse
order shown.
: Engine front
JPBIA1731ZZ
13. Remove the engine mount bracket (front).

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

specification in the order shown. M
: Front
N
Engine mount insulator (front) : 55 N·m (5.6 kg-m,
bolts 41 ft-lb)
O
JPBIA1735ZZ
P
3. Install the engine mount bracket (front) to the engine block.

ENGINE MOUNT
4. Tighten the engine mount bracket (front) bolts to specification in
the order shown.
: Engine front
Engine mount bracket (front) : 40 N·m (4.1 kg-m,

bolts 30 ft-lb)
JPBIA1731ZZ
5. Install the engine mount insulator (front) nut (A) and tighten to
specification.
Engine mount insulator (front) : 103 N·m (11 kg-m,

nut 76 ft-lb)
AWBIA1241GB

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION >
UNIT REMOVAL AND INSTALLATION A
ENGINE ASSEMBLY
FWD
EM
FWD : Exploded View INFOID:0000000012856674
AWBIA1639ZZ
1. Gusset 2. Rear torque rod 3. Rear torque rod bracket

L
4. Upper torque rod 5. Engine mounting insulator (RH) 6. Engine mounting bracket (RH)
7. Engine mounting insulator (front) 8. Engine mounting bracket (front) 9. Vacuum hose
M
10. Vacuum tube (front) 11. Vacuum hose 12. Engine mounting insulator (LH)
13. Engine mounting insulator (rear) 14. Engine mounting bracket (rear) 15. Engine mounting stay (rear)
A. To electronic controlled engine mount B. To transmission Front
control solenoid valve N
FWD : Removal and Installation INFOID:0000000012856675
O
WARNING:
P
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
dures are not included in the engine section.

ENGINE ASSEMBLY
• For supporting, lifting and jacking points, refer to GI-36, "2-Pole Lift" and GI-35, "Garage Jack and
Safety Stand".
• Always use the support point specified for lifting.
• Support the vehicle at the rear axle jacking point with transmission jack or similar tool before remov-
ing the engine in preparation for the backward shift of the center of gravity.
NOTE:
ing.
REMOVAL
Outline
Remove the engine and transmission with the front suspension member as a unit. Separate the engine from
the transmission and remove from the front suspension member.
Preparation
1. Release fuel pressure. Refer to EC-168, "Work Procedure" (For United States and Canada) or EC-707,
2. Drain engine coolant. Refer to CO-12, "Changing Engine Coolant".
CAUTION:
• Perform this step when the engine is cold.
• Do not allow the engine coolant to contact the drive belts.
5. Remove the fender protector side covers (RH and LH): Refer to EXT-28, "FENDER PROTECTOR :
6. Remove the front combination lamps (RH and LH). Refer to EXL-148, "Removal and Installation".
7. Remove the hood lock switch assembly. Refer to DLK-267, "HOOD LOCK RELEASE CABLE : Removal
and Installation".
8. Remove the upper fascia support. Refer to EXT-16, "Exploded View".
Engine Room
1. Remove the air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct
assembly. Refer to EM-24, "Removal and Installation".
3. Drain the power steering fluid. Refer to ST-48, "Draining and Refilling".
4. Disconnect engine room harness at the CVT and ECM connectors.
CAUTION:
Protect the harness connector with plastic bags or suitable covering to help prevent damage and
intrusion of foreign materials into the connectors.
5. Remove the battery and battery tray. Refer to PG-147, "Removal and Installation".
6. Remove battery bracket with ECM and CVT module.
7. Disconnect the brake fluid reservoir from the lower cowl panel and position aside.
8. Disconnect the fuse relay box from the lower cowl panel and position aside.
9. Remove the cowl top extension and cowl top. Refer to EXT-25, "Removal and Installation".
10. Remove the front wiper drive assembly. Refer to WW-73, "Removal and Installation".
11. Remove the lower cowl panel. Refer to EXT-25, "Removal and Installation".
12. Disconnect heater hoses. Refer to HA-48, "Removal and Installation".
13. Remove engine cooling fan shroud and motor assembly. Refer to CO-17, "Removal and Installation".
14. Remove upper and lower radiator hoses. Refer to CO-15, "Removal and Installation".
15. Remove the air conditioning condenser. Refer to HA-39, "Removal and Installation".
16. Remove the radiator. Refer to CO-15, "Removal and Installation".
17. Remove EVAP hose. Refer to EC-574, "ENGINE CONTROL SYSTEM : Component Parts Location".
18. Disconnect fuel feed hose quick connector at fuel tube side. Refer to EM-49, "Exploded View".
19. Disconnect transmission shift control cable at transmission side. Refer to TM-200, "Exploded View".
20. Disconnect brake booster vacuum hose at brake booster. Refer to BR-31, "Exploded View".
ENGINE ASSEMBLY
21. Remove harness ground cable.
22. Disconnect low pressure hose from steering pump. Refer to ST-61, "Removal and Installation". A
23. Disconnect high pressure piping from steering pump. Refer to ST-61, "Removal and Installation".
24. Disconnect the wiring harness from the distribution/fuse block.
EM
25. Disconnect the CVT fluid cooler hoses from the CVT.
26. Remove the E-PSF cover. Refer to ST-58, "Removal and Installation".
27. Remove the upper RH upper torque rod. C
28. Remove engine mounting insulator (RH) three upper nuts.
Vehicle Underbody
1. Remove exhaust front tube. Refer to EX-5, "Exploded View". D
2. Disconnect steering lower joint at power steering gear assembly and release steering lower shaft. Refer to
ST-63, "Exploded View".
3. Disconnect front stabilizer connecting rod. Refer to FSU-13, "Exploded View". E
4. Remove front brake caliper assembles with piping connected and position them aside. Refer to BR-37,
"BRAKE CALIPER ASSEMBLY : Exploded View".
5. Remove rear plate cover from oil pan (upper). Then remove nuts attaching the drive plate to the torque F
converter. Refer to EM-117, "Disassembly and Assembly".
6. Remove crankshaft position sensor (POS). Refer to EM-36, "Exploded View".
CAUTION: G
• Do not allow metal powder to adhere to magnetic part at sensor tip. H
• Do not place sensors in a location where they are exposed to magnetism.
Removal
1. Use suitable tool to securely support bottom of front suspension I
member.
CAUTION:
Put a piece of wood or something similar as the supporting J
surface to secure a completely stable condition.
PBIC1190E
L
2. Remove front suspension member nuts and bolts. Refer to FSU-8, "Exploded View".
3. Carefully lower table to remove the engine, the transmission and the front suspension member. When per- M
forming work, observe the following caution:
CAUTION:
• Confirm there is no interference with the vehicle.
N
• Repeatedly check to ensure all harnesses are disconnected before and during engine removal.
• Check all connection points have been disconnected.
• Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support the vehi-
cle at rear jacking point(s) to prevent it from falling off the lift. O
Separation

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

(4) : Engine front slinger (upper)
(5) : Engine front slinger (lower)
: Engine front
JPBIA1729ZZ
2. Disconnect vacuum hose from front engine mounting insulator.

3. Remove CVT fluid level indicator and CVT charging pipe. Refer to TM-228, "Exploded View".
4. Remove starter. Refer to STR-20, "Removal and Installation".
5. Remove exhaust manifold and three way catalyst (RH). Refer to EM-31, "Removal and Installation (bank
2)".
6. Remove front drive shaft (RH). Refer to FAX-17, "Removal and Installation (RH)".
7. Remove rear torque rod through bolt.
8. Remove engine mounting insulator (rear).
9. Remove transmission to engine bolts.
10. Separate engine and transmission assembly.
11. Lift the engine from the front suspension member.
CAUTION:
• Repeatedly check to ensure all harnesses are disconnected before and during engine lifting.
• Avoid spilling engine oil or grease onto the engine mounting insulators to prevent damage to
engine mounting insulators.
INSTALLATION
CAUTION:
• Do not damage the engine mounting insulator. Do not spill engine oil on the engine mounting insula-
tor.
• Check all mounting insulators are seated properly, then tighten nuts and bolts.
required quantity, fill to the specified level. Refer to MA-16, "FOR USA AND CANADA : Fluids and Lubri-
• 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.
NOTE:

ENGINE ASSEMBLY
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop A
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
EM
• Summary of the inspection items: C

Engine coolant Level Leaks Level D
Engine oil Level Leaks Level
Leaks Level/Leaks Leaks
Transaxle fluid CVT Models E
Level/Leaks Leaks Level/Leaks
Fuel Leaks Leaks Leaks F
Exhaust gas — Leaks —
AWD G
AWD : Exploded View INFOID:0000000012856676
AWBIA1640ZZ
1. Rear torque rod 2. Rear torque rod bracket 3. Engine mounting bracket (RH)
4. Upper torque rod 5. Engine mounting insulator (RH) 6. Engine mounting insulator (front)
7. Engine mounting bracket (front) 8. Vacuum tube (front) 9. Vacuum hose

ENGINE ASSEMBLY
10. Vacuum hose 11. Engine mounting insulator (LH) 12. Engine mounting insulator (rear)
13. Rear engine mount bracket (LH) A. To electronic controlled engine mount Front
control solenoid valve
AWD : Removal and Installation INFOID:0000000012856677
WARNING:
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
dures are not included in the engine section.
• For supporting, lifting and jacking points, refer to GI-36, "2-Pole Lift" and GI-35, "Garage Jack and
Safety Stand".
• Always use the support point specified for lifting.
• Support the vehicle at the rear axle jacking point with transmission jack or similar tool before remov-
ing the engine in preparation for the backward shift of the center of gravity.
NOTE:
ing.
REMOVAL
Outline
Remove the engine, transmission and transfer assembly with the front suspension member as a unit. Remove
the transfer assembly and separate the engine from the transmission.
Preparation
1. Release fuel pressure. Refer to EC-168, "Work Procedure" (For United States and Canada) or EC-707,
2. Drain engine coolant. Refer to CO-12, "Changing Engine Coolant".
CAUTION:
• Perform this step when the engine is cold.
• Do not allow the engine coolant to contact the drive belts.
5. Remove the fender protector side covers (RH and LH): Refer to EXT-28, "FENDER PROTECTOR :
6. Remove front bumper fascia assembly. Refer to EXT-17, "Removal and Installation".
7. Remove the front combination lamps (RH and LH). Refer to EXL-148, "Removal and Installation".
8. Remove the hood lock switch assembly. Refer to DLK-267, "HOOD LOCK RELEASE CABLE : Removal
and Installation".
9. Remove the upper fascia support. Refer to EXT-16, "Exploded View".
Engine Room
1. Remove the air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct
assembly. Refer to EM-24, "Removal and Installation".
3. Drain the power steering fluid. Refer to ST-48, "Draining and Refilling".
4. Disconnect engine room harness at the CVT and ECM connectors.
CAUTION:
Protect the harness connector with plastic bags or suitable covering to help prevent damage and
intrusion of foreign materials into the connectors.
5. Remove the battery and battery tray. Refer to PG-147, "Removal and Installation".
6. Remove battery bracket with ECM and CVT module.
ENGINE ASSEMBLY
7. Disconnect the brake fluid reservoir from the lower cowl panel and position aside.
8. Disconnect the fuse relay box from the lower cowl panel and position aside. A
9. Remove the cowl top extension and cowl top. Refer to EXT-25, "Removal and Installation".
10. Remove the front wiper drive assembly. Refer to WW-73, "Removal and Installation".
EM
11. Remove the lower cowl panel. Refer to EXT-25, "Removal and Installation".
12. Disconnect heater hoses. Refer to HA-48, "Removal and Installation".
13. Remove engine cooling fan shroud and motor assembly. Refer to CO-17, "Removal and Installation". C
14. Remove upper and lower radiator hoses. Refer to CO-15, "Removal and Installation".
15. Remove the air conditioning condenser. Refer to HA-39, "Removal and Installation".
16. Remove the radiator. Refer to CO-15, "Removal and Installation". D
17. Remove EVAP hose. Refer to EC-574, "ENGINE CONTROL SYSTEM : Component Parts Location".
18. Disconnect fuel feed hose quick connector at fuel tube side. Refer to EM-49, "Exploded View".
19. Disconnect transmission shift control cable at transmission side. Refer to TM-200, "Exploded View". E
20. Disconnect brake booster vacuum hose at brake booster. Refer to BR-31, "Exploded View".
21. Remove harness ground cable.
F
22. Disconnect low pressure hose from steering pump. Refer to ST-61, "Removal and Installation".
23. Disconnect high pressure piping from steering pump. Refer to ST-61, "Removal and Installation".
24. Disconnect the wiring harness from the distribution/fuse block. G
25. Disconnect the CVT fluid cooler hoses from the CVT.
26. Remove the E-PSF cover. Refer to ST-58, "Removal and Installation".
27. Remove the upper RH upper torque rod. H
28. Remove engine mounting insulator (RH) three upper nuts.
Vehicle Underbody
I
1. Remove exhaust front tube. Refer to EX-5, "Exploded View".
2. Remove heat insulator.
3. Remove rear propeller shaft. Refer to RAX-9, "Removal and Installation". J
4. Disconnect steering lower joint at power steering gear assembly and release steering lower shaft. Refer to
ST-63, "Exploded View".
5. Disconnect front stabilizer connecting rod. Refer to FSU-13, "Exploded View". K
6. Remove front brake caliper assembles with piping connected and position them aside. Refer to BR-37,
"BRAKE CALIPER ASSEMBLY : Exploded View".
7. Remove rear plate cover from oil pan (upper). Then remove nuts attaching the drive plate to the torque L
converter. Refer to EM-117, "Disassembly and Assembly".
8. Remove crankshaft position sensor (POS). Refer to EM-36, "Exploded View".
CAUTION: M
• Do not allow metal powder to adhere to magnetic part at sensor tip.
• Do not place sensors in a location where they are exposed to magnetism. N
Removal
1. Use suitable tool to securely support bottom of front suspension
O
member.
CAUTION:
Put a piece of wood or something similar as the supporting
surface to secure a completely stable condition. P
PBIC1190E

ENGINE ASSEMBLY
2. Remove front suspension member nuts and bolts. Refer to FSU-8, "Exploded View".
3. Carefully lower table to remove the engine, the transmission, transfer assembly and front suspension
member. When performing work, observe the following caution:
CAUTION:
• Confirm there is no interference with the vehicle.
• Repeatedly check to ensure all harnesses are disconnected before and during engine removal.
• Check all connection points have been disconnected.
• Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support the vehi-
cle at rear jacking point(s) to prevent it from falling off the lift.
Separation
1. Install engine slingers into front of cylinder head (bank 1) (3) and
rear of cylinder head (bank 2) (2).
(1) : Engine rear slinger

(4) : Engine front slinger (upper)
(5) : Engine front slinger (lower)
: Engine front
JPBIA1729ZZ
2. Disconnect vacuum hose from front engine mounting insulator.

3. Remove CVT fluid level indicator and CVT charging pipe. Refer to TM-228, "Exploded View".
4. Remove starter. Refer to STR-20, "Removal and Installation".
5. Remove exhaust manifold and three way catalyst (RH). Refer to EM-31, "Removal and Installation (bank
2)".
6. Remove transfer assembly. Refer to DLN-64, "Removal and Installation".
7. Remove front drive shaft (RH). Refer to FAX-17, "Removal and Installation (RH)".
8. Remove rear torque rod through bolt.
9. Remove engine mounting insulator (rear).
10. Remove transmission to engine bolts.
11. Separate engine and transmission assembly.
12. Lift the engine from the front suspension member.
CAUTION:
• Repeatedly check to ensure all harnesses are disconnected before and during engine lifting.
• Avoid spilling oil or grease onto the engine mounting insulators to prevent damage to engine
mounting insulators.
INSTALLATION
CAUTION:
• Do not damage the engine mounting insulator. Do not spill oil on the engine mounting insulator.
• Check all mounting insulators are seated properly, then tighten nuts and bolts.

ENGINE ASSEMBLY
required quantity, fill to the specified level. Refer to MA-16, "FOR USA AND CANADA : Fluids and Lubri- A
• Use procedure below to check for fuel leaks.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leaks
EM
at connection points.
• Start engine. With engine speed increased, check again for fuel leaks at connection points.
NOTE: C
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises. D
• Warm up engine thoroughly to make sure there are no leaks of fuel, exhaust gas, or any oils/fluids including
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- E
• Summary of the inspection items:
F
Engine coolant Level Leaks Level
Engine oil Level Leaks Level G
Leaks Level/Leaks Leak
Transaxle fluid CVT Models
Level/Leaks Leaks Level/Leaks
H
Fuel Leaks Leaks Leaks
Exhaust gas — Leaks — I

CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY >
UNIT DISASSEMBLY AND ASSEMBLY
CYLINDER BLOCK
AWBIA1645GB

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

4. Sub harness 5. Knock sensor 6. Cylinder block
7. Thrust bearing (upper) 8. Main bearing (upper) 9. Crankshaft
10. Crankshaft key 11. Thrust bearing (lower) 12. Main bearing (lower) EM
13. Main bearing cap 14. Main bearing cap bolt 15. Main bearing beam
16. Baffle plate 17. Connecting rod bolt 18. Connecting rod bearing cap
19. Connecting rod bearing 20. Connecting rod 21. Snap ring C
22. Piston pin 23. Piston 24. Oil ring
25. Second ring 26. Top ring 27. Pilot converter
28. Oil jet 29. Gasket (for CANADA) 30. Cylinder block heater (for CANADA) D
A. Crankshaft side B. Chamfered C. Refer to INSTALLATION
D. Front mark
E
Disassembly and Assembly INFOID:0000000012856679
CAUTION:
• Apply new engine oil to parts as marked in illustrations before installation. F
• Place removed parts such as bearings and bearing caps in their proper order and direction.
• When installing the connecting rod nuts and main bearing cap bolts, apply new engine oil to the
threads and mating surfaces G
• Do not allow any magnetic materials to contact the signal plate teeth on the drive plate.
DISASSEMBLY
1. Remove the engine assembly. Refer to EM-107, "FWD : Removal and Installation" (FWD) or EM-112, H
"AWD : Removal and Installation"(AWD).
2. Remove the drive plate. Refer to EM-136, "Dowel Pin Alignment".
3. Remove pilot converter. I
Tool number : ST16610001 (J-23907)

J
L
SEM005G
4. Cut away liquid gasket and remove rear oil seal retainer using
Tool. Refer to EM-4, "Precaution for Liquid Gasket". M
Tool number : KV10111100 (J-37228)

CAUTION: N
• Be careful not to damage mount surface.
• If rear oil seal retainer is removed, replace it with a new
one.
O
NOTE:
Rear oil seal and retainer form a single part and are replaced as
an assembly. SEM830E

CYLINDER BLOCK
5. Install the engine on engine stand. Any commercially available
engine stand can be used.
CAUTION:
• Use an engine stand that has a load capacity [approxi-
mately 240kg (529 lb) or more] large enough for support-
ing the engine weight.
• Before removing the hanging chains, make sure the
engine stand is stable and there is no risk of overturning.
PBIC0085E
6. Remove the knock sensor.

CAUTION:
Carefully handle sensor to avoid shocking it.
7. Drain the engine of all engine coolant and engine oil.
8. Remove the oil pan. Refer to EM-37, "Removal and Installation (Upper Oil Pan)".
9. Remove the crankshaft pulley.
• Use a suitable tool to prevent the crankshaft from turning.
10. Remove the timing chain. Refer to EM-67, "Removal and Installation".
11. Remove the cylinder head. Refer to EM-94, "Removal and Installation".
12. Remove the piston and connecting rod assemblies.
a. Position the crankshaft pin corresponding to the connecting rod
to be removed onto the bottom dead center.
b. Remove the connecting rod cap.
c. Using a hammer handle or similar tool, push the piston and con-
necting rod assembly out to the cylinder head side.
• Before removing the piston and connecting rod assembly,
check the connecting rod side clearance. Refer to EM-148,
"Connecting Rod Bearing".
PBIC0086E
13. Remove the connecting rod bearings.

CAUTION:
When removing the connecting rod side bearings, note the installation position. Keep them in the
correct order.
14. Remove the piston rings from the piston.
• Use a piston ring expander.
CAUTION:
• When removing the piston rings, be careful not to damage
the piston. Do not expand the rings excessively.
• Be careful to mark the rings if they are to be reused so
they are installed in their original position.
• Before removing the piston rings, check the piston ring side
clearance. Refer to EM-126, "Inspection".
PBIC0087E

CYLINDER BLOCK
15. Remove the piston from the connecting rod as follows.
a. Using a snap ring pliers, remove the snap ring. A
CAUTION:
Do not reuse snap rings, always replace with new ones.
EM
PBIC0260E
D
b. Heat the pistons to 60° - 70°C (140° - 158°F).
WARNING:
Pistons contain heat. When working, wear protective equip- E
ment to avoid getting burned.
G
SEM965A
c. Push out the piston pin with a suitable tool with an outer diame-
H
ter of approximately 20 mm (0.8 in).
PBIC0262E
K
16. Remove the rear oil seal retainer from the cylinder block.
• Insert a suitable tool between the rear end of the crankshaft counter weight and rear oil seal retainer, L
and separate the liquid gasket to remove.
CAUTION:
Be careful not to damage the mating surface.
17. Remove the baffle plate from the main bearing beam. M
18. Loosen the bolts in the reverse order shown and remove the
main bearing beam, bearing caps and crankshaft.
• Before loosening the main bearing cap bolts, measure the N
crankshaft side clearance. Refer to EM-126, "Inspection".
: Engine front O
P
JPBIA0439ZZ

CYLINDER BLOCK
19. Remove the oil jets and dowel pins.
20. Remove the main bearings and thrust bearings from the cylinder
block and main bearing caps.
• When removing them, note the direction and position. Keep
them in the correct order for installation.
PBIC0898E
ASSEMBLY
1. Blow out the engine coolant and engine oil passages and cylinder bore to remove any foreign materials.
CAUTION:
Use goggles to protect your eyes.
2. Install the cylinder block drain plugs (if removed).
• Apply sealant to the thread of the water drain plug (B), connec-
tor bolt (C) and water drain plug (D) (if removed).
CAUTION:
Do not reuse copper sealing washers.
: Front
NOTE:
• For Canada, water drain plug (B) is a block heater, not a
water drain plug.
• Install copper sealing washers (E) and (A) (if removed).
• Use Genuine High Performance Thread Sealant or equiva-
lent. Refer to GI-22, "Recommended Chemical Products and
Sealants".
• Tighten each plug and connector bolt to specifications.
AWBIA1194GB
Part Washer Tightening torque

(B) (except Canada) Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
(B) (for Canada) Yes 39.0 N·m (4.0 kg-m, 29 ft-lb)
(C) Yes 27.0 N·m (2.8 kg-m, 20 ft-lb)
(D) Yes 78.0 N·m (8.0 kg-m, 58 ft-lb)
3. Install the oil jets.

• Insert the oil jet dowel pin into the cylinder block dowel pin
hole, and tighten the bolts.
PBIC0898E

CYLINDER BLOCK
4. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and oil on the bearing mating surfaces of the A
cylinder block and the main bearing cap.
b. Install the thrust bearings to both sides of the No. 3 journal hous-
ing on the cylinder block and the main bearing cap. EM
• Install the thrust bearings with the oil groove facing the crank-
shaft arm (outside).
• Install bearing with a projection on one end on cylinder block
C
and bearing with a projection at center on cap. Align each pro-
jection with mating notch.
PBIC0807E
D
5. Set the upper main bearings in their proper positions on the cyl-
inder block.
• Confirm the correct main bearings are used. Refer to EM-126, E
"Inspection".
G
SEM175F
6. Instructions for the re-use of the main bearing cap bolts. H

• A plastic zone tightening method is used for tightening the
main bearing cap bolts. Measure (d1) and (d2) as shown.
• For (d2), select the minimum diameter in the measuring area. I
• If the difference between (d1) and (d2) exceeds the limit,
replace the bolts for assembly.
J
Limit (d1 - d2) : 0.11 mm (0.0043 in)
K
SEM177F
7. After installing the crankshaft, lower main bearings, main bear-

ing caps, main bearing beam, and bearing cap bolts. Tighten the L
bearing cap bolts in the numerical order as shown.
SEM851E
O

CYLINDER BLOCK
a. Make sure that the front marks on the main bearing beam faces
the front of the engine.
b. Prior to tightening all the bearing cap bolts, place the bearing
beam in its proper position by shifting the crankshaft in the axial
position.
c. After tightening the bearing cap bolts, make sure the crankshaft
turns smoothly.
d. Lubricate the threads and seat surfaces of the bolts with new
engine oil.
e. Tighten the bolts in two stages: SEM456G
CAUTION:
Measure the tightening angle in two stages using Tool. Do
not measure with eyes only, be sure to use Tool.
Stage 1 : 32.3 - 38.3 N·m (3.3 - 3.9 kg-m, 24 - 28 ft-lb)

Stage 2 : 90° - 95° degrees clockwise
PBIC0096E
8. Measure crankshaft end play.

• If beyond the limit, replace the thrust bearing with a new one.
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)

Limit : 0.30 mm (0.0118 in)
SEM852E
9. Install the piston to the connecting rod.

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

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

CYLINDER BLOCK
• Heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 - 70°C (140 - 158°F)]. From A
the front to the rear, insert the piston pin into the piston and
through the connecting rod.
WARNING: EM
Pistons contain heat. When working, wear protective
equipment to avoid getting burned.
C
SEM965A
D
• Assemble so that the piston front mark (B) on the crown and
the oil hole (C), connecting rod front mark (D) and Cylinder No.
(E) on the connecting rod are positioned as shown. E
: Engine front
(A) : Piston grade number F
(F) : Pin grade number
(G) : Crown I.D. code
G
AWBIA1399ZZ
c. Install the snap ring into the front of the piston pin-groove. H
• After installing, check that the connecting rod pivots smoothly
on the pin.
CAUTION:
Do not reuse snap rings, always replace with new ones. I
PBIC0260E K
10. Using a piston ring expander, install the piston rings.

L
(A) : Top ring
(B) : Second ring
CAUTION: M
• Be careful not to damage the piston.
• When the piston rings are not replaced, remount the rings
in their original positions.
• When replacing the piston rings, those without stamped N
surface (A) can be mounted either side up.
• Install the second ring with the stamped surface (B) facing JPBIA0263ZZ
upward. If the ring is not stamped it can face in either O

direction.

CYLINDER BLOCK
• Position each ring with the gap as shown, referring to the pis-
ton front mark.
PBIC0808E
11. Install the connecting rod bearings to the connecting rod and the
connecting rod cap.
• When installing the connecting rod bearings, apply engine oil
to the bearing surface (crankshaft side). Do not apply oil to the
back surface (connecting rod and cap side), but thoroughly
clean it.
• When installing, align the connecting rod bearing protrusion
with the notch of the connecting rod to install.
• Check that the engine oil holes on the connecting rod and on
the corresponding bearing are aligned.
PBIC0266E
12. Install the piston and connecting rod assembly into the corre-
sponding cylinder.
• Position the crankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston, and
crankshaft pin.
• Match the cylinder position with the cylinder No. (B) on the
connecting rod to install.
• Install the piston with the piston front mark (A) on the crown
facing the front of the engine ( ) using Tool.
AWBIA0029ZZ
(C) : Engine oil hole
Tool number : EM03470000 (J-8037)

CAUTION:
Be careful not to damage the crankshaft pin and cylinder wall, resulting from interference of the
connecting rod big end.
13. Install the connecting rod cap.
• Match the stamped cylinder number marks on the connecting
rod with those on the cylinder cap for installation.
• Install the piston connecting rod assembly and cap so that the
front mark on the cap and piston are facing the front of the
engine.
• Lubricate the threads and seat surfaces with new engine
oil.
SEM457G

CYLINDER BLOCK
14. Check the connecting rod cap bolts before reusing, then install
in their original position in the connecting rod. The bolts should A
screw in smoothly by hand.
• Measure the outer diameter of the connecting rod cap bolt as
shown.
EM
Outer diameter (d) of the connecting rod bolt

Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 in) C
Limit : 7.75 mm (0.3051 in)
SEM538G
D
15. Tighten the connecting rod nuts in two stages using Tool:
Stage 1 : 19 - 21 N·m (1.9 - 2.1 kg-m, 14 - 15 ft-lb) E

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

• Apply engine oil to the threads and seats of the connecting rod
bolts and nuts. SEM953E
• After tightening the nuts, make sure that the crankshaft rotates H
smoothly.
• Check the connecting rod side clearance. If beyond the limit, replace the connecting rod and/or crank-
shaft.
I
Connecting rod side clearance:

Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in) J
Limit : 0.40 mm (0.0157 in)
16. Install the baffle plate to the main bearing beam.
K
17. Install the knock sensor.
• Make sure that there is no foreign material on the cylinder
block mating surface and the back surface of the knock sen-
sor. L
• Install the knock sensor with the connector facing the rear of
the engine.
• Do not tighten the bolts while holding the connector. M
• Make sure that the knock sensor does not interfere with other
parts.
CAUTION:
If any impact by dropping occurs to the knock sensor, N
PBIC0810E
replace it with new one.
18. Install the cylinder head. Refer to EM-94, "Removal and Installation".
19. Install the timing chain. Refer to EM-67, "Removal and Installation". O
20. Install the oil pan. Refer to EM-37, "Removal and Installation (Upper Oil Pan)".
21. Remove engine from the stand.
P

CYLINDER BLOCK
22. Install the pilot converter with its chamfer facing crankshaft as
shown.
: Crankshaft side
JPBIA0210ZZ
23. Install the rear oil seal retainer using Tool (A).
Tool number (A) : — (J-47128)

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

Use Genuine Silicone RTV Sealant, or equivalent. Refer to
CAUTION:
ing liquid gasket.
ant to cure.
AWBIA0028ZZ
e. Lubricate the sealing surface of the new rear main seal with new engine oil.
f. Slide the new rear main seal (1) over the Tool (A) and onto the
crankshaft.
g. Loosen the wing nut and push the threaded rod into the handle
to remove the Tool (A).
h. Tighten the rear oil seal retainer bolts to specification. Refer to
EM-92, "Removal and Installation of Rear Oil Seal".
ALBIA0653ZZ
24. Install the drive plate. Refer to EM-136, "Dowel Pin Alignment".
25. Install the engine assembly into the vehicle. Refer to EM-107, "FWD : Removal and Installation" (FWD) or
EM-112, "AWD : Removal and Installation" (AWD).
Inspection INFOID:0000000012856680
PISTON AND PISTON PIN CLEARANCE

Inner Diameter of Piston Pin Hole

CYLINDER BLOCK
• Measure the inner diameter of piston pin hole (dp).
A
Standard diameter (dp)
Grade No. 0 : 21.993 – 21.999 mm (0.8659 – 0.8661 in)
Grade No. 1 : 21.999 – 22.005 mm (0.8661 – 0.8663 in) EM
AEM023
D
Outer Diameter of Piston Pin
• Measure outer diameter of piston pin (Dp).
Standard diameter (Dp) E

Grade No. 0 : 21.989 – 21.995 mm (0.8657 – 0.8659 in)
Grade No. 1 : 21.995 – 22.001 mm (0.8659 – 0.8662 in)
F
G
AEM024
H
: : Engine front
(A) : Piston grade No.
(B) : Piston front mark I
(C) : Oil hole
(D) : Connecting rod front mark
J
(E) : Cylinder No.
(F) : Pin grade No.
K
AWBIA1399ZZ
Piston and Piston Pin Interference Fit

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

• If clearance is exceeds specification, replace either or both of piston/piston pin assembly and connecting rod M
assembly with reference to specification of each part.
PISTON RING SIDE CLEARANCE
• Measure side clearance of piston ring and piston ring groove with N
feeler gauge.
Standard Side Clearance O

Top ring : 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring : 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring : 0.045 - 0.125 mm (0.0018 - 0.0049 in) P
Maximum Limit
SEM024AA
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.1 mm (0.004 in)
Oil ring :—

CYLINDER BLOCK
• If out of specification, replace piston ring assembly. If clearance exceeds maximum limit with new rings,
replace piston.
PISTON RING END GAP
• Insert piston ring until it is in the middle of the cylinder bore and
measure the end gap.
Standard
Top ring : 0.23 - 0.28 mm (0.0091 - 0.0110 in)
2nd ring : 0.33 - 0.43 mm (0.0130 - 0.0169 in)
Oil ring : 0.20 - 0.45 mm (0.0079 - 0.0177 in)
Limit:
SEM599A
Top ring : 0.50 mm (0.0197 in)
2nd ring : 0.62 mm (0.0244 in)
Oil ring : 0.80 mm (0.0315 in)
• If out of specification, replace piston ring.
CONNECTING ROD BEND AND TORSION
Bend : Limit 0.15 mm (0.0059 in) per 100 mm

(3.94 in) length
Torsion : Limit 0.30 mm (0.0118 in) per 100 mm
(3.94 in) length
SEM038F
• If it exceeds the limit, replace connecting rod assembly.
SEM003F
CONNECTING ROD BEARING HOUSING DIAMETER (BIG END)

• Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod nut to the specified
torque, measure the connecting rod bearing housing big end inner
diameter using an inside micrometer.
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
PBIC0119E
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)

CYLINDER BLOCK
Inner Diameter of Connecting Rod (Small End)
• Measure inner diameter of piston pin bushing. A
Standard Grade No. 0

: 22.000 - 22.006 mm (0.8661 - 0.8664 in) EM
Grade No. 1
: 22.006 - 22.012 mm (0.8664 - 0.8666 in)
C
PBIC0120E D
Outer Diameter of Piston Pin
• Measure outer diameter of piston pin.
E
Standard Grade No. 0
: 21.989 - 21.995 mm (0.8657 - 0.8659 in)
F
Grade No. 1
: 21.995 - 22.001 mm (0.8659 -0.8662 in)
G
PBIC0117E
H
Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of con-
necting rod small end) – (Outer diameter of piston pin)
I
Standard : 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit : 0.030 mm (0.0012 in)
J
• If the measured value exceeds the standard, replace the connect-
ing rod assembly and/or piston and piston pin assembly.
• If replacing the piston and piston pin assembly, use the Table for K
Selective Fitting for Piston to select the piston corresponding to the
applicable bore grade of the cylinder block to be used. Follow the
SEM457G
"PISTON-TO-CYLINDER BORE CLEARANCE" procedure.
L
Factory installed parts grading:
: : Engine front M
(A) : Piston grade No.
(B) : Piston front mark
(C) : Oil hole
N
(D) : Connecting rod front mark
(E) : Cylinder No.
O
(F) : Pin grade No.
AWBIA1399ZZ
P
Service parts apply only to grade 0.
Unit: mm (in)
Grade 0 1
22.000 - 22.006 22.006 - 22.012
Connecting rod small end inner diameter
(0.8661 - 0.8664) (0.8664 - 0.8666)

CYLINDER BLOCK
21.989 - 21.995 21.995 - 22. 001
Piston pin outer diameter
(0.8657 - 0.8659) (0.8659 - 0.8662)
21.993 - 21.999 21.999 - 22.005
Piston pin hole diameter
(0.8659 - 0.8661) (0.8661 - 0.8663)
CYLINDER BLOCK DISTORTION

• Using a scraper, remove any old gasket material on the cylinder
block surface and remove any oil, scale, carbon, or other contami-
nation.
CAUTION:
Be careful not to allow gasket flakes to enter the oil or coolant
passages.
• Measure the distortion on the block upper face at different points in
six directions.
Distortion limit : 0.10 mm (0.0039 in)

• If out of specification, resurface the cylinder block. The allowable SEM123C
amount of resurfacing is dependent on the amount of any cylinder

head resurfacing. The resurfacing limit is [amount of cylinder head resurfacing] + [amount of cylinder head
resurfacing] = 0.2 mm (0.008 in).
Cylinder block height : 214.95 - 215.05 mm

(8.4626 - 8.4665 in)
INNER DIAMETER OF MAIN BEARING HOUSING

• Install the main bearing caps with the main bearings removed, and tighten the bolts to the specified torque.
• Using a bore gauge, measure the inner diameter of the main bear-
ing housing (A).
Standard : 63.993 - 64.017 mm (2.5194 - 2.5203 in)

• If out of the standard, replace the cylinder block and main bearing
caps as an assembly.
NOTE:
These components cannot be replaced as a single unit, because
they were processed together.
SEM845E
PISTON-TO-CYLINDER BORE CLEARANCE

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

No. 1 95.500 - 95.510 mm (3.7598 - 3.7602 in)
No. 2 95.510 - 95.520 mm (3.7602 - 3.7606 in) 0.20 mm (0.0079 in)
No. 3 95.520 - 95.530 mm (3.7606 - 3.7610 in)
SEM843E

CYLINDER BLOCK
If it exceeds the limit, rebore all cylinders. Replace cylinder block
if necessary. A
Out-of-round (Difference : limit 0.015 mm (0.0006 in)

between X and Y) EM
Taper (Difference between : limit 0.010 mm (0.0004 in)
A and C)
C
JPBIA2238GB
D
2. Check for scratches and seizure. If seizure is found, hone it.
• If both cylinder block and piston are replaced with new
ones, select piston of the same grade number punched on E
cylinder block rear position. These numbers are punched
in either Arabic or Roman numerals.
G
SEM756G
3. Measure piston skirt diameter. H
Piston diameter (A) : Refer to EM-144,

"Cylinder Block". I
Measuring point (a) : 38.0 mm (1.496 in)
(Distance from the top)
J
SEM258C
K
4. Check that piston-to-bore clearance is within specification.

L
Piston-to-bore : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
clearance at (B)
• The piston-to-bore clearance is measured at the (B) level in M
the cylinder as shown.
JPBIA2238GB
O
5. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter (A).
Rebored size calculation :D=A+B−C P

where,
(D) : Bored diameter
(A) : Piston diameter as measured
(B) : Piston-to-bore clearance
(C) : Honing allowance 0.02 mm (0.0008 in)

CYLINDER BLOCK
6. Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted
after boring.
7. Cut cylinder bores.
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter
at a time.
8. Hone cylinders to obtain specified piston-to-bore clearance.
9. Measure finished cylinder bore for out-of-round and taper.
• Measurement should be done after cylinder bore cools down.
CRANKSHAFT
1. Check the crankshaft main and pin journals for scoring, wear, or
cracks.
2. Measure the journals for taper and out-of-round.
Standard
Out-of-round (X - Y) : 0.002 mm (0.0001 in)
Taper (A - B) : 0.002 mm (0.0001 in)
SEM316A
3. Measure crankshaft runout.

a. Place a V-block on a precise flat table to support the journals on
the both ends of the crankshaft.
b. Place a dial gauge straight up on the No. 3 journal.
c. While rotating the crankshaft, read the movement of the pointer
on the dial gauge.
Runout limit (total indicator : 0.10 mm (0.0039 in)

reading)
SEM346D
BEARING CLEARANCE
• Use either of the following two methods, however method (A) gives more reliable results and so is the pre-
ferred method.
Method A (Using Bore Gauge and Micrometer)
Main Bearing
1. Set the main bearings in their proper positions on the cylinder
block and the main bearing cap.
2. Install the main bearing caps and bearing beam to the cylinder
block. Tighten all bolts in the numerical order as specified. Refer
to EM-117, "Disassembly and Assembly".
SEM175F

CYLINDER BLOCK
3. Measure the inner diameters (A) of each main bearing as
shown. A
EM
SEM845E
D
4. Measure the outer diameters (Dm) of each crankshaft main jour-
nal as shown.
5. Calculate the main bearing clearance. E
Main bearing clearance = (A)- (Dm)
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in) F

Limit : 0.065 mm (0.0026 in)
• If it exceeds the limit, replace the bearing.
• If clearance cannot be adjusted using any standard bearing G
grade, grind crankshaft journal and use an undersized bear- AEM033
ing.
H
• When grinding the crankshaft journal, confirm that the (L)
dimension in the fillet role is more than the specified limit.
I
(L) : 0.10 mm (0.0039 in)
K
SEM964
6. If the crankshaft or the cylinder block is replaced with a new one, select thickness of the main bearings as L
follows:
a. The grade number of each cylinder block main journal is
punched on the respective cylinder block. These numbers are M
punched in either Arabic or Roman numerals. If measured diam-
eter is out of the grade punched, decide suitable grade from
available main bearings.
N
SEM756G

CYLINDER BLOCK
b. The grade number of each crankshaft main journal is punched
on the crankshaft end. These numbers are punched in either
Arabic or Roman numerals. If measured diameter is out of grade
punched, decide the suitable grade from available main bear-
ings.
SEM452G
c. Select the main bearing suitable thickness according to the following table:
PBIC0814E
Connecting Rod Bearing (Big End)

1. Install the connecting rod bearing to the connecting rod and cap.
2. Install the connecting rod cap to the connecting rod. Tighten to specification. Refer to EM-117, "Disassem-
bly and Assembly".

CYLINDER BLOCK
3. Measure the inner diameter (C) of each connecting rod (big end)
as shown. A
EM
AEM027
D
4. Measure the outer diameter (Dp) of each crankshaft pin journal.
5. Calculate the connecting rod bearing clearance.
Connecting rod bearing clearance = (C) - (Dp) E
Standard : 0.020 - 0.045 mm (0.0008 - 0.0018 in)

Limit : 0.070 mm (0.0028 in) F
6. If the calculated clearance exceeds the specified limit, replace

the bearings.
G
7. If the clearance cannot be adjusted within the standard of any
bearing, grind the crankshaft journal and use undersized bear- AEM034
ings.
H
8. If the crankshaft is replaced with a new one, select the connect-

ing rod bearings according to the following table:
Connecting Rod Bearing Grade Number (Identification I
Color)
Crankshaft pin journal grade Connecting rod bearing grade J

number number
0 0 (black)
1 1 (brown) K
2 2 (green)
SEM452G
These numbers are punched in either Arabic or Roman numer-

L
als.
Method B (Using Plastigage)
• Remove engine oil and dust on the crankshaft pin and the surfaces M
of each bearing completely.
• Cut a Plastigage slightly shorter than the bearing width, and place
it in crankshaft axial direction, avoiding oil holes.
• Install the connecting rod bearings to the connecting rod cap, and N
tighten the connecting rod nuts to the specified torque.
CAUTION:
Do not rotate the crankshaft. O
• Remove the connecting rod cap and bearings, and using the scale
on the Plastigage bag, measure the Plastigage width.
NOTE:
The procedure when the measured value exceeds the repair limit
SEM142
P
is same as that described in "Method A (Using Bore Gauge and Micrometer)".
DRIVE PLATE RUNOUT

CYLINDER BLOCK
Use a suitable tool to measure the runout (Total Indicator Reading)
as shown.
Drive plate torque : less than 0.35 mm (.0138 in)

converter surface
Ring gear : less than 0.5 mm (.0197 in)
CAUTION:
• The signal plate is built into the drive assembly. Be careful not
to damage the signal plate, particularly the teeth.
SEM849EB
• Check the drive plate and signal plate for deformation or

cracks.
• Keep all magnetized objects away from the signal plate, par-
ticularly the teeth.
SEM760G
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
• If it is not operating properly, replace oil jet.
OIL JET RELIEF VALVE
• Using a clean plastic stick, press check valve in oil jet relief valve.
Make sure that valve moves smoothly with proper reaction force.
• If it is not operating properly, replace oil jet relief valve.
EMU0468D
Dowel Pin Alignment INFOID:0000000012856681
REMOVAL
1. Use suitable tool to lock the drive plate and match mark (A) the
drive plate before removing the bolts.
CAUTION:
Do not damage the ring gear teeth or the signal plate teeth
behind the ring gear.
ALBIA0522ZZ

CYLINDER BLOCK
2. Remove drive plate.
• Loosen the drive plate in a diagonal order. A
CAUTION:
• Never place drive plate with signal plate facing down.
• When handling the signal plate, take care not to damage
EM
or scratch it.
• Handle the signal plate in a manner that prevents it from
becoming magnetized.
C
SEM760G
D
INSTALLATION
• When installing the drive plate to the crankshaft, use the match
mark (A) as shown to correctly align the crankshaft side dowel pin E
to the drive plate side dowel pin hole.
ALBIA0522ZZ
H
• Install the drive plate and the reinforcement plate in the direction
as shown.
I
PBIC0910E
L
• Tighten the drive plate bolts in a diagonal pattern in two steps. Refer to EM-117, "Disassembly and Assem-
bly".
- Use a suitable tool to lock the drive plate.
M

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000012856682
GENERAL SPECIFICATIONS
Cylinder arrangement V-6

3 3,498 (213.45)
Displacement cm (cu in)
Bore and stroke mm (in) 95.5 x 81.4 (3.760 x 3.205)
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1
Number of main bearings 4
Compression ratio 10.6:1
Standard 1,275 (13.0, 185)
Compression pressure
Minimum 981 (10.0, 142)
kPa (kg/cm2, psi)/300 rpm
Differential limit between cylinders 98 (1.0, 14)
Cylinder number
SEM713A
Valve timing
(Valve timing control - “OFF”)
PBIC0187E
Unit: degree
a b c d e f
240 240 −10 70 10 50
Drive Belt INFOID:0000000012856683
DRIVE BELT
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Spark Plug INFOID:0000000012856684
A
SPARK PLUG
Unit: mm (in)
EM
Make DENSO
Standard type* FXE22HR11
Gap Standard 1.1 (0.043) C
Intake Manifold INFOID:0000000012856685

D
INTAKE MANIFOLD
Unit: mm (in)
E
Items Limit
Surface distortion Intake manifold 0.1 (0.004)
F
Exhaust Manifold INFOID:0000000012856686
EXHAUST MANIFOLD
G
Unit: mm (in)
Items Limit
Surface distortion Exhaust manifold 0.3 (0.012) H
Camshaft INFOID:0000000012856687
I
CAMSHAFT
Unit: mm (in)
Items Standard Limit

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

Camshaft sprocket runout [TIR*2] Less than 0.15 (0.0059) —

Difference in level between front end
faces of No. 1 camshaft bracket and cyl- : – 0.14 to 0.14mm (– 0.0055 to 0.0055 in) —
inder head
SEM671
*1: Cam wear limit

*2: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter bore diameter 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter clearance 0.013 - 0.039 (0.0005 - 0.0015)
VALVE CLEARANCE
Unit: mm (in)
Items Cold Hot* (reference data)

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

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

788U 7.88 (0.3102)
790U 7.90 (0.3110)
792U 7.92 (0.3118)
794U 7.94 (0.3126)
796U 7.96 (0.3134)
798U 7.98 (0.3142)
800U 8.00 (0.3150)
802U 8.02 (0.3157)
804U 8.04 (0.3165)
806U 8.06 (0.3173)
808U 8.08 (0.3181)
810U 8.10 (0.3189)
812U 8.12 (0.3197)
814U 8.14 (0.3205)
816U 8.16 (0.3213)
818U 8.18 (0.3220)

Identification (stamped) mark* Thickness
A
820U 8.20 (0.3228)
822U 8.22 (0.3236)
824U 8.24 (0.3244) EM
826U 8.26 (0.3252)
828U 8.28 (0.3260)
830U 8.30 (0.3268) C
832U 8.32 (0.3276)
834U 8.34 (0.3283)
D
836U 8.36 (0.3291)
838U 8.38 (0.3299)
840U 8.40 (0.3307) E
SEM758G
I
Cylinder Head INFOID:0000000012856688
J
CYLINDER HEAD
Unit: mm (in)
Items Standard Limit K

Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height (H) 126.3 - 126.5 (4.97 - 4.98) —
L
Spark plug tube installation height 38.2 +0.9/- 0.5 (1.5 +0.035 / -0.020) —
PBIC0924E
P
VALVE DIMENSIONS

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

Valve head diameter (D)
Exhaust 30.2 - 30.5 (1.189 - 1.201)
Intake 97.13 (3.8240)
Valve length (L)
Exhaust 94.67 (3.7272)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter (d)
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle α) 45°15′ - 45°45′
Exhaust
Intake 1.15 - 1.45 (0.0453 - 0.0571)
Valve margin (T)
Exhaust 1.45 - 1.75 (0.0571 - 0.0689)
Valve margin (T) limit More than 0.5 (0.020)
Valve stem end surface grinding limit Less than 0.2 (0.008)
VALVE OIL SEAL

Unit: mm (in)
Description Standard
Valve oil seal installation height 14.3 - 14.9 (0.563 - 0.587)
VALVE GUIDE
Unit: mm (in)
SEM950E
Items Standard Oversize (Service) [0.2 (0.008)]

Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)

Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance A
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.01 (0.004)
Valve deflection Intake — 0.24 (0.0094)

Exhaust — 0.28 (0.0110) EM
Projection length (L) 12.6 - 12.8 (0.496 - 0.504)
VALVE SEAT
C
Unit: mm (in)
Items Standard Oversize (Service) [0.5 (0.02)]
I
AWBIA0033GB
SEM621F
Intake (A) 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164) M
Cylinder head seat recess diameter (D)
Exhaust (B) 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Valve seat outer diameter N
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038) O
Intake (A) 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height (h)
Exhaust (B) 5.9 - 6.0 (0.232 - 0.236) 4.9 - 5.0 (0.193 - 0.197)
P
Intake (A) 1.18 - 1.22 (0.0465 - 0.0480)
Contacting width (W)*
Exhaust (B) 1.38 - 1.42 (0.0543 - 0.0559)
Cylinder head seat recess depth (H) 6.0 (0.236)
Intake (A) 41.16 - 41.76 (1.6205 - 1.6441)
Depth (L)
Exhaust (B) 41.09 - 41.69 (1.6177 - 1.6413)
*:Machining data

VALVE SPRING
Items Standard
Free height 47.07 mm (1.8531 in)
Installation height 37.00 mm (1.4567 in)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open 27.20 mm (1.0709 in)
Load with valve open 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb)
Unit: mm (in)
Items Limit
Squareness 2.0 (0.079)
Cylinder Block INFOID:0000000012856689
CYLINDER BLOCK
Unit: mm (in)
JPBIA2238GB
Standard Less than 0.03 (0.0012)

Surface distortion
Limit 0.10 (0.0039)
Main bearing housing inner diameter Standard 63.993 - 64.017 (2.5194 - 2.5203)
Grade No. 1 95.500 - 95.510 (3.7598 - 3.7602)
Standard Grade No. 2 95.510 - 95.520 (3.7602 - 3.7606)
Cylinder bore Inner diameter
Grade No. 3 95.520 - 95.530 (3.7606 - 3.7610)
Wear limit 0.20 (0.0079)
Out-of-round 0.015 (0.0006)
Limit
Taper (Difference between A and C) 0.015 (0.0006)

Grade No. A 63.993 - 63.994 (2.5194 - 2.5194)
Grade No. B 63.994 - 63.995 (2.5194 - 2.5195) A
Grade No. C 63.995 - 63.996 (2.5195 - 2.5195)
Grade No. D 63.996 - 63.997 (2.5195 - 2.5196)
Grade No. E 63.997 - 63.998 (2.5196 - 2.5196)
Grade No. F 63.998 - 63.999 (2.5196 - 2.5196) EM
Grade No. G 63.999 - 64.000 (2.5196 - 2.5197)
Grade No. H 64.000 - 64.001 (2.5197 - 2.5197)
Grade No. J 64.001 - 64.002 (2.5197 - 2.5198)
Grade No. K 64.002 - 64.003 (2.5198 - 2.5198)
C
Grade No. L 64.003 - 64.004 (2.5198 - 2.5198)
Grade No. M 64.004 - 64.005 (2.5198 - 2.5199)
Main bearing housing inner diameter grade (Without bearing)
Grade No. N 64.005 - 64.006 (2.5199 - 2.5199) D
Grade No. P 64.006 - 64.007 (2.5199 - 2.5200)
Grade No. R 64.007 - 64.008 (2.5200 - 2.5200)
Grade No. S 64.008 - 64.009 (2.5200 - 2.5200)
Grade No. T 64.009 - 64.010 (2.5200 - 2.5201) E
Grade No. U 64.010 - 64.011 (2.5201 - 2.5201)
Grade No. V 64.011 - 64.012 (2.5201 - 2.5202)
Grade No. W 64.012 - 64.013 (2.5202 - 2.5202)
Grade No. X 64.013 - 64.014 (2.5202 - 2.5202) F
Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203)
Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203)
Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203)
G
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
AVAILABLE PISTON
Unit: mm (in) H
SEM882E
L
Items Grade* Standard
Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594)
Piston skirt diameter (A) Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) M
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602)
(a) dimension 38.0 (1.496)
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) N
Piston pin hole diameter
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663)
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012)
O
PISTON RING
Unit: mm (in) P
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.1 (0.004)
Oil ring 0.065 - 0.125 (0.0018 - 0.0049) —

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

Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —
Piston pin outer diameter
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) —
Piston to piston pin oil clearance 0.002 - 0.010 (0.0001 - 0.0004) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
CONNECTING ROD
Unit: mm (in)
Items Grade1 Standard Limit

Center distance 144.15 - 144.25 (5.68 - 5.68) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Connecting rod small end inner diameter 23.980 - 24.000 (0.9441 - (0.9449)
Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —
Connecting rod bushing inner diameter2
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —
Connecting rod big end diameter (Without bearing) 55.000 - 55.013 (2.1654 - 2.1659) —
Side clearance 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157)
1
: Always check with the Parts Department for the latest parts information.
2: After installing in connecting rod.
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E

Grade1 Dimension
A
Grade No. A 59.975 - 59.974 (2.3612 - 2.3612)
Grade No. B 59.974 - 59.973 (2.3612 - 2.3611)
Grade No. C 59.973 - 59.972 (2.3611 - 2.3611)
Grade No. D 59.972 - 59.971 (2.3611 - 2.3611) EM
Grade No. E 59.971 - 59.970 (2.3611 - 2.3610)
Grade No. F 59.970 - 59.969 (2.3610 - 2.3610)
Grade No. G 59.969 - 59.968 (2.3610 - 2.3609)
Grade No. H 59.968 - 59.967 (2.3609 - 2.3609) C
Grade No. J 59.967 - 59.966 (2.3609 - 2.3609)
Grade No. K 59.966 - 59.965 (2.3609 - 2.3608)
Grade No. L 59.965 - 59.964 (2.3608 - 2.3608)
Main journal diameter.(Dm) grade Standard Grade No. M 59.964 - 59.963 (2.3608 - 2.3607) D
Grade No. N 59.963 - 59.962 (2.3607 - 2.3607)
Grade No. P 59.962 - 59.961 (2.3607 - 2.3607)
Grade No. R 59.961 - 59.960 (2.3607 - 2.3606) E
Grade No. S 59.960 - 59.959 (2.3606 - 2.3606)
Grade No. T 59.959 - 59.958 (2.3606 - 2.3605)
Grade No. U 59.958 - 59.957 (2.3605 - 2.3605)
Grade No. V 59.957 - 59.956 (2.3605 - 2.3605) F
Grade No. W 59.956 - 59.955 (2.3605 - 2.3604)
Grade No. X 59.955 - 59.954 (2.3604 - 2.3604)
Grade No. Y 59.954 - 59.953 (2.3604 - 2.3603)
Grade No. 4 59.953 - 59.952 (2.3603 - 2.3603) G
Grade No. 7 59.952 - 59.951 (2.3603 - 2.3603)
Grade No. 0 51.968 - 51.974 (2.0460 - 2.0462)
Pin journal diameter. (Dp) grade Standard Grade No. 1 51.962 - 51.968 (2.0457 - 2.0460) H
Grade No. 2 51.956 - 51.962 (2.0445 - 2.0457)
Center distance (r) 40.66 - 40.74 (1.6008 - 1.6039)
I
Taper [Difference between (A) and (B)] Less than 0.002 (0.0001)
Limit
Out-of-round [Difference between (X) and (Y)] Less than 0.002 (0.0001)
Standard Less than 0.05 (0.0020) J
Crankshaft runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.10 - 0.25 (0.0039 - 0.0098)
Crankshaft end play K
Limit 0.30 (0.0118)
Fillet role of crankshaft journal Standard More than 0.10 (0.0039)
*: Total indicator reading L
Main Bearing INFOID:0000000012856690
M
MAIN BEARING
Unit: mm (in)
PBIC2619E
Grade number* Thickness Width Identification color Remarks

0 2.000 - 2.003 (0.0787 - 0.0789) Black
1 2.003 - 2.006 (0.0789 - 0.0790) Brown
2 2.006 - 2.009 (0.0790 - 0.0791) Green
3 2.009 - 2.012 (0.0791 - 0.0792) Yellow Grade is the same
for upper and lower
4 2.012 - 2.015 (0.0792 - 0.0793) Blue bearings.
5 2.015 - 2.018 (0.0793 - 0.0794) Pink
6 2.018 - 2.021 (0.0794 - 0.0796) Purple
7 2.021 - 2.024 (0.0796 - 0.0797) White
UPR 2.003 - 2.006 (0.0789 - 0.0790) Brown
01
LWR 2.000 - 2.003 (0.0787 - 0.0789) Black
UPR 2.006 - 2.009 (0.0790 - 0.0791) 19.9 - 20.1 Green
12
LWR 2.003 - 2.006 (0.0789 - 0.0790) (0.783 - 0.791) Brown
UPR 2.009 - 2.012 (0.0791 - 0.0792) Yellow
23
LWR 2.006 - 2.009 (0.0790 - 0.0791) Green
UPR 2.012 - 2.015 (0.0792 - 0.0793) Blue Grade and color are
34 different for upper
LWR 2.009 - 2.012 (0.0791 - 0.0792) Yellow and lower bearings.
UPR 2.015 - 2.018 (0.0793 - 0.0794) Pink
45
LWR 2.012 - 2.015 (0.0792 - 0.0793) Blue
UPR 2.018 - 2.021 (0.0794 - 0.0796) Purple
56
LWR 2.015 - 2.018 (0.0793 - 0.0794) Pink
UPR 2.021 - 2.024 (0.0796 - 0.0797) White
67
LWR 2.018 - 2.021 (0.0794 - 0.0796) Purple
UNDERSIZE
Unit: mm (in)
Items Thickness Main journal diameter

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

Unit: mm (in)

Main bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026)
*: Actual clearance
Connecting Rod Bearing INFOID:0000000012856691
CONNECTING ROD BEARING

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

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

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

CONNECTING ROD BEARING OIL CLEARANCE
Unit: mm (in) A
Connecting rod bearing oil clearance 0.020 - 0.045 (0.0008 - 0.0018)* 0.070 (0.0028)
EM
*: Actual clearance
Drive Plate INFOID:0000000012856692
C
Unit: mm (in)
Drive plate runout [TIR]* - on torque converter mount surface Less than 0.35 (0.0138)
Drive plate runout [TIR]* - on ring gear 0.5 (0.0197) D
*: Total indicator reading

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ENGINE

PRECAUTIONS ................................................... 3 SPARK PLUG ................................................... 16

AIR CLEANER FILTER ......................................15 IGNITION COIL ................................................. 42

Revision: April 2016 EM-1 2016 QX60

Revision: April 2016 EM-2 2016 QX60

Precaution for Disconnecting Fuel Piping INFOID:0000000012856609

Revision: April 2016 EM-3 2016 QX60

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

REMOVAL OF LIQUID GASKET

Tool number : KV10111100 (J-37228)

LIQUID GASKET APPLICATION PROCEDURE

Revision: April 2016 EM-4 2016 QX60

• If there is a groove for the liquid gasket application, apply the H

Revision: April 2016 EM-5 2016 QX60

KV10107902 Removing valve oil seal

KV10115600 Installing valve oil seal

EM03470000 Installing piston assembly into cylinder bore

ST16610001 Removing crankshaft pilot bushing

KV10111100 Removing steel oil pan and rear timing chain

Revision: April 2016 EM-6 2016 QX60

KV10112100 Tightening bolts for cylinder head, main bear- D

KV10114400 Loosening or tightening rear heated oxygen

— Installing rear main seal

Commercial Service Tool INFOID:0000000012856616

Revision: April 2016 EM-7 2016 QX60

( — ) Loosening nuts, screws and bolts

( — ) Removing and installing spark plug

( — ) Finishing valve seat dimensions

( — ) Removing and installing piston ring

( — ) Removing and installing valve guide

( — ) Reaming valve guide 1 or hole for oversize

Revision: April 2016 EM-8 2016 QX60

( — ) Lubricating oxygen sensor thread cleaning

Revision: April 2016 EM-9 2016 QX60

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

Revision: April 2016 EM-10 2016 QX60

1. Locate the area where noise occurs. C

Operating condition of engine

Piston and piston pin

Revision: April 2016 EM-11 2016 QX60

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

Checking Drive Belt INFOID:0000000012856620

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

Revision: April 2016 EM-12 2016 QX60

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

Revision: April 2016 EM-13 2016 QX60

1. Drive belt auto-tensioner

Revision: April 2016 EM-14 2016 QX60

Removal and Installation INFOID:0000000012856625

Revision: April 2016 EM-15 2016 QX60

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

Removal and Installation INFOID:0000000012856627

INSPECTION AFTER REMOVAL

Revision: April 2016 EM-16 2016 QX60

Cleaner air pressure : less than 588 kPa (6 kg/cm2,

Revision: April 2016 EM-17 2016 QX60

a. Align pointer with TDC mark (A) on crankshaft pulley.

Revision: April 2016 EM-18 2016 QX60

a. Using a feeler gauge, measure the clearance between the valve