Engine Mechanical

ENGINE
EM
A
EM
SECTION
ENGINE MECHANICAL C
E
CONTENTS
QR25DE Inspection ................................................................24 F
Adjustment ...............................................................24
PRECAUTION ............................................... 6
AIR CLEANER FILTER ..................................... 25
G
PRECAUTIONS ................................................... 6 Exploded View .........................................................25
Precaution for Supplemental Restraint System Removal and Installation .........................................25
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Inspection (Dry Paper Type) ....................................26
SIONER" ................................................................... 6 H
Precaution Necessary for Steering Wheel Rota- SPARK PLUG ................................................... 27
tion After Battery Disconnect ..................................... 6 Exploded View .........................................................27
Precaution for Procedure without Cowl Top Cover...... 7 Removal and Installation .........................................27 I
Precautions For Engine Service ................................ 7 Inspection ................................................................27
Special Cautions to Ensure the Safe Disposal of
Sodium-filled Exhaust Valves .................................... 8
REMOVAL AND INSTALLATION ............... 29
J
Parts Requiring Angle Tightening ............................. 9 DRIVE BELT AUTO-TENSIONER .................... 29
Precaution for Liquid Gasket ..................................... 9 Exploded View .........................................................29
Removal and Installation .........................................29
PREPARATION ........................................... 11 K
AIR CLEANER AND AIR DUCT ....................... 30
PREPARATION ..................................................11
Exploded View .........................................................30
Special Service Tools ............................................ 11 L
Removal and Installation .........................................30
Commercial Service Tool ........................................ 12
Inspection ................................................................31
BASIC INSPECTION ................................... 16 ROCKER COVER ............................................. 32
M
CAMSHAFT VALVE CLEARANCE ...................16 Exploded View .........................................................32
Inspection and Adjustment ...................................... 16 Removal and Installation .........................................32
Inspection ................................................................35
COMPRESSION PRESSURE ............................19 N
Inspection ................................................................ 19 INTAKE MANIFOLD ......................................... 36
Exploded View .........................................................36
SYMPTOM DIAGNOSIS .............................. 21 Removal and Installation .........................................36 O
Inspection ................................................................38
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................21 EXHAUST MANIFOLD AND THREE WAY
NVH Troubleshooting Chart .................................... 21 CATALYST ........................................................ 39 P
Exploded View .........................................................39
PERIODIC MAINTENANCE ......................... 23 Removal and Installation .........................................39
Inspection ................................................................41
DRIVE BELTS ....................................................23
Exploded View ........................................................ 23 FUEL INJECTOR AND FUEL TUBE ................ 42
Removal and Installation ......................................... 23 Exploded View .........................................................42
Revision: November 2016 EM-1 2017 D23

Removal and Installation ........................................ 42 SERVICE DATA AND SPECIFICATIONS
Inspection ............................................................... 46 (SDS) ......................................................... 117
OIL PAN AND OIL STRAINER .......................... 47 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 47 (SDS) ................................................................ 117
Removal and Installation ........................................ 47
General Specification ........................................... 117
Inspection ............................................................... 49
Drive belt ............................................................... 117
TIMING CHAIN .................................................. 50 Spark Plug ............................................................ 117
Exploded View ........................................................ 50 Exhaust Manifold .................................................. 118
Removal and Installation ........................................ 51 Camshaft ............................................................... 118
Inspection ............................................................... 59 Cylinder Head ...................................................... 119
Cylinder Block ...................................................... 122
CAMSHAFT ....................................................... 61 Main Bearing ........................................................ 125
Exploded View ........................................................ 61 Connecting Rod Bearing ..................................... 127
Removal and Installation ........................................ 62 YD25DDTi
Inspection ............................................................... 66
PRECAUTION ........................................... 128
CYLINDER HEAD .............................................. 70
Exploded View ........................................................ 70 PRECAUTIONS ................................................ 128
Removal and Installation ........................................ 71 Precaution for Supplemental Restraint System
Disassembly and Assembly .................................... 73 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
Inspection ............................................................... 77 SIONER" ............................................................... 128
Precaution Necessary for Steering Wheel Rota-
FLYWHEEL ........................................................ 80 tion After Battery Disconnect ................................ 128
Exploded View ........................................................ 80 Precaution for Procedure without Cowl Top Cover. 129
Removal and Installation ........................................ 80 Precautions For Engine Service ........................... 129
Inspection ............................................................... 81 Parts Requiring Angle Tightening ......................... 129
Precaution for Liquid Gasket ................................. 130
OIL SEAL ........................................................... 82 Precaution for Diesel Equipment .......................... 131
VALVE OIL SEAL ..................................................... 82
VALVE OIL SEAL : Removal and Installation ......... 82
PREPARATION ......................................... 135
FRONT OIL SEAL ..................................................... 83 PREPARATION ................................................ 135

FRONT OIL SEAL : Removal and Installation ........ 83 Special Service Tool ............................................. 135
Commercial Service Tool ...................................... 138
REAR OIL SEAL ....................................................... 84 Sealant or/and Lubricant ....................................... 139
REAR OIL SEAL : Removal and Installation .......... 84
BASIC INSPECTION ................................. 141
UNIT REMOVAL AND INSTALLATION ..... 86
CAMSHAFT VALVE CLEARANCE ................. 141
ENGINE ASSEMBLY ......................................... 86 Inspection and Adjustment .................................... 141
Exploded View ........................................................ 86
Removal and Installation ........................................ 86 COMPRESSION PRESSURE .......................... 145
Inspection ............................................................... 88 Inspection .............................................................. 145
UNIT DISASSEMBLY AND ASSEMBLY ... 89 SYMPTOM DIAGNOSIS ........................... 147
ENGINE STAND SETTING ................................ 89 NOISE, VIBRATION AND HARSHNESS

Setting .................................................................... 89 (NVH) TROUBLESHOOTING ........................... 147
NVH Troubleshooting - Engine Noise ................... 147
CYLINDER BLOCK ........................................... 90 Use the Chart Below to Help You Find the Cause
Exploded View ........................................................ 90 of the Symptom ..................................................... 148
Disassembly and Assembly .................................... 90
Inspection ............................................................... 98 PERIODIC MAINTENANCE ...................... 149
HOW TO SELECT PISTON AND BEARING ... 108 DRIVE BELT ..................................................... 149
Description .............................................................108 Exploded View ...................................................... 149
Piston .....................................................................108 Removal and Installation ....................................... 149
Connecting Rod Bearing .......................................109 Inspection .............................................................. 150
Main Bearing .........................................................112 Adjustment ............................................................ 151

AIR CLEANER FILTER .................................... 152 SECONDARY TIMING CHAIN ........................ 182
Exploded View ...................................................... 152 Exploded View ....................................................... 182 A
Removal and Installation ....................................... 152 Removal and Installation ....................................... 182
Inspection .............................................................. 186
REMOVAL AND INSTALLATION ............. 154
FUEL PUMP .................................................... 187 EM
ENGINE COVER .............................................. 154 Exploded View ....................................................... 187
Exploded View ...................................................... 154 Removal and Installation ....................................... 188
Removal and Installation ....................................... 154 Disassembly and Assembly ................................... 193 C
Inspection .............................................................. 194
DRIVE BELT AUTO TENSIONER AND IDLER
PULLEY ............................................................ 155 CAMSHAFT ..................................................... 195 D
Exploded View ...................................................... 155 Exploded View ....................................................... 195
Removal and Installation ....................................... 155 Removal and Installation ....................................... 195
Inspection .............................................................. 198
AIR CLEANER AND AIR DUCT ...................... 156 E
Exploded View ...................................................... 156 CYLINDER HEAD ........................................... 203
Removal and Installation ....................................... 156 Exploded View ....................................................... 203
Inspection .............................................................. 157 Removal and Installation ....................................... 204 F
Disassembly and Assembly ................................... 207
CHARGE AIR COOLER ................................... 158 Inspection .............................................................. 209
Exploded View ...................................................... 158
Removal and Installation ....................................... 158 OIL PAN AND OIL STRAINER ....................... 214 G
Inspection .............................................................. 159 Exploded View ....................................................... 214
Removal and Installation ....................................... 214
INTAKE MANIFOLD ......................................... 160 Inspection .............................................................. 217 H
Exploded View ...................................................... 160
Removal and Installation ....................................... 160 PRIMARY TIMING CHAIN .............................. 219
Removal and Installation ....................................... 220 I
EGR SYSTEM .................................................. 163 Inspection .............................................................. 231
Exploded View ...................................................... 163
Removal and Installation ....................................... 164 VACUUM PUMP .............................................. 233 J
Exploded View ....................................................... 233
CATALYST ....................................................... 166 Removal and Installation ....................................... 233
Exploded View ...................................................... 166 Inspection .............................................................. 234
Removal and Installation ....................................... 166 K
DRIVE PLATE ................................................. 235
TURBO CHARGER .......................................... 167 Exploded View ....................................................... 235
Exploded View ...................................................... 167 Removal and Installation ....................................... 235 L
Removal and Installation ....................................... 167 Inspection .............................................................. 237
Inspection .............................................................. 168
FLYWHEEL ..................................................... 238
EXHAUST MANIFOLD ..................................... 171 Exploded View ....................................................... 238 M
Exploded View ...................................................... 171 Removal and Installation ....................................... 238
Removal and Installation ....................................... 171 Inspection .............................................................. 239
Inspection .............................................................. 172 N
OIL SEAL ........................................................ 241
GLOW PLUG .................................................... 173
Exploded View ...................................................... 173 VALVE OIL SEAL .................................................... 241
Removal and Installation ....................................... 173 VALVE OIL SEAL : Removal and Installation ........ 241 O
INJECTION TUBE AND FUEL INJECTOR ...... 174 FRONT OIL SEAL .................................................... 242
Exploded View ...................................................... 174 FRONT OIL SEAL : Removal and Installation ....... 242
P
REAR OIL SEAL ...................................................... 243
Inspection .............................................................. 178
REAR OIL SEAL : Removal and Installation ......... 243
ROCKER COVER ............................................. 179
Exploded View ...................................................... 179 UNIT REMOVAL AND INSTALLATION .... 245
Removal and Installation ....................................... 179 ENGINE ASSEMBLY ...................................... 245
Inspection .............................................................. 181
Exploded View ....................................................... 245

Removal and Installation .......................................245 NOISE, VIBRATION AND HARSHNESS
Inspection ..............................................................247 (NVH) TROUBLESHOOTING ........................... 297
NVH Troubleshooting - Engine Noise ................... 297
UNIT DISASSEMBLY AND ASSEMBLY .. 249 Use the Chart Below to Help You Find the Cause
ENGINE STAND SETTING .............................. 249 of the Symptom ..................................................... 298
Setting ...................................................................249 PERIODIC MAINTENANCE ...................... 299
CYLINDER BLOCK ......................................... 250 DRIVE BELT ..................................................... 299
Exploded View .......................................................250
Exploded View ...................................................... 299
Disassembly and Assembly ...................................251
Inspection ..............................................................257
Inspection .............................................................. 301
HOW TO SELECT PISTON AND BEARING ... 268 Adjustment ............................................................ 302
Description .............................................................268 AIR CLEANER FILTER .................................... 303
Piston .....................................................................268
Exploded View ...................................................... 303
Connecting Rod Bearing .......................................269
Main Bearing .........................................................271
Inspection (Dry Paper Type) ................................. 304
SERVICE DATA AND SPECIFICATIONS REMOVAL AND INSTALLATION ............. 305
(SDS) .......................................................... 274
ENGINE COVER ............................................... 305
SERVICE DATA AND SPECIFICATIONS Exploded View ...................................................... 305
(SDS) ................................................................ 274 Removal and Installation ....................................... 305
General Specification ............................................274
Drive belt ...............................................................274 DRIVE BELT AUTO TENSIONER AND IDLER
Intake Manifold ......................................................275 PULLEY ............................................................ 306
Exhaust Manifold ...................................................275 Exploded View ...................................................... 306
Camshaft ...............................................................275 Removal and Installation ....................................... 306
Cylinder Head ........................................................277
Cylinder Block ........................................................280 AIR CLEANER AND AIR DUCT ....................... 307
Main Bearing .........................................................282 Exploded View ...................................................... 307
Connecting Rod Bearing .......................................283 Removal and Installation ....................................... 307
YS23DDT/YS23DDTT (M9T) Inspection .............................................................. 308
CHARGE AIR COOLER ................................... 309

PRECAUTION ............................................ 285
Exploded View ...................................................... 309
PRECAUTIONS ............................................... 285 Removal and Installation ....................................... 310
Precaution for Supplemental Restraint System Inspection .............................................................. 312
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
INTAKE MANIFOLD ......................................... 314
SIONER" ................................................................285
Exploded View ...................................................... 314
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect .................................285
Inspection .............................................................. 315
Precaution for Procedure without Cowl Top Cover..286
Precautions For Engine Service ............................286 EGR SYSTEM ................................................... 316
Parts Requiring Angle Tightening ..........................287 Exploded View ...................................................... 316
Precaution for Liquid Gasket .................................287 Removal and Installation ....................................... 317
Precaution for Diesel Equipment ...........................288
DPF (DIESEL PARTICULATE FILTER) ........... 319
PREPARATION .......................................... 292 Exploded View ...................................................... 319
Removal and installation ....................................... 319
PREPARATION ............................................... 292
Special Service Tools ............................................292 EXHAUST MANIFOLD AND TURBOCHARG-
Commercial Service Tools .....................................293 ER ASSEMBLY ................................................ 321
Exploded View ...................................................... 321
BASIC INSPECTION .................................. 296 Removal and Installation ....................................... 322
COMPRESSION PRESSURE .......................... 296 Inspection .............................................................. 325
Inspection ..............................................................296 TURBOCHARGER ........................................... 326
SYMPTOM DIAGNOSIS ............................ 297 Exploded View ...................................................... 326

Removal and Installation ....................................... 326 ENGINE ASSEMBLY ...................................... 366
Inspection .............................................................. 327 Exploded View ....................................................... 366 A
OIL PAN (LOWER) ........................................... 329 Inspection .............................................................. 372
Exploded View ...................................................... 329
Removal and Installation ....................................... 330 UNIT DISASSEMBLY AND ASSEMBLY . 373 EM
Inspection .............................................................. 331
ENGINE STAND SETTING ............................. 373
GLOW PLUG .................................................... 332 Setting ................................................................... 373 C
Exploded View ...................................................... 332
Removal and Installation ....................................... 332 FLYWHEEL ..................................................... 374
Exploded View ....................................................... 374
VACUUM PUMP ............................................... 333 D
Exploded View ...................................................... 333
Removal and Installation ....................................... 333 DRIVE PLATE ................................................. 376
Exploded View ....................................................... 376 E
OIL SEPARATOR ............................................ 335 Removal and Installation ....................................... 376
Exploded View ...................................................... 335
Removal and Installation ....................................... 335 OIL PAN (UPPER) .......................................... 378
Exploded View ....................................................... 378 F
INJECTION TUBE AND FUEL INJECTOR ...... 338 Removal and Installation ....................................... 379
Exploded View ...................................................... 338
Removal and Installation ....................................... 338 CYLINDER HEAD ........................................... 381 G
FUEL PUMP ..................................................... 341 Disassembly and Assembly ................................... 383
Exploded View ...................................................... 341 H
Inspection .............................................................. 385
Inspection .............................................................. 342 CYLINDER BLOCK ......................................... 387
Exploded View ....................................................... 387 I
FUEL PUMP SPROCKET ................................ 343 Disassembly and Assembly ................................... 388
Exploded View ...................................................... 343 Backlash Adjustment ............................................. 398
Removal and Installation ....................................... 343 Inspection .............................................................. 401 J
TIMING CHAIN ................................................. 346 HOW TO SELECT PISTON AND BEARING .. 407
Exploded View ...................................................... 346 Description ............................................................. 407
Removal and Installation ....................................... 347 Piston ..................................................................... 407 K
Inspection .............................................................. 352 Connecting Rod Bearing ...................................... 408
Main Bearing ......................................................... 410
TIMING SPROCKET ........................................ 354
Exploded View ...................................................... 354 L
SERVICE DATA AND SPECIFICATIONS
Removal and installation ....................................... 355 (SDS) .......................................................... 413
CAMSHAFT ...................................................... 358 SERVICE DATA AND SPECIFICATIONS M
Exploded View ...................................................... 358
(SDS) ............................................................... 413
General Specification ............................................ 413
Inspection .............................................................. 362
Drive Belts ............................................................. 413 N
OIL SEAL ......................................................... 364 Intake Manifold ...................................................... 413
Exhaust Manifold ................................................... 413
FRONT OIL SEAL ................................................... 364 Turbocharger ......................................................... 414 O
FRONT OIL SEAL : Removal and Installation ...... 364 Camshaft ............................................................... 414
Cylinder Head ........................................................ 414
REAR OIL SEAL ..................................................... 364
Cylinder Block ........................................................ 416
REAR OIL SEAL : Removal and Installation ......... 364 P
Main Bearing ......................................................... 420
UNIT REMOVAL AND INSTALLATION .... 366 Connecting Rod Bearing ....................................... 421

PRECAUTIONS
< PRECAUTION > [QR25DE]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000014504279
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the SR and SB section of
this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, 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
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-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
battery or batteries, and wait at least three minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000014267029
NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If
a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure
below before starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Carry the Intelligent Key or insert it to the key slot and turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT.

PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000014267030
A
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. EM
D
PIIB3706J
Precautions For Engine Service INFOID:0000000014267031

E
DISCONNECTING FUEL PIPING
• Before starting work, check no fire or spark producing items are in the work area.
• Release fuel pressure before disconnecting and disassembly. F
• After disconnecting pipes, plug openings to stop fuel leakage.
DRAINING ENGINE COOLANT G

Drain engine coolant and engine oil when the engine is cooled.
H
INSPECTION, REPAIR AND REPLACEMENT
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
I
REMOVAL AND DISASSEMBLY
• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations. J
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position. K
• Must cover openings of engine system with a tape or equivalent, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used L
in the step.
ASSEMBLY AND INSTALLATION M

• 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, N
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
O
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.
• After disassembling, exposing any internal engine parts, change engine oil and replace oil filter with a new P
one.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.

PRECAUTIONS
Special Cautions to Ensure the Safe Disposal of Sodium-filled Exhaust Valves
INFOID:0000000014267032
Handling and disposal of sodium-filled exhaust valves requires spe-

cial care and consideration. Under conditions such as breakage with
subsequent contact with water, metal sodium which lines the inner
portion of exhaust valve will react violently, forming sodium hydrox-
ide and hydrogen which may result in an explosion. Sodium-filled
exhaust valve is identified on the top of its stem as shown in illustra-
tion.
Identification mark of sodium-filled exhaust valve (A) :4JM
JPBIA6407ZZ
DEALER DISPOSAL INSTRUCTIONS

CAUTION:
• Use approved shatter-resistant eye protection when performing this procedure.
• Perform this and all subsequent disposal work procedures in an open room, away from flammable
liquids. Keep a fire extinguisher, rated at least 10 ABC, in close proximity to the work area.
• Be sure to wear rubber gloves when performing the following operations.
• Make sure the resultant (high alkalinity) waste water does not contact your skin. If the waste water
does contact you, wash the contacted area immediately with large quantities of water.
• Dealers should check their respective state and local regulations concerning any chemical treatment
or waste water discharge permits which may be required to dispose of the resultant (high alkalinity)
waste water.
1. Clamp valve stem in a vice.
2. The valve has a specially-hardened surface. To cut through it,
first remove a half-round section, approximately 30 mm (1.18 in)
long using air-powered grinder until black color is removed and
silver color appears.
(A) : Black color

(B) : Silver color
(c) : 47 mm (1.85 in)
(d) : 17 mm (0.67 in)
JPBIA4964ZZ
3. Use hacksaw to cut through approximately half the diameter of

valve stem. Make the serration at a point 40 mm (1.57 in) from
the end of valve stem.
(a) : 40 mm (1.57 in)
JPBIA4965ZZ

PRECAUTIONS
4. Cover the serrated end of the valve with a large shop towel (A).
Strike the valve face end with a hammer, separating it into two A
pieces.
EM
JPBIA4966ZZ
D
5. Fill a bucket (A) (such as a 20 oil can) with at least 10 (2-1/
4 lmp gal) of water. Carefully place the already cut (serrated)
valves into the water one-at-a-time using a set of large tweezers E
and quickly move away at least 2.7 m (9 ft).
6. The valves should be placed in a standing position as shown in
the illustration to allow complete reaction. After the bubbling
action has subsided, additional valves can be placed into the F
bucket allowing each subsequent chemical reaction to subside.
However, no more than 8 valves should be placed in the same
10 (2-1/4 lmp gal) amount of water. The complete chemical G
reaction may take as long as 4 to 5 hours. Remove the valves JPBIA4967ZZ
using a set of large tweezers after the chemical reaction has
stopped. Afterwards, valves can be disposed as ordinary scrap.
H
Parts Requiring Angle Tightening INFOID:0000000014267033
• For the final tightening of the following engine parts use Tool: I
Tool number : KV10112100 (BT-8653-A)

- Cylinder head bolts J
- Lower cylinder block bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as bolt flange is provided with notches for angle tighten-
ing) K
• 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. L
Precaution for Liquid Gasket INFOID:0000000014267034
M
REMOVAL OF LIQUID GASKET SEALING
CAUTION:
Do not damage the mating surfaces.
• After removing the bolts and nuts, separate the mating surface and N
remove the liquid gasket using Tool (A).
Tool number (A) : KV10111100 (J-37228) O

• In areas where the cutter is difficult to use, use a plastic hammer to
lightly tap (1) the cutter where the liquid gasket is applied. Use a
plastic hammer to slide (2) the cutter by tapping on the side. P
AWBIA1249GB
LIQUID GASKET APPLICATION PROCEDURE

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

Use Genuine Silicone RTV Sealant, or equivalent. Refer to
GI-22, "Recommended Chemical Products and Sealants".
4. Apply liquid gasket without gaps to the specified location accord-
ing to the specified dimensions.
• If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
EMA0622D
• As for bolt holes (B), normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Check to read the text of this manual.
(A) : Groove
: Inside
• Within five minutes of liquid gasket application, install the mat-

ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill JPBIA0010ZZ
engine oil and engine coolant. Refer to LU-10, "Changing Engine Oil" and LU-10, "Changing Engine
Oil".
CAUTION:
If there are more specific instructions in the procedures contained in this manual concerning liquid
gasket application, observe them.

PREPARATION
< PREPARATION > [QR25DE]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000014267035
EM
The actual shape of the tools may differ from those illustrated here.
Tool number Description C
(TechMate No.)
Tool name
— Reconditioning the exhaust system threads D
(J-43897-18) before installing a new oxygen sensor (Use
Oxygen sensor thread cleaner with anti-seize lubricant shown below.)
J-43897-18 (18 mm dia.) for zirconia oxy-
gen sensor E
AWBIA2076ZZ F
— Removing and installing crankshaft pulley
(J-50288)
Ring gear stopper G
H
ALBIA0675ZZ
— Removing and installing spark plug

(J-48891) I
Spark plug socket
AWBIA1785ZZ
K
KV10111100 Removing oil pan and timing chain case
(J-37228)
Seal cutter
L
M
S-NT046
KV991J0050 Loosening or tightening air fuel ratio A/F sen-

(J-44626) sor
Air fuel sensor Socket a: 22 mm (0.87 in) N
LBIA0444E
KV10114400 Loosening or tightening rear heated oxygen P

(J-38365) sensor
Heated oxygen sensor wrench a: 22 mm (0.87 in)
NT636

PREPARATION
Tool number Description
(TechMate No.)
Tool name
— Installing front main seal
(J-37066)
Seal installer
AWBIA2081ZZ
— Installing rear main seal

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

(BT-8653-A) head, etc.
Torque angle meter
S-NT014
Commercial Service Tool INFOID:0000000014267036

(TechMate No.)
Tool name
KV10117100 Loosening or tightening air fuel ratio sensor 1
(J-36471-A) a: 22 mm (0.87 in)
Heated oxygen sensor wrench
NT379
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
— Removing and installing engine

( — )
Manual lift table caddy
ZZA1210D

PREPARATION
(TechMate No.) A
Tool name
ST16610001 Removing crankshaft pilot converter
(J-23907) EM
Pilot converter puller
S-NT045
— Pressing the tube of liquid gasket D

( — )
Tube presser
E
S-NT052 F
— Installing piston assembly into cylinder bore
( — )
Piston ring compressor G
H
S-NT044
— Removing and installing crankshaft pulley

( — ) (Holding crankshaft pulley) I
Pulley holder
ZZA1010D
K
— Removing crankshaft pulley
( — )
Pulley puller
L
M
NT676
— Finishing valve seat dimensions

( — )
N
Valve seat cutter set
S-NT048
— Removing and installing piston ring P

( — )
Piston ring expander
S-NT030

PREPARATION
(TechMate No.)
Tool name
— Installing valve oil seal
(J-39386)
Valve oil seal drift
NT024
— Removing and installing valve guide

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

( — ) 2: Reaming hole for oversize valve guide
Valve guide reamer Intake & Exhaust:
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
S-NT016
— Lubricating oxygen sensor thread cleaning

( — ) tool when reconditioning exhaust system
Anti-seize lubricant (Permatex 133AR threads
or equivalent meeting MIL specifica-
tion MIL-A-907)
AEM489
KV10115600 Installing valve oil seal

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

( — )
Power tool
PIIB1407E
KV10107902 Removing valve oil seal

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

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

( — )
Engine sub-attachment G
ZZA1078D

CAMSHAFT VALVE CLEARANCE
< BASIC INSPECTION > [QR25DE]
BASIC INSPECTION
Inspection and Adjustment INFOID:0000000014267037
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-32, "Exploded View".
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
JPBIA7010ZZ
• At the same time, check that both intake and exhaust cam
noses of No. 1 cylinder face outside as shown in the figure.
• If they do not face outside, rotate crankshaft pulley once more
(360 degrees) and align as shown in the figure.
ALBIA0882GB
b. Use a feeler gauge, measure the clearance between valve lifter

and camshaft.
Valve clearance : Refer to EM-118, "Camshaft".
SEM139D

• By referring to the figure, measure the valve clearances at
locations marked “×” as shown in the table below [locations A
indicated with black arrow ( ) in the figure] with a feeler
gauge.
EM
(A) : No. 1 cylinder at compression TDC
(B) : Intake side
(C) : No. 1 cylinder
C
(D) : No. 2 cylinder
(E) : No. 3 cylinder
JSBIA3309ZZ
(F) : No. 4 cylinder
D
(G) : Exhaust side
: Engine front
E
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
INT × × F
No. 1 cylinder at compression TDC
EXH × ×
c. Rotate crankshaft pulley (1) one revolution (360 degrees) and
align TDC mark (no paint) (B) to timing indicator (A) on front G
cover.
JPBIA7010ZZ
J
• By referring to the figure, measure the valve clearance at loca-

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

(B) : Intake side L
(C) : No. 1 cylinder
(D) : No. 2 cylinder
(E) : No. 3 cylinder
M
(F) : No. 4 cylinder
JSBIA3310ZZ
(G) : Exhaust side
N
: Engine front
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
O
INT × ×
No. 4 cylinder at compression TDC
EXH × ×
P
3. If out of standard, perform adjustment. Refer to "ADJUSTMENT".
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-61, "Exploded View".
2. Remove valve lifters at the locations that are out of the standard.

3. Measure the center thickness of the removed valve lifters with a
micrometer (A).
JSBIA2416ZZ
4. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1 – C2)

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.28 mm (0.011 in)
Exhaust : 0.30 mm (0.012 in)
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder).
• Stamp mark “720” indicates 7.20 mm (0.2835 in) in thickness.
NOTE:
Available thickness of valve lifter: 26 sizes range 6.96 to 7.46
mm (0.1181 to 0.1378 in) in steps of 0.02 mm (0.0008 in)
(when manufactured at factory). Refer to EM-118, "Camshaft".
PBIC3196J
5. Install the selected valve lifter.

6. Install camshaft. Refer to EM-61, "Exploded View".
7. Install timing chain and related parts. Refer to EM-50, "Exploded View".
8. Manually rotate crankshaft pulley a few rotations.
9. Check that the valve clearances is within the standard. Refer to “INSPECTION”.
10. Install remaining parts in the reverse order of removal.
11. Warm up the engine, and check for unusual noise and vibration.

COMPRESSION PRESSURE
A
Inspection INFOID:0000000014267038
1. Warm up engine thoroughly. Then, stop it. EM

2. Release fuel pressure. Refer to EC-140, "Work Procedure".
3. Disconnect fuel pump fuse to avoid fuel injection during measurement. Refer to PG-137, "Fuse, Connec-
tor and Terminal Arrangement". C
4. Remove ignition coil and spark plug from each cylinder. Refer to EM-27, "Exploded View".
5. Connect engine tachometer (not required in use of CONSULT).
6. Install compression tester (A) with adapter onto spark plug hole. D
JPBIA7079ZZ
G
• Use compression tester whose end (a) (rubber portion) is

smaller than 25 mm (0.98 in) in diameter. Otherwise, it may be H
caught by cylinder head during removal.
JPBIA0171ZZ
K
7. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cyl-
inder. L
Compression pressure : Refer to EM-117, "General Specification".

CAUTION: M
Always use a fully changed battery to obtain specified engine speed.
• If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine speed
again with normal battery gravity. N
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure the compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole O
of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary. P
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, gaskets are leaking. In such a case, replace cylinder head gas-
kets.
8. After inspection is completed, install removed parts.
9. Start engine, and confirm that engine runs smoothly.

10. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-143, "Diagnosis Procedure".

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [QR25DE]
SYMPTOM DIAGNOSIS A
NVH Troubleshooting Chart INFOID:0000000014267039
EM
AWBIA2723ZZ
1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of engine.

< SYMPTOM DIAGNOSIS > [QR25DE]
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-16
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
Cylinder Rattle C A — A B C bearing clearance EM-118
head noise Camshaft runout
Piston to piston pin oil

Slap or Piston pin clearance
— A — B B — EM-98
knock noise Connecting rod bushing
oil clearance
Piston to cylinder bore
Crank- clearance
EM-122
shaft pul- Piston ring side clear-
Slap or Piston EM-122
ley A — — B B A ance
rap slap noise EM-122
Cylinder Piston ring end gap
EM-122
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-122
Knock B A C B B B
bearing Connecting rod bearing EM-127
noise oil clearance
Main bearing oil clear-
Main bear- EM-125
Knock B A — A B C ance
ing noise EM-122
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-59
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-51
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-23
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-22
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

DRIVE BELTS
< PERIODIC MAINTENANCE > [QR25DE]
PERIODIC MAINTENANCE A
DRIVE BELTS
Exploded View INFOID:0000000014267040
EM
AWBIA2712ZZ
G
1. Power steering oil pump 2. Idler pulley 3. Generator

4. Crankshaft pulley 5. Drive belt auto tensioner 6. A/C compressor or idler pulley H
7. Water pump A. Indicator (notch on the fixed side) B. Possible use range
C. Range when new drive belt is in-
stalled I
Removal and Installation INFOID:0000000014267041
J
REMOVAL
1. Securely hold the hexagonal part (A) of drive belt auto-tensioner
(1) using suitable tool, and move in the direction of arrow ( ) K
(loosening direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off. L
2. Insert a rod approximately 6.0 mm (0.24 in) in diameter through
the rear of the drive belt auto-tensioner into retaining boss (B) to
lock drive belt auto-tensioner pulley. M
NOTE:
Leave drive belt auto-tensioner pulley arm locked until drive belt JPBIA7013ZZ
is installed again. N
3. Loosen drive belt from drive belt auto-tensioner and then remove it from the other pulleys.
INSTALLATION
1. Install the drive belt onto all of the pulleys except for the drive belt auto-tensioner. Then install the drive O
belt onto drive belt auto-tensioner last.
CAUTION:
Confirm belts are completely set on the pulleys. P
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm the indicator is within the possible use range. Refer to EM-24, "Inspection".

DRIVE BELTS
JPBIA7012ZZ
1. Power steering oil pump 2. Idler pulley 3. Generator

4. Crankshaft pulley 5. Drive belt auto tensioner 6. A/C compressor or idler pulley
7. Water pump A. Indicator (notch on the fixed side) B. Possible use range
C. Range when new drive belt is in-
stalled
WARNING:
Inspect and check the drive belt with the engine off.
• Check that the indicator (A) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(B) in the figure.
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (C) in the fig-
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Adjustment INFOID:0000000014267043
Refer to : EM-117, "Drive belt".

AIR CLEANER FILTER
AIR CLEANER FILTER
A
EM
I
ALBIA1311ZZ
1. Mass air flow sensor 2. Air cleaner cover 3. Air cleaner filter J
4. Air cleaner case 5. Bracket 6. Grommet
7. Bracket 8. Grommet 9. Resonator
10. Air inlet 11. Clip 12. Air duct K
A. To rocker cover B. To hoodledge (RH) C. To hoodledge (RH)
D. To hoodledge (RH) E. To upper core support Front
L
REMOVAL M
1. Release the air cleaner case clips (A).
: Front N
P
JPBIA7080ZZ

AIR CLEANER FILTER
2. Open the air cleaner cover (1).
JPBIA7081ZZ
3. Remove the air cleaner filter (1).
JPBIA7082ZZ
INSTALLATION
Installation is in the reverse order of removal.
Inspection (Dry Paper Type) INFOID:0000000014267046
INSPECTION AFTER REMOVAL

Examine with eyes that there is no stain, clogging, or damage on air cleaner element.
• Remove dusts (such as dead leafs) on air cleaner element surface and inside cleaner case.
• To clean air cleaner element (1), blow air on it from the air intake manifold side (A) to remove trash or dust.
(B) : Ambient air side

: Air blow direction
CAUTION:
• When blowing air on the air cleaner element, attach the
cover to the air cleaner case and stay away from the vehicle
as much as possible to prevent the entry of dirt into the air
cleaner case.
• Do not blow air from the ambient air side to prevent clog-
ging. When the ambient air side needs to be cleaned, attach
the cover to the intake manifold side and lightly dust by JSBIA3460ZZ
hand.
• If clogging or damage is observed, replace the air cleaner element.

SPARK PLUG
SPARK PLUG
A
EM
G
AWBIA2609ZZ
1. Ignition coil 2. Spark plug 3. Rocker cover

H
Engine front
I
REMOVAL
1. Remove ignition coil.
CAUTION: J
Do not disassemble ignition coil.
2. Remove spark plug using Tool.
K
Tool number : — (J-48891)
CAUTION:
Do not drop or shock spark plug. L
AWBIA1785ZZ
N
INSTALLATION
O
INSPECTION AFTER REMOVAL P

Use standard type spark plug for normal condition.
Spark plug (standard) : Refer to EM-117, "Spark Plug".

Visually check the electrode for dirt and wear and the insulator for burning.
CAUTION:
• Do not drop or shock spark plug.
SPARK PLUG
• Do not use wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used.
Cleaner air pressure : Less than 588 kPa (5.9 bar , 6 kg/
cm2, 85 psi)
Cleaning time : Less than 20 seconds
SMA773C
• Checking and adjusting plug gap is not required between

change intervals.
JPBIA0031ZZ

DRIVE BELT AUTO-TENSIONER
< REMOVAL AND INSTALLATION > [QR25DE]
REMOVAL AND INSTALLATION A

DRIVE BELT AUTO-TENSIONER
EM
AWBIA2610ZZ J
1. Idler pulley 2. Cap 3. Drive belt auto-tensioner

Front K
L
Removal
CAUTION:
The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
M
1. Remove the drive belt. Refer to EM-23, "Removal and Installation".
2. Remove the drive belt auto-tensioner.
Installation N
CAUTION:
• When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
O
• Do not swap the pulley between new and old drive belt auto-tensioner.

AIR CLEANER AND AIR DUCT
ALBIA1311ZZ
1. Mass air flow sensor 2. Air cleaner cover 3. Air cleaner filter
4. Air cleaner case 5. Bracket 6. Grommet
7. Bracket 8. Grommet 9. Resonator
10. Air inlet 11. Clip 12. Air duct
A. To rocker cover B. To hoodledge (RH) C. To hoodledge (RH)
D. To hoodledge (RH) E. To upper core support Front
REMOVAL
1. Remove air duct (inlet).
2. Remove the air cleaner filter. Refer to EM-25, "Removal and Installation".
3. Disconnect the harness connector (A) from mass air flow sensor
and remove the harness retainers (B) from the air cleaner cover.
: Front
JPBIA7083ZZ
4. Disconnect the blow-by hose from air duct side.

5. Loosen clamps at the air duct.

6. Remove the air cleaner cover with mass air flow sensor.
7. Remove air duct. A
8. Remove the air cleaner case.
9. Remove resonator.
EM
10. Remove mass air flow sensor from air cleaner case assembly (if necessary).
CAUTION:
Handle the mass air flow sensor with care:
• Do not shock it. C
• Do not disassemble it.
• Do not touch the internal sensor.
INSTALLATION D
• Align marks. Attach each joint. Screw clamps firmly.
E
(A) : Stopper (electric throttle control actuator side)
(B) : Tab (air duct side)
(C) : Stopper (air cleaner cover side) F
(D) : Tab (air duct side)
: Front
G
K
JPBIA7084ZZ
L
Inspect air duct and resonator assembly for crack or tear.
• If anything found, replace air duct assembly. M

ROCKER COVER
ROCKER COVER
AWBIA2611ZZ
1. Clamp 2. Blow-by hose 3. Clamp

4. PCV valve hose 5. PCV valve 6. O-ring
7. Oil filler cap 8. Rocker cover 9. Rocker cover gasket
A. To air duct B. To intake manifold C. Refer to EM-27, "Exploded View".
D. Comply with the assembly procedure Front
when tightening. Refer to EM-32
REMOVAL
1. Release the fuel pressure. Refer to EC-140, "Work Procedure".
2. Disconnect fuel feed hose. Refer to EM-42, "Exploded View".
3. Disconnect the blow-by hose (1).
(2) : PCV hose

: Front
4. Disconnect the PCV hose.
JPBIA7095ZZ

ROCKER COVER
5. Remove the ignition coils. Refer to EM-27, "Exploded View". A

6. Loosen the bolts in the numerical order as shown using power
tool.
EM
: Engine front
D
JSBIA3328ZZ
7. Remove the rocker cover and the rocker cover gasket.

CAUTION: E
Do not reuse the rocker cover gasket.
8. Remove the oil filler cap (if necessary).
F
INSTALLATION

ROCKER COVER
1. Apply liquid gasket to the position shown (A) with the following procedure:
JSBIA3340ZZ
a. Refer to figure (B) to apply liquid gasket (D) to joint part of camshaft bracket (No. 1) camshaft position
sensor bracket and cylinder head.
b. Refer to figure (C) to apply liquid gasket (E) in 90 degrees to figure (B).
Use Genuine Liquid Gasket or equivalent.
CAUTION:
Attaching should be done within 5 minutes after liquid gasket application.
(f) : {5 mm (0.39 in), φ 4 mm (0.16 in)} from the liquid gasket application center point.
(g) : Liquid gasket application center point is 4 mm (0.16 in) from the edge of camshaft brack-
et surface.
(H) : Liquid gasket application center point
(i) : {10 mm (0.20 in), φ 3 mm (0.12 in)} from the liquid gasket application center point.
2. Install rocker cover gasket to rocker cover.

CAUTION:
Do not reuse the rocker cover gasket.
NOTE:
The rocker cover gasket must be securely installed in the groove in the rocker cover.

ROCKER COVER
3. Install the rocker cover and rocker cover gasket onto the cylinder head.
4. Tighten the rocker cover bolts to specification in two steps in the A
order shown.
: Engine front EM
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) C
JSBIA3328ZZ
D
5. Installation of the remaining components is in the reverse order of removal.

Inspection INFOID:0000000014267057 E
INSPECTION AFTER INSTALLATION

1. Check engine oil level and adjust engine oil. Refer to LU-10, "Changing Engine Oil". F
2. Start engine, and check there is no leaks of engine oil.
3. Stop engine and wait for 10 minutes.
G
4. Check engine oil level again. Refer to LU-10, "Changing Engine Oil".

INTAKE MANIFOLD
INTAKE MANIFOLD
AWBIA2633ZZ
1. EVAP canister purge volume control 2. Clamp 3. EVAP hose

solenoid valve
4. EVAP tube 5. Clamp 6. EVAP hose
7. Intake manifold 8. Intake manifold gasket 9. Stud bolt
10. Electric throttle control actuator gas- 11. Electric throttle control actuator A. To vacuum pipe (canister)
ket
B. To vacuum line C. Refer to INSTALLATION Engine front
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain the engine coolant when the engine is hot.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
1. Remove the air cleaner and air duct. Refer to EM-30, "Removal and Installation".
2. Remove blow-by hose. Refer to EM-32, "Exploded View".

INTAKE MANIFOLD
3. Disconnect the PCV hose (1) and EVAP hose (2) from the intake
manifold. A
: Front
EM
JPBIA7085ZZ
D
4. Remove the brake booster vacuum hose (1) and tube (2) from
the intake manifold.
: Front
E
G
JSBIA5999ZZ
5. Loosen bolts in reverse order as shown, then remove electric

throttle control actuator and electric throttle control actuator gas- H
ket.
CAUTION:
Handle carefully to avoid any damage.
I
AWBIA2634ZZ
K
6. Remove the bolts and nuts in the reverse order shown and
remove the intake manifold assembly with intake manifold gas-
ket. L
: Engine front
CAUTION: M
Cover engine openings to prevent entry of foreign materi-
als.
NOTE:
Disregard No. 6 when loosening. N
AWBIA2635ZZ
INSTALLATION
Installation is in the reverse order of removal. O
• Perform the ″Throttle Valve Closed Position Learning″ when harness connector of electric throttle control
actuator is disconnected. Refer to EC-136, "Description".
• Perform the ″Idle Air Volume Learning″ and ″Throttle Valve Closed Position Learning″ when electric throttle P
control actuator is replaced. Refer to EC-137, "Description" or EC-136, "Description".
Intake Manifold
1. Securely install intake manifold gasket to the groove.
CAUTION:
Do not reuse intake manifold gasket.
2. If studs were removed, install them and tighten to specification.

INTAKE MANIFOLD
Studs : 9.4 N·m (0.96 kg-m, 83 in-lb)

3. Tighten bolts and nuts in numerical order as shown.
: Engine front
CAUTION:
After tightening the five bolts in the order shown, the 1, 6
position designates that the first bolt tightened is to be
retightened to specification.
Bolts 1, 2, 3, 6 : 25.0 N·m (2.6 kg-m, 18 ft-lb)

Nuts 4, 5 : 25.0 N·m (2.6 kg-m, 18 ft-lb) AWBIA2635ZZ
Electric Throttle Control Actuator

1. Install a new electric throttle control actuator gasket on the electric throttle control actuator.
CAUTION:
Do not reuse electric throttle control actuator gasket.
2. Tighten the bolts of electric throttle control actuator equally and
diagonally in several steps in numerical order as shown.
Bolts : 10.0 N·m (1.0 kg-m, 7 ft-lb)
AWBIA2634ZZ

1. Make sure there are no fuel leaks at connections as follows:
a. Apply fuel pressure to fuel lines by turning ignition switch ON (with engine stopped).Then check for fuel
leaks at connections.
NOTE:
Use mirrors for checking on connections out of the direct line of sight.
b. 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.

EXHAUST MANIFOLD AND THREE WAY CATALYST
A
EM
J
JPBIA7023GB
1. Exhaust manifold cover 2. Air fuel ratio sensor 1 3. Exhaust manifold and three way cat- K
alyst assembly
4. Stud bolt 5. Bracket 6. Stud bolt
7. Exhaust manifold gasket A. To exhaust front tube Engine front L
M
REMOVAL
1. Remove the exhaust front tube. Refer to EX-6, "Exploded View".
2. Disconnect the harness connector from air fuel ratio sensor 1. N
3. Remove the fuel tube from clamp (A) and EVAP hose clamp (B).
: Front O
JPBIA7087ZZ

4. Remove the exhaust manifold cover (1).
(A) : Bolts
: Front
JPBIA7025ZZ
5. Loosen the exhaust manifold and three way catalyst nuts in the reverse order as shown.
NOTE:
Only exhaust manifold and three way catalyst nuts 1-5 are appli-
cable to removal. Exhaust manifold and three way catalyst nuts
6-10 will be applicable during installation.
: Front
JPBIA7026ZZ
6. Remove the exhaust manifold and three way catalyst assembly and exhaust manifold and three way cat-
alyst gasket. Discard the exhaust manifold and three way catalyst gasket.
7. Remove the air fuel ratio sensor 1 using suitable tool (A) (if nec-
essary).
CAUTION:
• Be careful not to damage air fuel ratio sensor.
• Discard any air fuel ratio sensor which has been dropped
from a height of more than 0.5 m (19.7 in) onto a hard sur-
face such as a concrete floor; replace with a new one.
JPBIA7088ZZ
INSTALLATION
1. Install studs on cylinder head (if removed). Then tighten to specification.

CAUTION:
Do not reuse studs.
2. Install the exhaust manifold and three way catalyst assembly
and exhaust manifold and three way catalyst gasket. Then
tighten the exhaust manifold and three way catalyst assembly
nuts to specification in the numerical order shown.
CAUTION:
• Do not reuse exhaust manifold and three way catalyst
gasket.
• Do not reuse exhaust manifold and three way catalyst
assembly nuts.
: Front JPBIA7026ZZ

3. Install the air fuel ratio sensor 1 using suitable tool (A) and
tighten to specification (if removed). A
CAUTION:
• Be careful not to damage air fuel ratio sensor.
• Discard any air fuel ratio sensor which has been dropped
EM
from a height of more than 0.5 m (19.7 in) onto a hard sur-
face such as a concrete floor; replace with a new one.
• Do not over-tighten the air fuel ratio sensor 1. Doing so
may cause damage to the air fuel ratio sensor 1, resulting C
in a malfunction and the MIL coming on.
JPBIA7088ZZ
D
4. Install the exhaust manifold cover (1).
(A) : Bolts
E
: Front
CAUTION:
Do not reuse bolts. F
G
JPBIA7025ZZ
5. Installation of remaining components is in the reverse order of removal.

H
INSPECTION AFTER REMOVAL I

Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur-
face with a straightedge (A) and a feeler gauge (B). J
Limit : Refer to EM-118, "Exhaust Manifold".

K
• If it exceeds the limit, replace exhaust manifold.
JSBIA3333ZZ
M

FUEL INJECTOR AND FUEL TUBE
JPBIA7016GB
1. Fuel feed hose 2. Fuel tube 3. O-ring (black)

4. Fuel injector 5. O-ring (green) 6. Clip
A. To under floor piping Engine front
CAUTION:
Do not remove or disassemble parts unless instructed in the figure.
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
NOTE:
ing.
REMOVAL
1. Release the fuel pressure. Refer to EC-140, "Work Procedure".
2. Disconnect the battery negative terminal. Refer to PG-154, "Exploded View".
3. Remove the intake manifold. Refer to EM-36, "Exploded View".

4. Disconnect quick connector (A) with the following procedure:
A
: Front
a. Disconnect fuel feed hose (1) from bracket hose clamp (B).
EM
JPBIA7089ZZ
D
b. Disengage (A) and pull up (B) the pawl of the fuel feed hose
connector retainer (C) to disconnect the fuel feed hose from high
pressure fuel pump.
E
CAUTION:
• Keep parts away from heat source. Especially, be careful
when welding is performed around them.
• Do not expose parts to battery electrolyte or other acids. F
• Do not bent or twist connection between quick connector
and fuel feed hose (with damper) during installation/
removal.
G
• Pull quick connector holding (D).
• Do not remove the retainer.
• Prepare a tray and waste beforehand as fuel leaks out.
• Do not pull with lateral force applied. O-ring inside quick H
connector may be damaged.
Retainer color : Red I
JPBIA4377ZZ
K
• To prevent damage to each joint and protect it from the
entry of foreign matter, cover the joint with plastic bag (A)
or an equivalent. L
NOTE:
If the fuel feed hose is stuck, hold the fuel pipe by hand and dis-
connect it by pushing and pulling.
M
N
JPBIA4378ZZ
5. Disconnect harness connector from fuel injector. O

6. Remove fuel tube and fuel injector assembly.

• Loosen bolts in the reverse order as shown.
: Engine front
CAUTION:
• Be careful to avoid any interference with fuel injector.
• Use a shop cloth to absorb any fuel leakage from fuel
tube.
JPBIA7017ZZ
7. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip (1).
b. Remove fuel injector (2) from fuel tube (3) by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube.
• Be careful not to damage fuel injector nozzle during
removal.
• Do not bump or drop fuel injector.
• Do not disassemble fuel injector.
c. Remove O-ring.
JPBIA7018ZZ
INSTALLATION
1. Install O-rings to fuel injector.
CAUTION:
• Do not reuse O-rings.
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Black

Nozzle side : Green
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil.
• 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 it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring is stretched while installing, do not insert it quickly into fuel
tube.
• Insert O-ring straight into fuel tube. Do not decenter or twist it.
2. Install fuel injector to fuel tube with the following procedure:

a. Insert clip (4) into clip mounting groove (A) on fuel injector (1).
A
(2) : O-ring (Black)
(3) : O-ring (Green)
• Insert clip so that protrusion (B) of fuel injector matches cut- EM
out (C) of clip.
CAUTION:
• Do not reuse clip. Replace it with a new one. C
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (5) with clip attached.
D
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (D) of fuel tube matches
cut-out (E) of clip.
• Check that fuel tube flange (G) is securely fixed in flange fixing E
groove (F) on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off. F
G
JSBIA6025ZZ
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.
CAUTION: H
Be careful not to interfere with fuel injector nozzle.
4. Install fuel tube and injector assembly onto cylinder.
• Tighten bolts in the order as shown. I
: Engine front
J
JPBIA7017ZZ L
5. Connect harness connector to fuel injector.

6. Connect fuel feed hose with the following procedure, and them install the fuel feed hose. M
a. Check no foreign substances are deposited in and around matching pipe and quick connector, and no
damage on them.
b. Quick connector shall be inserted gradually, aligning with the axis of the matching pipe. N
c. Insert the retainer until it clicks and check the retainer is locked.
After insertion, pull the connector and check that the connector
is locked.
O
(A) : Lock position
(B) : Unlock position
P
CAUTION:
If retainer cannot be installed smoothly, quick connector
may be have not been installed correctly. Check connection
again.
JPBIA4381ZZ
d. After attaching the quick connector and fix the hose to the clamp.
7. Install intake manifold. Refer to EM-36, "Exploded View".

Check on Fuel Leakage
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leaks at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
• Perform procedures for “Throttle Valve Closed Position Learning” after finishing repairs. Refer to EC-
136, "Description".
• If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after
finishing repairs. Refer to EC-137, "Description".
2. Start the engine. With engine speed increased, check again that there are no fuel leaks at connection
points.
CAUTION:
Do not touch the engine immediately after stopped, as the engine becomes extremely hot.

OIL PAN AND OIL STRAINER
A
EM
I
JPBIA7028GB
1. Oil pan 2. Drain plug washer 3. Drain plug J

A. Oil pan side Engine front

K
REMOVAL
WARNING: L
To avoid the danger of being scalded, do not drain the engine oil when the engine is hot.
1. Remove steering gear assembly. Refer to ST-30, "Exploded View".
2. Remove front cross member assembly (1). M
: Front
N
JPBIA7090ZZ P
3. Drain engine oil. Refer to LU-10, "Changing Engine Oil".
4. Remove oil pan with the following procedure:

a. Loosen bolts in reverse order as shown.
: Engine front
JPBIA7031ZZ
b. Insert Tool (A) between oil pan and lower cylinder block, and
slide it by tapping on the side of the Tool (A) with a hammer.
CAUTION:
Be careful not to damage the mating surface.
Tool number (A) : KV10111100 (J-37228)
JSBIA2555ZZ
INSTALLATION
1. Install oil pan with the following procedure:
a. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove the old liquid gasket from mating surface of cylin-
der block.
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
JPBIA0053ZZ

b. Apply a continuous bead of liquid gasket (C) using suitable tool
as shown. A
(1) : Oil pan

(b) : 7.5 - 9.5 mm (0.295 - 0.374 in) EM
(d) : φ 4.0 - 5.0 mm (0.157 - 0.197 in)
: Engine outside
Use Genuine Liquid Gasket or equivalent. C

CAUTION:
• Attaching should be done within 5 minutes after liquid
gasket application. D
• Then allow 30 minutes for the liquid gasket to set before
adding oil to the engine.
E
G
JPBIA7034ZZ
c. Tighten bolts in numerical order as shown.

H
: Engine front
JPBIA7031ZZ
K
2. Install oil pan drain plug.
CAUTION:
Do not reuse drain plug washer. L
• Refer to the figure of components of former page for installation direction of washer. Refer to EM-47,
"Exploded View".
NOTE: M
Pour engine oil at least 30 minutes after oil pan is installed.
N

1. Check engine oil level and adjust engine oil. Refer to LU-9, "Inspection". O
2. Start engine, and check there is no leaks of engine oil.
4. Check engine oil level again. Refer to LU-9, "Inspection". P

TIMING CHAIN
TIMING CHAIN
For Chile
AWBIA3137ZZ
1. Chain tensioner 2. O-ring 3. Camshaft sprocket (EXH)

4. Timing chain slack guide 5. Camshaft sprocket (INT) 6. Timing chain
7. Front cover 8. O-ring 9. Valve timing control solenoid valve
cover
10. O-ring 11. Valve timing control solenoid valve 12. Valve timing control solenoid valve
(INT) (EXH)
13. O-ring 14. Front oil seal 15. Crankshaft pulley
16. O-ring 17. Crankshaft key 18. Timing chain tension guide
19. Balancer unit timing chain 20. Crankshaft sprocket 21. Spacer
22. Balancer unit sprocket 23. Balancer unit timing chain tensioner 24. Balancer unit
25. O-ring A. Refer to INSTALLATION Front

TIMING CHAIN
Except for Chile
A
EM
I
AWBIA3136ZZ
1. Chain tensioner 2. O-ring 3. Camshaft sprocket (EXH)

J
4. Timing chain slack guide 5. Camshaft sprocket (INT) 6. Timing chain
7. Front cover 8. Front oil seal 9. Crankshaft pulley
10. O-ring 11. Crankshaft key 12. Timing chain tension guide
K
13. Balancer unit timing chain 14. Crankshaft sprocket 15. Spacer
16. Balancer unit sprocket 17. Balancer unit timing chain tensioner 18. Balancer unit
19. O-ring A. Refer to INSTALLATION Front
L
M
REMOVAL
1. Remove the following parts:
• Air cleaner cover and air duct: Refer to EM-30, "Exploded View".
• Drive belt: Refer to EM-23, "Removal and Installation". N
• Drive belt auto-tensioner and idler pulley: Refer to EM-29, "Exploded View".
• Radiator shroud (upper and lower): Refer to CO-19, "Exploded View".
• Cooling fan: Refer to CO-19, "Exploded View". O
• PCV hose and blow-by hose: Refer to EM-32, "Exploded View".
• Ignition coil: Refer to EM-27, "Exploded View".
• EVAP canister purge volume control solenoid: Refer to EM-36, "Exploded View".
P
• Oil pan: Refer to EM-47, "Exploded View".
2. Remove rocker cover. Refer to EM-32, "Removal and Installation".

TIMING CHAIN
3. Remove engine harness bracket (1).
JPBIA7091ZZ
4. Pull chain guide between camshaft sprockets out through front cover.
5. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
(C) : Paint mark (Not use for service)
JPBIA7043ZZ
b. At the same time, check that the cam lobes of the No. 1 cylinder
are located ( ) as shown.
(1) : Camshaft (EXH)

(2) : Camshaft (INT)
: Engine front
• If not, rotate crankshaft pulley one revolution (360 degrees)

and align as shown.
JPBIA4347ZZ
6. Remove crankshaft pulley with the following procedure:

a. Fix crankshaft pulley (1) using suitable tool (A), loosen crank-
shaft pulley bolt, and locate bolt seating surface at 10 mm (0.39
in) from its original position.
JSBIA2452ZZ

TIMING CHAIN
b. Attach a suitable tool (A) in the M6 thread hole on crankshaft
pulley, and remove crankshaft pulley. A
EM
JSBIA2453ZZ
D
7. Remove front cover with the following procedure:
a. Remove valve timing control solenoid valve (INT and EXH) and valve timing control solenoid valve cover.
• Loosen bolts in reverse order as shown. E
ALBIA3174ZZ
H
b. Loosen front cover bolts in reverse order as shown, and remove

them. I
(A) : Dowel pin

(B) : Dowel pin hole J
O
JPBIA7044ZZ
8. If front oil seal needs to be replaced, lift it with a suitable tool, and remove it.
CAUTION: P
Be careful not to damage front cover.
• If not, rotate crankshaft pulley one more turn to align mating marks to the positions in the figure.
9. Remove timing chain and camshaft sprockets with the following procedure:

TIMING CHAIN
a. Push in chain tensioner plunger. Insert a stopper pin (A) into
hole on chain tensioner body to secure chain tensioner plunger
and remove chain tensioner (1).
NOTE:
Use approx. 0.5 mm (0.02 in) dia. hard metal pin as a stopper
pin.
AWBIA2715ZZ
b. Secure hexagonal part of camshaft with a wrench. Loosen cam-

shaft sprocket bolts and remove timing chain and camshaft
sprockets.
CAUTION:
Do not rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
AWBIA2680ZZ
10. Remove timing chain slack guide, timing chain tension guide and oil pump drive spacer.
11. Remove balancer unit timing chain tensioner with the following procedure:
a. Press stopper tab (A) in the direction shown in the figure to push
the timing chain slack guide (B) to the bottom toward timing
chain tensioner (for oil pump) (1).
• The slack guide is released by pressing the stopper tab. As
the result, the slack guide can be moved.
b. Insert a stopper pin (D) into tensioner body hole (C) to secure
the timing chain slack guide.
NOTE:
Use a hard metal pin with the diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
c. Remove balancer unit timing chain tensioner.
• When the holes on lever and tensioner body cannot be
aligned, align these holes by slightly moving the slack guide.
JPBIA1491ZZ
12. Remove balancer unit timing chain and crankshaft sprocket.

TIMING CHAIN
13. Loosen bolts in reverse order as shown, and remove balancer
unit. A
: Engine front
CAUTION: EM
Do not disassemble balancer unit.
JPBIA7045ZZ
D
INSTALLATION
CAUTION:
Do not reuse O-rings.
NOTE: E
The figure shows the relationship between the mating mark on each
timing chain and that on the corresponding sprocket, with the com-
ponents installed. F
(1) : Timing chain
(2) : Camshaft sprocket (INT)
G
(3) : Chain tensioner
(4) : Timing chain slack guide
(5) : Crankshaft sprocket
H
(6) : Balancer unit sprocket
(7) : Balancer unit chain tensioner
(8) : Balancer unit timing chain
I
(9) : Timing chain tension guide
(10) : Camshaft sprocket (EXH)
(A) : Mating mark (peripheral stamp line) J
: Orange link (for chile)
(B)
: Blue link (except for chile)
(C) : Mating mark (lug)
K
(D) : Crankshaft key
(E) : Mating mark (stamp)
: Yellow link (for chile) AWBIA2681ZZ
(F) L
: Pink link (except for chile)
: Yellow link (for chile)
(G)
: Pink link (for chile) M
(H)
1. Check that crankshaft key points straight up.
2. Tighten bolts in numerical order as shown with the following pro- N
cedure, and install balancer unit.
: Engine front O
CAUTION:
If bolts are re-used, check their outer diameter before instal-
lation. Refer to EM-59, "Inspection". P
a. Apply new engine oil to threads and seat surfaces of bolts.
b. Tighten No. 1 to 4 bolts.
JPBIA7045ZZ
Balancer unit bolts : 48.1 N·m (4.9 kg-m, 35 ft-lb)
c. Tighten No. 5, 6 bolt.

TIMING CHAIN
Balancer unit bolts : 21.35 N·m (2.2 kg-m, 16 ft-lb)
d. Turn No. 1 to 5 bolts 120 degrees clockwise using Tool (A).
Tool number (A) : KV10112100 (BT-8653-A)

CAUTION:
Do not make judgment by visual inspection.
e. Turn No. 6 bolt 90 degrees clockwise using Tool (A).

CAUTION:
Do not make judgment by visual inspection.
f. Completely loosen all bolts. JPBIA7046ZZ
Balancer unit bolts : 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
In this step, loosen bolts in reverse order as shown in the figure.
g. Repeat step ″b″ to ″e″.
3. Install crankshaft sprocket (1) and balancer unit timing chain (2).

(B)
(D) : Mating mark
: Pink link (for chile)
(E)
• Check that crankshaft sprocket is positioned with mating
marks (A) on cylinder block and crankshaft sprocket meeting
(C) at the top.
• Install it by aligning mating marks on each sprocket and bal- JSBIA3381ZZ
ancer unit timing chain.

4. Install balancer unit timing chain tensioner.
• Be careful not to let mating marks of each sprocket and timing chain slip.
• After installation, check the mating marks have not slipped, then remove stopper pin and release ten-
sioner sleeve.
5. Install timing chain and related parts.
• Install the camshaft sprocket (INT and EXH) to camshafts.
Camshaft sprocket bolts : 50 N·m (5.1 kg-m, 37 ft-lb)

(INT and EXH) (For Chile)
Camshaft sprocket bolts : 142.1 N·m (14 kg-m, 105 ft-lb)
(INT and EXH) (Except
for Chile)
AWBIA2680ZZ

TIMING CHAIN
• Install by aligning mating marks on each sprocket and timing
chain. A
(1) : Timing chain

(2) : Camshaft sprocket (INT) EM
(3) : Chain tensioner
(4) : Timing chain slack guide
(5) : Crankshaft sprocket C
(6) : Balancer unit sprocket
(7) : Balancer unit chain tensioner
(8) : Balancer unit timing chain D
(9) : Timing chain tension guide
(10) : Camshaft sprocket (EXH)
(A) : Mating mark (peripheral stamp line) E
: Orange link (for chile)
(B)
(C) : Mating mark (lug)
F
(D) : Crankshaft key
(E) : Mating mark (stamp)
: Yellow link (for chile) G
(F)
: Pink link (except for chile) AWBIA2681ZZ

(G)
H
: Pink link (for chile)
(H)
• Before and after installing chain tensioner, check again to check that mating marks have not slipped.
• After installing chain tensioner, remove stopper pin, and check that tensioner moves freely. I
CAUTION:
• For the following note, after the mating marks are aligned, keep them aligned by holding them
with a hand. J
• To avoid skipped teeth, do not rotate crankshaft and camshaft until front cover is installed.
NOTE:
Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for
K
that on each sprocket for alignment.
6. Install front oil seal to front cover. Refer to EM-83, "FRONT OIL SEAL : Removal and Installation".
7. Install front cover with the following procedure: L
CAUTION:
a. Install O-rings to cylinder head and cylinder block.
M

TIMING CHAIN
b. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to front cover as shown.
(1) : Front cover

(A) : Apply liquid gasket outside the bolt holes
(E) : Dowel pin hole
(J) : Liquid gasket
: Engine outside

NOTE:
Application instruction differs depending on the position.
: 30.6 mm (1.205 in) Apply liquid gasket φ 6.0 - 7.0

(c)
mm (0.236 - 0.275 in) between this area.
(d) : 179.6 mm (7.07 in)
(f) : 35.5 mm (1.398 in)
: 31.3 mm (1.232 in) Apply liquid gasket φ 6.0 - 7.0
(g)
mm (0.236 - 0.275 in) between this area.
(h) : 4.0 - 5.6 mm (0.157 - 0.220 in)
(i) : φ 3.4 - 4.4 mm (0.134 - 0.173 in) JPBIA7047ZZ
c. Check that mating marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION:
Be careful not to damage front oil seal by interference with front end of crankshaft.
d. Tighten bolts in numerical order as shown.
e. After all bolts are tightened, retighten them to specified torque in
numerical order as shown.
(A) : Dowel pin

(B) : Dowel pin hole
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface for fitting oil pan.
Tightening torque
M10 bolt : 49.0 N·m (5.0 kg-m, 36 ft-lb)
M6 bolt : 12.7 N·m (1.3 kg-m, 9 ft-lb)
JPBIA7044ZZ
8. Install chain guide between camshaft sprockets.

9. Insert crankshaft pulley by aligning with crankshaft key.
• When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Install protecting front oil seal lip section from any damage.
10. Tighten crankshaft pulley bolt.
• Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley
bolt.
• Perform angle tightening with the following procedure:

TIMING CHAIN
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt. A
Crankshaft pulley bolt : 42.1 N·m (4.3 kg-m, 31 ft-lb)

EM
c. Put a paint mark (A) on crankshaft pulley (2), mating with any
one of six easy to recognize angle marks on bolt flange.
C
(1) : Crankshaft pulley bolt
d. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark
D
(B).
E
ALBIA0862GB

F
INSPECTION AFTER REMOVAL G

Timing Chain
• Check timing chain for cracks (A) and any excessive wear (B) at
the roller links of timing chain. Replace timing chain if necessary. H
PBIC3169J
K
Balancer Unit Bolt Outer Diameter
• Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
• If reduction appears in “A” range, regard it as “d2 ”. L
Limit (“d1”–“d2”) : 0.15 mm (0.0059 in)

• If it exceeds the limit (large difference in dimensions), replace it M
with a new one.
N
JSBIA2568GB
INSPECTION AFTER INSTALLATION O

• 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-23, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- P
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.

TIMING CHAIN
• Warm up engine thoroughly to make sure there is no leakage 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.
• 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:
Item Before starting engine Engine running After engine stopped

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

transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
*Power steering fluid, brake fluid, etc.

CAMSHAFT
CAMSHAFT
A
For Chile EM
L
AWBIA3138ZZ
1. Camshaft position sensor (INT) 2. O-ring 3. Camshaft position sensor bracket M

4. Camshaft bracket (No. 2 to 5) 5. Camshaft (INT) 6. Camshaft bracket (No. 1)
7. Camshaft sprocket (INT) 8. Camshaft sprocket (EXH) 9. Valve lifter
10. Camshaft (EXH) 11. Signal plate (INT) 12. Signal plate (EXH) N
13. Camshaft position sensor (EXH) A. Refer to INSTALLATION B. Refer to EM-50, "Exploded View"
Front
O

CAMSHAFT
Except for Chile
AWBIA2713ZZ
1. Camshaft position sensor 2. O-ring 3. Camshaft position sensor bracket

4. Camshaft bracket (No. 2 to 5) 5. Camshaft (INT) 6. Camshaft bracket (No. 1)
7. Camshaft sprocket (INT) 8. Camshaft sprocket (EXH) 9. Valve lifter
10. Camshaft (EXH) 11. Signal plate (INT) A. Refer to INSTALLATION
B. Refer to EM-50, "Exploded View" Front
REMOVAL
1. Remove timing chain. Refer to EM-51, "Removal and Installation".
2. Remove camshaft position sensor.
3. Remove camshaft position sensor bracket.

CAMSHAFT
• Loosen bolts in reverse order as shown.
A
: Engine front
EM
AWBIA2646ZZ
D
4. Remove camshaft sprockets with the following procedure:
a. Line up the mating marks on camshaft sprockets, and paint indelible mating marks on timing chain link
plate. E
b. Push in chain tensioner plunger. Insert a stopper pin (A) into
hole on chain tensioner body to secure chain tensioner plunger
and remove chain tensioner (1). F
NOTE:
Use approx. 0.5 mm (0.02 in) dia. hard metal pin as a stopper
pin.
G
H
JSBIA3376ZZ
c. Secure hexagonal part of camshaft with a wrench. Loosen cam- I

shaft sprocket bolts and remove camshaft sprockets.
CAUTION:
Do not rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston. J
NOTE:
Chain tension holding work is not necessary. Crankshaft
sprocket and timing chain do not disconnect structurally while K
front cover is attached.
AWBIA2680ZZ L
5. Loosen bolts in reverse order as shown in the figure, and

remove camshaft brackets and camshafts.
M
(A) : Intake side
(B) : Exhaust side
: Engine front N
• Remove camshaft bracket (No. 1) by slightly tapping it with a

plastic hammer.
O
AWBIA2647ZZ
6. Remove valve lifters. P

• Identify installation positions, and store them without mixing them up.
INSTALLATION
CAUTION:
1. Install valve lifters.
• Install them in the original positions.

CAMSHAFT
2. Install camshafts.
• Distinction between intake and exhaust camshafts is per-
formed with the different shapes of rear end.

AWBIA2648ZZ
• Install camshafts so that camshaft dowel pins (A) on the front

side are positioned ( ) as shown.

JSBIA2439ZZ
3. Install camshaft brackets with the following procedure:

a. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.
b. Install camshaft brackets aligning the identification marks on
upper surface as shown.
(A) : Intake side

(B) : Exhaust side
: Engine front
NOTE:
Install so that identification mark can be correctly read when
viewed from the exhaust side.
JSBIA2440ZZ
c. Install camshaft bracket (No. 1) with the following procedure:

i. Apply liquid gasket to camshaft bracket (No. 1) as shown in the
figure.
: Engine front
A : φ2.0 - 3.0 mm
B : 10.5 mm
CAUTION:
After installation, be sure to wipe off any excessive liquid JSBIA2441ZZ
gasket leaking.

CAMSHAFT
ii. Apply liquid gasket to camshaft bracket (No. 1) contact surface
on the front cover (1) backside. A
: Engine front
EM
A : φ2.6 - 3.6 mm
• Apply liquid gasket to the outside of bolt hole on front cover. C
JSBIA2442ZZ
D
iii. Locate camshaft bracket (No. 1) (2) near installation position,
and install ( ) it without disturbing the liquid gasket applied to
the surfaces. E
(1) : Front cover
(3) : Cylinder head
F
(A) : Liquid gasket application face
G
JSBIA2443ZZ
4. Tighten camshaft bracket bolts in the following steps, in numeri-

cal order as shown. H
(A) : Intake side

(B) : Exhaust side I
: Engine front
a. Tighten No. 9 to 11 in numerical order.

J
Camshaft bracket : 1.96 N·m (0.2 kg-m, 17 in-lb)

bolts ALBIA0846GB
K
b. Tighten No. 1 to 8 in numerical order.
Camshaft bracket : 1.96 N·m (0.2 kg-m, 17 in-lb) L

bolts
c. Tighten all bolts in numerical order.
M
Camshaft bracket : 5.88 N·m (0.6 kg-m, 52 in-lb)
bolts
N
d. Tighten all bolts in numerical order.
Camshaft bracket : 10.41 N·m (1.1 kg-m, 8 ft-lb)

bolts O
CAUTION:
After tightening bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the
parts listed below. P
• Mating surface of rocker cover.
• Mating surface of front cover. (When installed without front cover)
5. Install the camshaft sprockets to the camshafts. Refer to EM-50, "Exploded View".
6. Install chain tensioner. Refer to EM-50, "Exploded View".
CAUTION:

CAMSHAFT
After installation, pull the stopper pin off completely, and check that chain tensioner plunger is
released.
7. Install chain guide.Refer to EM-50, "Exploded View".
8. Install camshaft position sensor bracket.
a. Apply liquid gasket using a suitable tool to camshaft position
sensor bracket as shown.
: Engine front
(a) : 2.0 – 3.0 mm (0.079 – 0.118 in)

(b) : 10.5 mm (0.413 in)
CAUTION:
• After installation, be sure to wipe off any excessive liquid AWBIA2649ZZ
gasket leaking from component (b).

• Attaching should be done within 5 minutes after liquid gasket application.
• Do not fill the engine with engine oil for at least 30 minutes after the components are installed to
allow the liquid gasket to cure.
b. Tighten bolts in numerical order as shown in the figure.
: Engine front
JSBIA3385ZZ
9. Install camshaft position sensor.

CAUTION:
Do not reuse O-ring.
10. Inspect and adjust valve clearance. Refer to EM-16, "Inspection and Adjustment".
11. Installation of remaining components is in the reverse order or removal.

Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 jour-
nal of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft
sprocket) because it has a different diameter from the other
four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
Standard : Refer to EM-118, "Camshaft". JSBIA2445ZZ
4. If out of the standard, replace camshaft.

Camshaft Cam Height

CAMSHAFT
1. Measure the camshaft cam height with a micrometer (A).
A
Standard and Limit : Refer to EM-118, "Camshaft".
2. If it exceeds the limit, replace camshaft.
EM
JSBIA2447ZZ
D
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer
(A). E
Standard : Refer to EM-118, "Camshaft".

F
JPBIA0122ZZ
H
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolts with specified torque. Refer to EM-61, "Exploded View".
• Measure the inner diameter (A) of camshaft bracket with an cylin- I
der gauge (B).

J
JSBIA2446ZZ L
CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter) M
• If out of the standard, replace either or both camshaft and cylinder head. N
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
O
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-62, "Removal and Installation".
P

CAMSHAFT
2. Install dial indicator (A) in thrust direction on front end of cam-
shaft. Read the end play of dial indicator when camshaft is
moved forward/backward (in direction to axis).
JSBIA2448ZZ
• Measure the following parts if out of the standard.

- Dimension “A” for camshaft No. 1 journal
Standard : 25.800 - 25.848 mm (1.0157 - 1.0176 in)

- Dimension “B” for cylinder head No. 1 journal
Standard : 25.660 - 25.685 mm (1.0102 - 1.0112 in)

• Refer to the standards above, and then replace camshaft and/
or cylinder head.
KBIA2426J
Camshaft Sprocket Runout

1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
2. Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
Limit : Refer to EM-118, "Camshaft".

• If it exceeds the limit, replace camshaft sprocket.
JPBIA4413ZZ
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-61,
"Exploded View".
KBIA0182E
Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

CAMSHAFT
• Measure the outer diameter of valve lifter with a micrometer (A).
A
EM
JPBIA0125ZZ
D
VALVE LIFTER HOLE DIAMETER
Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A). E

VALVE LIFTER CLEARANCE F
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter
outer diameter)
G
• If out of the standard, referring to the each standard of valve lifter JSBIA2450ZZ
outer diameter and valve lifter hole diameter, replace either or both H
valve lifter and cylinder head.

CYLINDER HEAD
CYLINDER HEAD
REMOVAL
AWBIA2650ZZ
1. Cylinder head assembly 2. Cylinder head gasket 3. Engine coolant temperature sensor
4. Cylinder head bolt A. Refer to INSTALLATION Front
DISASSEMBLY

CYLINDER HEAD
EM
H
AWBIA2651ZZ
1. Valve collet 2. Valve spring retainer 3. Valve spring (with valve spring seat)
4. Valve oil seal 5. Valve guide 6. Spark plug tube I
7. Cylinder head 8. Valve seat (INT) 9. Valve (INT)
10. Valve seat (EXH) 11. Valve (EXH) Front
J
REMOVAL K
2. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant".
L
3. Remove the following components and related parts.
• Intake manifold: Refer to EM-36, "Removal and Installation".
• Fuel tube assembly: Refer to EM-42, "Removal and Installation".
• Exhaust manifold and three way catalyst assembly: Refer to EM-39, "Removal and Installation". M
• Water outlet: Refer to CO-26, "Exploded View".
NOTE:
Can be removed and installed even when assembled with cylinder head. N
4. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside.
Refer to ST-33, "Removal and Installation - QR25DE".
5. Remove front cover and timing chain. Refer to EM-50, "Exploded View". O
6. Remove camshafts. Refer to EM-62, "Removal and Installation".

CYLINDER HEAD
7. Remove cylinder head loosening bolts in reverse order as
shown.
: Engine front
AWBIA1325GB
8. Remove cylinder head gasket.

9. Remove engine coolant temperature sensor (if necessary).
INSTALLATION
1. Install engine coolant temperature sensor (if removed).
2. Clean surfaces of cylinder head and cylinder block.
3. Install cylinder head gasket.
CAUTION:
Do not reuse cylinder head gasket.
4. Tighten cylinder head bolts in numerical order as shown with the
following procedure, and install cylinder head.
: Engine front
CAUTION:
• If cylinder head bolts are reused, check their outer diame-
ters before installation. Refer to EM-77, "Inspection".
• Clean threads and seating surfaces of bolts.
a. Apply new engine oil to threads and seating surface of bolts.
b. Tighten all bolts. AWBIA1325GB
Bolts : 50.0 N·m (5.1 kg-m, 37 ft-lb)

c. Turn all bolts 60 degrees clockwise (angle tightening).
d. Completely loosen.
Bolts : 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
In this step, loosen bolts in reverse order of that indicated in the figure.
e. Tighten all bolts.
Bolts : 39.2 N·m (4.0 kg-m, 29 ft-lb)
f. Turn all bolts 75 degrees clockwise using Tool (A).

g. Turn all bolts 75 degrees clockwise again using Tool (A).
CAUTION:
Check and confirm the tightening angle by using Tool (A).
Avoid judgment by visual inspection without Tool (A).
JSBIA2465ZZ

CYLINDER HEAD
Disassembly and Assembly INFOID:0000000014267078
A
DISASSEMBLY
1. Remove spark plug. Refer to EM-27, "Removal and Installation".
EM
2. Remove spark plug tube (if necessary).
• Using pliers, remove it from cylinder head.
CAUTION:
• Be careful not to damage cylinder head. C
• Do not remove spark plug tube if not necessary. Once removed, spark plug tube cannot be
reused because of deformation.
3. Remove valve lifter. D
4. Remove valve collet.
• Compress valve spring with using suitable tool (A). E
AWBIA1760ZZ H
CAUTION:
• Do not damage valve lifter holes. I
• Fit suitable tool (A) in the center of valve spring retainer
(1) to press it.
J
L
JSBIA3390ZZ
5. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION: M
Do not remove valve spring seat from valve spring.
6. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up. N
7. Remove valve oil seal using suitable tool (A).
JSBIA2467ZZ
8. Remove valve seat, if valve seat must be replaced.

CYLINDER HEAD
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-119, "Cylinder Head".
CAUTION:
Prevent to scratch cylinder head by excessive boring.
9. Remove valve guide, if valve guide must be replaced.
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
PBIC3214J
b. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US

ton, 2.0 lmp ton) pressure] or hammer and suitable tool (A).
CAUTION:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
JSBIA2470ZZ
ASSEMBLY
1. Install valve guide if removed.
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide.
a. Ream cylinder head valve guide hole using suitable tool (A).
For service parts : Oversize [0.2 mm (0.008 in)]

Refer to EM-119, "Cylinder Head".
JSBIA2468ZZ
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
PBIC3214J

CYLINDER HEAD
c. Press valve guide (1) from camshaft side to dimensions as
shown in the figure. A
(2) :Cylinder head
EM
Projection “H” : Refer to EM-119, "Cylinder Head".
CAUTION:
Cylinder head contains heat, when working, wear protective C
PBIC3217J
D
d. Apply reamer finish to valve guide using suitable tool (A).
Standard : Refer to EM-119, "Cylinder Head". E
G
JSBIA2468ZZ
2. Install valve seat (if removed).

CAUTION: H
Replace with oversize [0.5 mm (0.020 in)] valve seat.
a. Ream cylinder head (1) recess diameter for service valve seat.
I
(2) : Valve seat
For service parts : Oversize [0.5 mm (0.020 in)] J

• Be sure to ream in circles concentric to the valve guide center.
K
This will enable valve seat to fit correctly.
PBIC3218J
L
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
M
O
PBIC3214J
c. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head. P
CAUTION:
• Avoid directly to touching cold valve seats.
• Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.

CYLINDER HEAD
d. Using valve seat cutter set using suitable tool (A) or valve seat
grinder, finish valve seat to the specified dimensions. For dimen-
sions, refer to EM-119, "Cylinder Head".
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
JSBIA2471ZZ
e. Using compound, grind to adjust valve fitting.

f. Check again for normal contact. Refer to EM-77, "Inspection".
3. Install valve oil seal.
• Install with a valve oil seal drift using suitable tool (A) to match
dimension in the figure.
NOTE:
Dimension “H” is height that measured before installing valve
spring (with valve spring seat).
Height “H” : 11.8 - 12.4 mm (0.465 - 0.488 in)
ALBIA0864GB
4. Install valve.
• Install larger diameter to intake side.
5. Install valve spring (with valve spring seat).
• Install smaller pitch (valve spring seat side) to cylinder head
side (B).
(1) : Valve spring seat

• Confirm identification color (A) of valve spring.
Intake : White
Exhaust : Light blue
JPBIA4479ZZ
6. Install valve spring retainer.

7. Install valve collet.
• Compress valve spring with valve spring compressor using
suitable tool (A).
CAUTION:
Be careful not to damage valve lifter holes.
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
AWBIA1760ZZ
8. Install valve lifter.

• Install it in the original position.

CYLINDER HEAD
9. Install spark plug tube (if removed).
• Press-fit it into cylinder head with the following procedure: A
a. Remove old thread locking sealant from cylinder head side
installation hole.
b. Apply thread locking sealant all round on spark plug tube within EM
approximately 12 mm (0.47 in) (A) width from edge of spark plug
tube on the press-fit side.
Use Genuine Thread Locking Sealant or equivalent.
C
c. Using a drift, press-fit spark plug tube so that height is as same
as “H” shown in figure.
ALBIA0870GB
D
Standard press-fit height “H”: 41.2 - 42.2 mm (1.622 - 1.661 in)
CAUTION:
• When press-fitting, be careful not to deform spark plug tube. E
• After press-fitting, wipe off any protruding thread locking sealant on top surface of cylinder
head.
10. Install spark plug. Refer to EM-27, "Removal and Installation".
F
INSPECTION AFTER REMOVAL G

Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2” H
exceeds the limit, replace them with a new one.
Limit (“d1”–“d2”): 0.23 mm (0.0091 in) I

• If reduction of outer diameter appears in a position other than “d2”,
use it as “d2” point.
J
JSBIA2565GB
K
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-98, "Inspec-
tion". L
1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION:
Do not allow gasket fragments to enter engine oil or engine coolant passages. M
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions.
N
(A) : Straightedge
(B) : Feeler gauge
O
Limit : Refer to EM-119, "Cylinder Head".
• If it exceeds the limit, replace cylinder head.
P
JSBIA2474ZZ
VALVE DIMENSIONS
• Check dimensions of each valve. For dimensions, refer to EM-119, "Cylinder Head".
• If dimensions are out of the standard, replace valve.
VALVE GUIDE CLEARANCE

CYLINDER HEAD
Valve Stem Diameter
Measure the diameter of valve stem with a micrometer (A).
Standard : Refer to EM-119, "Cylinder Head".
JPBIA0183ZZ
Valve Guide Inner Diameter

Measure the inner diameter of valve guide with a bore gauge.

Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Standard and Limit : Refer to EM-119, "Cylinder Head".

• If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced. Refer to EM-73,
"Disassembly and Assembly".
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within specifications, perform this proce-
dure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circum-
ference.
(A) : OK
(B) : NG
• 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. Refer to EM-73, "Disassembly and Assembly".
JPBIA0187ZZ
VALVE SPRING SQUARENESS

• Set try square (A) along the side of valve spring and rotate the
spring. Measure the maximum clearance between the top of valve
spring and try square.
(B) : Contact
(C) : V-block
CAUTION:
Limit (d) : Refer to EM-119, "Cylinder Head".

JSBIA4163ZZ
• If it exceeds the limit, replace valve spring (with valve spring seat).
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

CYLINDER HEAD
• Check valve spring pressure with valve spring seat installed at the
specified spring height. A
(A) : Valve spring tester

CAUTION: EM
Standard : Refer to EM-119, "Cylinder Head". C
JSBIA2477ZZ
D
• If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring
seat).
INSPECTION AFTER INSTALLATION E
• Use procedure below to check for fuel leakage. F
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
• Run engine to check for unusual noise and vibration. G
NOTE:
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop H
I
• Summary of the inspection items: J

Engine coolant Level Leakage Level K
Transmission/ Leakage Level/Leakage Leakage
CVT Models L
transaxle fluid
M
Exhaust gas — Leakage —
N

FLYWHEEL
FLYWHEEL
AWBIA2653ZZ
1. Pilot converter 2. Flywheel Engine front
REMOVAL
1. Remove the transmission assembly from the vehicle. Refer to TM-30, "2WD : Exploded View".
2. Secure flywheel using suitable tool and remove flywheel bolts.
CAUTION:
Do not disassemble flywheel.
3. Remove pilot bushing (1), from the rear end of the crankshaft
using suitable tool (A).
JSBIA2484ZZ
INSTALLATION
• Fix crankshaft using suitable tool and install flywheel bolts.
• Install flywheel bolts in diagonal order.
CAUTION:

FLYWHEEL
• Be careful not to damage or scratch and contact surface for clutch disc of flywheel.
• Rotate crankshaft 2 to 3 rotations to ensure there is no interference with adjacent components. A
EM
FLYWHEEL DEFLECTION
• Measure the deflection of flywheel contact surface to torque with a
dial indicator (A).
• Measure the deflection at 210 mm (8.27 in) diameter. C
Limit : 0.45 mm (0.0177 in) or less.

• If measured value is out of the standard, replace flywheel. D
• If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
E
JSBIA2488ZZ
MOVEMENT AMOUNT IN RADIAL (ROTATION) DIRECTION F

Check the movement amount of radial (rotation) direction with the following procedure:
1. Install clutch cover bolt (1) to clutch cover hole, and place a
torque wrench (C) on the extended line of the flywheel (2) center G
line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it
from loosening.
H
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction, I
and mark the movement amount on the mass on the transaxle
side. JSBIA2489ZZ
4. Measure the dimensions of movement amounts “A” and “B” on J

circumference of the flywheel on the transaxle side.
Limit : 35.2 mm (1.385 in) or less. K

• If measured value is out of the standard, replace flywheel.

OIL SEAL
OIL SEAL
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000014267083
REMOVAL
1. Remove camshafts. Refer to EM-61, "Exploded View".
2. Remove valve lifters. Refer to EM-61, "Exploded View".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
CAUTION:
Be careful to avoid scarring front cover with timing chain.
• Compress valve spring using suitable tool (A). Remove valve
collet with a magnet hand.
AWBIA1760ZZ
CAUTION:
• Be careful not to damage valve lifter holes.
• Install suitable tool (A) in the center of valve spring
retainer (1) to press it.
JSBIA3390ZZ
5. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
6. Remove valve oil seal using suitable tool (A).
ALBIA0863GB
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.

OIL SEAL
2. Press in valve oil seal to the height “H” using suitable tool (A).
A
Height “H” : 11.8 - 12.4 mm (0.465 - 0.488 in)
EM
ALBIA0864GB
D
FRONT OIL SEAL
E
FRONT OIL SEAL : Removal and Installation INFOID:0000000014267084
REMOVAL
F
1. Remove the following parts.
• Front fender protector: Refer to EXT-29, "Exploded View".
• Drive belt: Refer to EM-23, "Removal and Installation".
• Crankshaft pulley: Refer to EM-50, "Exploded View". G
2. Remove front oil seal using suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft. H
SEM829E
INSTALLATION K
1. Apply new engine oil to seal lip.
2. Install front oil seal so that each seal lip is oriented as shown.
CAUTION: L
Do not reuse front oil seal.
(A) : Dust seal lip

M
(B) : Oil seal lip
: Engine outside
: Engine inside N
PBIC3485J

OIL SEAL
• Press-fit front oil seal until it is flush with front end surface of
front cover using a suitable tool (A) with outer diameter 56 mm
(2.20 in) and inner diameter 48 mm (1.89 in).
CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Do not touch the grease applied to the oil seal lip.
ALBIA0865GB

REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000014267085
REMOVAL
1. Remove flywheel. Refer to EM-80, "Exploded View".
2. Remove rear oil seal using suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply new engine oil to seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
CAUTION:
Do not reuse rear oil seal.
(A) : Dust seal lip

(B) : Oil seal lip
: Drive plate side
: Engine front
PBIC3485J
• Press-fit rear oil seal with a suitable drift (A) [outer diameter
102 mm (4.02 in), inner diameter 86 mm (3.39 in)].
CAUTION:
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
JSBIA3341ZZ

OIL SEAL
• Press in the new rear oil seal (1) to the position (b) shown in
the figure. A
(A) : Rear surface of cylinder block
EM
(b) : 0.8 mm (0 - 0.031 in)
JPBIA3011ZZ
D

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [QR25DE]
UNIT REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
AWBIA2654ZZ
1. Engine mounting insulator (RH) 2. Engine mounting bracket (RH) 3. Engine mounting bracket (LH)
4. Heat insulator 5. Engine mounting insulator (LH) 6. Transmission cross member
7. Engine mounting insulator (rear) Front
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Do not start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-30, "2-Pole Lift" (for 2-pole
lift) or GI-29, "Garage Jack and Safety Stand" (except for 2-pole lift).
NOTE:
ing.
REMOVAL
Preparation

ENGINE ASSEMBLY
1. Disconnect battery cable from negative terminal. Refer to PG-154, "Exploded View".
2. Relieve fuel system pressure. Refer to EC-140, "Work Procedure". A
3. Drain engine coolant from radiator. Refer to CO-10, "Changing Engine Coolant".
• Front under cover: Refer to EXT-30, "FRONT UNDER COVER : Exploded View". EM
• Hood assembly: Refer to DLK-128, "HOOD ASSEMBLY : Removal and Installation" (WITH INTELLI-
GENT KEY SYSTEM) or DLK-276, "HOOD ASSEMBLY : Removal and Installation" (WITHOUT INTEL-
LIGENT KEY SYSTEM). C
• Front grill: Refer to EXT-24, "Exploded View".
• Air duct and air cleaner case: Refer to EM-30, "Removal and Installation".
• Radiator hose (upper and lower): Refer to CO-14, "Removal and Installation".
D
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. Disconnect all the body-side vacuum hoses and air hoses at engine side.
Engine room front E
1. Remove the radiator shroud (upper and lower). Refer to CO-14, "Exploded View".
2. Remove drive belt. Refer to EM-23, "Removal and Installation".
3. Remove the cooling fan assembly. Refer to CO-19, "Removal and Installation (Crankshaft driven type)". F
4. Remove the water pump pulley. Refer to CO-21, "Exploded View".
Engine room RH
G
1. Remove generator. Refer to CHG-51, "QR25DE : Removal and Installation".
2. Remove brake booster hose in engine side.
3. Remove the engine ground cable in engine side. H
Engine room LH
1. Remove power steering oil pump from bracket with piping connected, and temporarily secure it
aside.Refer to ST-33, "Exploded View - QR25DE". I
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
3. Remove A/C compressor from bracket with piping connected, and temporarily secure it aside. Refer to
J
HA-31, "COMPRESSOR : Removal and Installation".
Vehicle underbody
1. Remove exhaust front tube. Refer to EX-6, "Removal and Installation". K
2. Remove rear propeller shaft. Refer to DLN-148, "Exploded View" (3S1330).
3. Remove clutch operating cylinder from transmission, and move it aside. Refer to CL-22, "QR25DE :
Exploded View". L
4. Remove starter motor. Refer to STR-37, "QR25DE : Exploded View".
5. Remove transmission assembly. Refer to TM-30, "2WD : Removal and Installation".
M
Removal
1. In order to attach the (rear) engine slinger, remove the engine cover bracket.
2. Install engine slingers into front left of cylinder head and rear N
right of cylinder head.
: Engine front
O
Slinger bolts
Front side: : 48.1 N·m (4.9 kg-m, 35 ft-lb) P
Rear side: : 28.0 N·m (2.9 kg-m, 21 ft-lb)
JPBIA7039ZZ
3. Lift with hoist and secure engine in position.

4. Loosen LH and RH engine insulator nuts.

ENGINE ASSEMBLY
5. Remove engine.
CAUTION:
• During the operation, check that no part interferes with
body side.
• Before and during this lifting, always check if any har-
nesses are left connected.
SEM896G
INSTALLATION
• Do not allow engine oil to get on insulator. Be careful not to damage insulator.
• When installation directions are specified, install parts according to the direction marks on them referring to
figure of components.
• Check that each insulator is seated properly, and tighten bolts and nuts.

• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
NOTE:
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
• Summary of the inspection items:

Engine coolant Level Leaks Level
Engine oil Level Leaks Level
Transmission/ A/T and CVT Models Leaks Level/Leaks Leaks

transaxle fluid M/T Models Level/Leaks Leaks Level/Leaks
Other oils and fluids* Level Leaks Level
Fuel Leaks Leaks Leaks
Exhaust gas — Leaks —

ENGINE STAND SETTING
< UNIT DISASSEMBLY AND ASSEMBLY > [QR25DE]
UNIT DISASSEMBLY AND ASSEMBLY A

Setting INFOID:0000000014267089
EM
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, note with difference in steps and etc. C
1. Remove flywheel. Refer to EM-80, "Removal and Installation".
2. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION: D
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• Before removing the hanging chains, check the engine stand is stable and there is no risk of E
overturning.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Intake manifold: Refer to EM-36, "Exploded View". F
- Exhaust manifold: Refer to EM-39, "Exploded View".
- Rocker cover: Refer to EM-32, "Exploded View".
NOTE: G
The figure shows an example of widely used engine stand (A)
that can support mating surface of transmission.
H
J
JSBIA2481ZZ

K
CAUTION:
Be sure to clean drain plug and install with new washer.
L

CYLINDER BLOCK
CYLINDER BLOCK
AWBIA2657ZZ
1. Knock sensor 2. Crankshaft position sensor (POS) 3. O-ring

4. Oil pressure switch 5. Cylinder block 6. Top ring
7. Second ring 8. Oil ring 9. Piston
10. Snap ring 11. Piston pin 12. Connecting rod
13. Oil jet 14. Connecting rod bearing 15. Connecting rod bearing cap
16. Dowel pin 17. Lower cylinder block 18. O-ring
19. Oil level gauge guide 20. Oil level gauge 21. Rear oil seal
22. Signal plate 23. Thrust bearing 24. Main bearing upper
25. Crankshaft 26. Crankshaft key 27. Main bearing lower
A. Refer to INSTALLATION Engine front
DISASSEMBLY
1. Remove cylinder head. Refer to EM-70, "Exploded View".

CYLINDER BLOCK
2. Remove knock sensor (1).
A
: Engine front
CAUTION:
Carefully handle knock sensor avoiding shocks. EM
JPBIA7050ZZ
D
3. Remove crankshaft position sensor (POS) (2).
(1) : O-ring
E
: Engine front
CAUTION:
• Avoid impacts such as a dropping. F
• Do not disassemble.
• Keep it away from metal particles.
• Do not place the sensor in a location where it is exposed
G
to magnetism.
JSBIA2491ZZ
4. Remove oil pressure switch.
5. Remove piston and connecting rod assembly with the following procedure: H
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-98, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
I
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool (A), push piston and con-
necting rod assembly out to the cylinder head side.
J
CAUTION:
Be careful not to damage the cylinder wall, resulting from
an interference of the connecting rod big end.
K
JSBIA2492ZZ
M
6. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct order.
7. Remove piston rings form piston using suitable tool (A). N
CAUTION:
• When removing piston rings, be careful not to damage the
piston. O
• Be careful not to damage piston rings by expanding them
excessively.
P
JSBIA2493ZZ
8. Remove piston from connecting rod with the following procedure:

CYLINDER BLOCK
a. Using snap ring pliers (A), remove snap ring.
JSBIA2494ZZ
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use drier (A) or equivalent.
WARNING:
Pistons contain heat. When working, wear protective equip-
ment to avoid getting burned.
JSBIA2495ZZ
c. Push out piston pin with stick (A) of outer diameter approximately 19 mm (0.75 in).
WARNING:
Pistons contain heat. When working, wear protective equip-
ment to avoid getting burned.
JSBIA2496ZZ
9. Remove lower cylinder block bolts.

• Loosen bolts in reverse order as shown, and remove them.
: Engine front
• Before loosening lower cylinder block bolts, measure crank-

shaft end play. Refer to EM-98, "Inspection".
JPBIA1494ZZ
10. Remove lower cylinder block.

• Using Tool to cut liquid gasket for removal.
Tool number : KV10111100 (J-37228)

CAUTION:
Be careful not to damage the surface.
CYLINDER BLOCK
11. Remove crankshaft.
CAUTION: A
• Be careful not damage or deform signal plate (2) mounted
on crankshaft.
• When setting crankshaft (1) on a flat floor surface, use a
EM
block of wood to avoid interference between signal plate
(A) and the floor surface.
• Do not remove signal plate (A) unless it is necessary to do
so. C
12. Pull rear oil seal out from rear end of crankshaft.
CAUTION:
Be careful not to damage crankshaft and cylinder block. D
NOTE: JSBIA2497ZZ
When replacing rear oil seal without removing lower cylinder
block, use a screwdriver to pull it out from between crankshaft and cylinder block.
E
13. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
Identify installation positions, and store them without mixing them up.
14. Remove oil jets (1) (if necessary). F
: Engine front
G
I
JSBIA3393ZZ
ASSEMBLY
CAUTION: J
Do not reuse O-rings or washers.
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material. K
CAUTION:
Use a goggles to protect your eyes.
2. Install each plug to cylinder block as shown in the figure.
L
(3) : Washer
: Engine front
M
• Apply liquid gasket to the thread of water drain plug (1).
CAUTION:
N
Do not reuse washers.
NOTE:
Do not apply liquid gasket to the thread of plug (2).
• Apply liquid gasket to the thread of plug (4). JSBIA6001ZZ
O
CAUTION:
Do not reuse washers.
P
• Tighten each plug as specified below.
Part Washer Tightening torque

(1) No 9.8 N·m (1.0 kg-m, 87 in-lb)
(2) Yes 53.9 N·m (5.5 kg-m, 40 ft-lb)
(4) Yes 62.8 N·m (6.4 kg-m, 46 ft-lb)

CYLINDER BLOCK
3. Install oil jet (if removed).
• Insert oil jet dowel pin (A) into cylinder block dowel pin hole,
and tighten bolts.
: Engine front
JSBIA3395ZZ
4. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and lower cylinder
block.
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing (A) on cylinder block.
: Engine front
• Install thrust bearings (1) with the oil groove (B) facing crank-
shaft arm (outside).
JSBIA2498ZZ
c. Install the main bearings paying attention to the direction.

• Main bearing with an oil hole and groove goes on cylinder
block. The one without them goes on lower cylinder block.
(1) : Journal other than No.3

(C) : Lower cylinder block side
(D) : Thrust bearing
• Only main bearing (on cylinder block) (E) for No. 3 journal (2)
has different specifications.
• Before installing main bearings, apply new engine oil to the
bearing surface (inside). Do not apply engine oil to the back
surface, but thoroughly clean it. JSBIA2499ZZ
• When installing, align main bearing stopper (B) to the notch.

• Ensure the oil holes (A) on cylinder block and those on the corresponding bearing are aligned.
5. Install signal plate to crankshaft (if removed).
(1) : Signal plate

(2) : Crank shaft
(3) : Dowel pin (used to position the signal plate)
a. Position crankshaft and signal plate using dowel pin, and tighten
bolts.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each. If dowel pin is not available (when reusing crankshaft and
signal plate), use M8 bolt [length 10 mm (0.39 in) or more] as a JSBIA2500ZZ
substitute.
b. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
6. Install crankshaft to cylinder block.
• While turning crankshaft by hand, check that it turns smoothly.

CYLINDER BLOCK
7. Install lower cylinder block with the following procedure:
a. Apply liquid gasket (A) with a suitable tool to lower cylinder block A
(1) as shown in the figure.
(2) : Cylinder block EM

(C) : Apply liquid gasket to an end
(d) : φ 3.8 mm (0.150 in)
(E) : Groove C
: Engine front

CAUTION: D
After liquid gasket is applied, rear oil seal installation must
be finished within 5 minutes. Therefore, the following pro-
cedure must be performed quickly. E
NOTE:
Lower cylinder block cannot be replaced as a single part,
because it is machined together with cylinder block.
F
JSBIA6020ZZ
H
b. Tighten lower cylinder block bolts with the following procedure:
i. Apply new engine oil to threads and seat surfaces of bolts.
ii. Tighten M8 bolts in numerical order from No. 11 to 22 as shown.
I
Lower cylinder block bolts : 25.1 N·m (2.6 kg-m, 19
ft-lb)
J
NOTE:
There are more processes to complete the tightening of bolts.
However stop procedure here to install rear oil seal.
K
JPBIA0904ZZ
L
c. Install rear oil seal. Refer to EM-84, "REAR OIL SEAL : Removal and Installation".
d. Restart tightening of lower cylinder block bolts with the following procedure:
M
i. Tighten M10 bolts in numerical order from No. 1 to 10 as shown.
Lower cylinder block bolts : 39.2 N·m (4.0 kg-m, 29 ft-lb)

N
P
JPBIA0904ZZ

CYLINDER BLOCK
ii. Turn M10 bolts 60 degrees clockwise using Tool (A) in order
from No. 1 to 10.

CAUTION:
Avoid judgment by visual inspection without the Tool (A).
• After installing bolts, check that crankshaft can be rotated
smoothly by hand.
• Wipe off completely any protruding liquid gasket on front side
of engine.
• Check the crankshaft end play. Refer to EM-122, JPBIA0687ZZ
"Cylinder Block".
8. Install piston to connecting rod with the following procedure:
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
b. Assemble piston to connecting rod.
• Heat piston to 60 to 70°C (140 to 158°F) with an industrial use drier (A) or equivalent.
WARNING:
Pistons contain heat. When working, wear protective
JSBIA2495ZZ
• Assemble so that the front mark (A) on the piston head and
the oil splash (B) and the cylinder number (C) on connecting
rod are positioned as shown in the figure.
: Engine front
c. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install.
• After installing, check that connecting rod moves smoothly.
JSBIA3397ZZ
9. Using a suitable tool install piston rings.

CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown in the figure referring
to the piston front mark (D).
(a) : 90°
(B) : Top ring gap
(c) : 45°
(E) : Oil ring upper or lower rail gap (either of them)
(F) : Second ring and oil ring spacer gap
(G) : Oil ring upper or lower rail gap (either of them)
• Install second ring with the stamped (H) surface facing JSBIA2504ZZ
upward.
CYLINDER BLOCK
Stamped mark: A
Top ring :—
Second ring : 2 ND
EM
NOTE:
If there is no stamped mark on piston ring, no specific orientation is required for installation.
10. Inspect outer diameter of connecting rod bolts. Refer to EM-98, "Inspection".
C
11. Install connecting rod bearings to connecting rod and connecting rod cap.
• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply engine oil to the back surface, but thoroughly clean it.
• When installing, align the connecting rod bearing stopper pro- D
trusion (A) with the cutout (B) of connecting rod and connect-
ing rod cap to install.
• Ensure the oil hole on connecting rod and that on the corre- E
sponding bearing are aligned.
JSBIA2505ZZ
G
12. Install piston and connecting rod assembly to crankshaft. H

• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number on connecting rod to install.
I
• Using suitable tool (A) or suitable tool, install piston with the
front mark on the piston head facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft J
pin, resulting from an interference of the connecting rod
big end.
K
L
JSBIA2506ZZ
13. Install connecting rod cap.

• Match the stamped cylinder number marks on connecting rod M
with those on connecting rod cap to install.
(A) : Oil splash N

(B) : Small end diameter grade
(C) : Management code
(D) : Bearing stopper groove O
(E) : Management code
(F) : Cylinder number
(G) : Big end diameter grade JSBIA2507ZZ P
14. Tighten connecting rod bolt with the following procedure:
a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten bolts.
Connecting rod bolts : 27.4 N·m (2.8 kg-m, 20 ft-lb)

CYLINDER BLOCK
c. Completely loosen bolts.
Connecting rod bolts : 0 N·m (0 kg-m, 0 ft-lb)

d. Tighten bolts.
Connecting rod bolts : 19.6 N·m (2.0 kg-m, 14 ft-lb)

e. Then turn all bolts 90 degrees clockwise using Tool (A).

CAUTION:
Avoid judgment by visual inspection without the Tool (A).
• After tightening connecting rod bolt, check that crankshaft
rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-98,
"Inspection".
JPBIA0688ZZ
15. Install knock sensor (1).

• Install knock sensor with connector facing (A) between ribs (B)
as shown in the figure.
CAUTION:
• Do not tighten bolt while holding the connector.
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE:
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
• Check that knock sensor does not interfere with other parts.
JPBIA7051ZZ
16. Install crankshaft position sensor (POS).
17. Assembly of remaining components is in the reverse order of disassembly.
CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
Standard and Limit : Refer to EM-122, "Cylinder Block".

• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also.
JSBIA2509ZZ
CONNECTING ROD SIDE CLEARANCE

CYLINDER BLOCK
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A). A
Standard and Limit : Refer to EM-122,

"Cylinder Block". EM
• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also. C
JPBIA0689ZZ
D
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside E
micrometer (A).
Standard : Refer to EM-122, "Cylinder Block".

F
JSBIA2510ZZ H
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A).
I
JSBIA2511ZZ
L
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
M
• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to “PISTON TO CYLINDER BORE CLEARANCE”.
N
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.) O
PISTON RING SIDE CLEARANCE
P

CYLINDER BLOCK
• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge (A).

• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
JSBIA2512ZZ
PISTON RING END GAP

• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).

"Cylinder Block".
measure again. If it still exceeds the limit, replace cylinder block.
JSBIA2513ZZ
CONNECTING ROD BEND AND TORSION

• Check with a connecting rod aligner.
(A) : Bend
(B) : Torsion
(C) : Feeler gauge
Limit : Refer to EM-122, "Cylinder Block".

• If it exceeds the limit, replace connecting rod assembly.
JSBIA2514ZZ
CONNECTING ROD BIG END DIAMETER

CYLINDER BLOCK
• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod bolts to the specified A
torque. Refer to EM-90, "Disassembly and Assembly".
(2) : Connecting rod

EM
(A) : Example
(B) : Measuring direction of inner diameter
• Measure the inner diameter of connecting rod big end with an C
inside micrometer.
JSBIA2521ZZ
D
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
E
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
F
JPBIA0223ZZ
Piston Pin Outer Diameter I

Standard : Refer to EM-122, "Cylinder Block". J
L
JPBIA0218ZZ
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame- M
ter)
Standard : Refer to EM-122, "Cylinder Block". N

• If the measured value is out of the standard. Replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly. Refer to EM-108, "Piston". O
• If replacing connecting rod assembly. Refer to EM-109, "Connecting Rod Bearing" to select connecting rod
bearing.
P
CYLINDER BLOCK DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.

CYLINDER BLOCK
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and a
feeler gauge (B).
Limit : Refer to EM-122, "Cylinder Block".

• If it exceeds the limit, replace cylinder block.
JSBIA2526ZZ
MAIN BEARING HOUSING INNER DIAMETER

• Install lower cylinder block (2) without main bearings installed, and
tighten lower cylinder block bolts to the specified torque. Refer to
EM-90, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge.

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

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using a cylinder gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. (A) and (B)
directions at (C), (D), and (E). (A) is in longitudinal direction of
engine)
(f) : 10 mm (0.39 in)

(g) : 60 mm (2.36 in)
(h) : 120 mm (4.72 in)
NOTE:
When determining cylinder bore grade, measure the cylinder bore
(B) direction at (D) position. JPBIA2059ZZ
Standard:
Cylinder bore inner diameter
: Refer to EM-122, "Cylinder Block".
Limit:
Out-of-round (Difference between (A) and (B)
Taper (Difference between (C) and (E))
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
CAUTION:
When using an oversize piston, use oversize pistons for all cylinders with oversize piston rings.
Oversize (O/S): 0.2 mm (0.008 in)

Piston Skirt Diameter

CYLINDER BLOCK
Measure the outer diameter of piston skirt with a micrometer (A).
A
EM
JPBIA0227ZZ
D
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter
(direction (B), position (D). E
(A) : Direction A
(c) : Position C
F
(E) : Position E
(f) : 10 mm (0.39 in)
(g) : 60 mm (2.36 in)
G
(h) : 120 mm (4.72 in)
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame- JPBIA2059ZZ
ter) H

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-122, I
"Cylinder Block".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter. J
Re-bored size calculation: D = A + B - C

K
where,
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value) L
C: Honing allowance 0.02 mm (0.0008 in)
D: Bored diameter
M
2. Install lower cylinder block, and tighten bolts to the specified torque. Otherwise, cylinder bores may be dis-
torted in final assembly. Refer to EM-90, "Disassembly and Assembly" for the tightening procedure.
3. Cut cylinder bores.
NOTE: N
• 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. O
4. Hone cylinders to obtain the specified piston to cylinder bore clearance.
5. Measure the finished cylinder bore for out-of-round and taper.
NOTE: P
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER

CYLINDER BLOCK
• Measure the outer diameter of crankshaft main journals with a
micrometer (A).

• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-125, "Main Bearing".
JPBIA0228ZZ
CRANKSHAFT PIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft pin journal with a micrometer.

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to EM-127, "Connecting Rod Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in dimensions between
(a) and (b) at (c) and (d).
• Taper is indicated by the difference in dimension between (c) and
(d) at (a) and (b).
Limit:
Out-of-round [Difference between (c) and (d)]
Taper [Difference between (a) and (b)]
JPBIA0229ZZ
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to EM-127, "Connecting Rod Bearing" and/or EM-125,
"Main Bearing".
CRANKSHAFT RUNOUT
• Place a V-block (A) on a precise flat table to support the journals
on the both end of the crankshaft.
• Place a dial indicator (B) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)

"Cylinder Block".
• If it exceeds the limit, replace crankshaft.
JSBIA2531ZZ
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation

CYLINDER BLOCK
• Install connecting rod bearings (2) to connecting rod (3) and cap,
and tighten connecting rod bolts to the specified torque. Refer to A
EM-90, "Disassembly and Assembly" for tightening procedure.
(1) : Connecting rod bearing cap

EM
(A) : Example
(B) : Inner diameter measuring direction
PBIC3275J
D
• Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)
E
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-109, F
"Connecting Rod Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. G
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified H
torque. Refer to EM-90, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
Do not rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale (A) I
on the plastigage bag, measure the plastigage (B) width.
NOTE:
The procedure when the measured value exceeds the limit is J
same as that described in the “Method by Calculation”.
JSBIA2534ZZ
L
MAIN BEARING OIL CLEARANCE

Method by Calculation M
• Install main bearings (3) to cylinder block (1) and lower cylinder
block (2), and tighten lower cylinder block bolts to the specified
torque. Refer to EM-90, "Disassembly and Assembly" for the tight-
N
ening procedure.
(A) : Example
(B) : Inner diameter measuring direction O
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter) P
PBIC3277J

CYLINDER BLOCK
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-90, "Disassembly
and Assembly".
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
holes.
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the
specified torque. Refer to EM-90, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage (B) width.
NOTE:
The procedure when the measured value exceeds the limit is
JSBIA2534ZZ
MAIN BEARING CRUSH HEIGHT

• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude (B). Refer to EM-90, "Disassembly and
Assembly".
(A) : Example
Standard : There must be crush height.

• If the standard is not met, replace main bearings.
PBIC3279J
CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod cap is removed after being tightened to the
specified torque with connecting rod bearings (1) installed, the tip
end of bearing must protrude (B). Refer to EM-90, "Disassembly
and Assembly".
(A) : Example

• If the standard is not met, replace connecting rod bearings.
PBIC3279J
LOWER CYLINDER BLOCK BOLT OUTER DIAMETER

• Perform only with M10 bolts.

CYLINDER BLOCK
in the figure. A
• If reduction appears in “A” range, regard it as “d2”.
Limit (“d1”–“d2”): 0.13 mm (0.0051 in) EM

• If it exceeds the limit (a large difference in dimensions), replace
lower cylinder block bolt with a new one.
C
PBIC0911E
D
CONNECTING ROD BOLT OUTER DIAMETER
• Measure the outer diameter “d” at position as shown in the figure.
• If reduction appears in a position other than “d”, regard it as “d”.
E
Limit: 7.75 mm (0.3051 in)
• When “d ” exceeds the limit (when it becomes thinner), replace
connecting rod bolt with a new one. F
PBIC0912E

HOW TO SELECT PISTON AND BEARING
Description INFOID:0000000014267093
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston outer diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
Between piston and connecting
— — —
rod*
*For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only grade “0” is available.) The
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000014267094
WHEN NEW CYLINDER BLOCK IS USED

• Check the cylinder bore grade on rear left side of cylinder block,
and select piston of the same grade.
(A) : Corrected stamping position

(B) : Basic stamping position
(C) : No.1 - 4 from left
(D) : Cylinder bore grade
(E) : No.1 - 5 from left
(F) : Main bearing housing grade
: Engine front JSBIA2542ZZ
• If there is a corrected stamp mark on the cylinder block, use it as a

correct reference.
WHEN CYLINDER BLOCK IS REUSED
1. Measure the cylinder bore inner diameter. Refer to EM-98, "Inspection".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.

3. Select piston of the same grade.
A
(A) : Front mark
(B) : Piston pin bore grade number
(C) : Piston grade identification stamp number EM
(D) : Piston upper surface identification code stamp
(E) : Identification code
C
AWBIA1373ZZ
D
PISTON SELECTION TABLE
Unit: mm (in)
Grade number (Mark) 2 3
E
Cylinder bore Inner diameter 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
Piston skirt diameter 88.990 - 89.000 (3.5035 - 3.5039) 89.000 - 89.010 (3.5039 - 3.5043)
NOTE: F
• There is no piston grade “1”.
• Piston is available together with piston pin as an assembly.
• The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no G
grades can be selected. (Only grade “0” is available.)
Connecting Rod Bearing INFOID:0000000014267095
H
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
1. Apply connecting rod big end diameter grade stamped on con-
I
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
(A) : Oil splash J

(B) : Small end diameter grade
(D) : Bearing stopper groove K
(E) : Management code
(F) : Cylinder number
(G) : Big end diameter grade
JSBIA2507ZZ
L
2. Apply crankshaft pin journal diameter grade stamped on crank- M

shaft front side to the column in the “Connecting Rod Bearing
Selection Table”.
(1) : Key N
(A) : Main jounal diameter grade (No.1 - 5 from left)
(B) : Pin jounal diameter grade (No.1 - 4 from left)
O
JSBIA2543ZZ
P
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED

1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-98, "Inspection".
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
Connecting Rod Bearing Grade Table
Connecting Rod Bearing Grade Table : Refer to EM-127, "Connecting Rod Bearing".
Undersize Bearings Usage Guide
• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
Bearing undersize table:

Refer to EM-127, "Connecting Rod Bearing".
PBIC3263J

CONNECTING ROD BEARING SELECTION TABLE
A
EM
K
JPBIA0797GB
CONNECTING ROD BEARING GRADE TABLE

L
Connecting rod bearing grade table : Refer to EM-127, "Connecting Rod Bearing".
UNDERSIZE BEARINGS USAGE GUIDE

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod M
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. N
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
O
Refer to EM-127, "Connecting Rod Bearing".
P
PBIC3263J

Main Bearing INFOID:0000000014267096
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED

1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear-left side of cylinder block.
(A) : Corrected stamping position

(B) : Basic stamping position
(C) : No.1 - 4 from left
(D) : Cylinder bore grade
(E) : No.1 - 5 from left
(F) : Main bearing housing grade
: Engine front JSBIA2542ZZ
• If there is a corrected stamp mark on cylinder block, use it as a

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

side to column in the “Main Bearing Selection Table”.
(1) : key
(A) : Main journal diameter grade (No.1 - 5 from left)
(B) : Pin journal diameter grade (No.1 - 4 from left)
JSBIA2543ZZ
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are three main bearing selection tables. Make certain to use the appropriate table. This is
due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-98, "Inspection".
2. Apply the measured dimension to the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are three main bearing selection tables. Make certain to use the appropriate table. This is
due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.

MAIN BEARING SELECTION TABLE (No. 1 and 5 journals)
A
EM
K
PBIC2201E

MAIN BEARING SELECTION TABLE (No. 2 and 4 journals)
PBIC2202E

MAIN BEARING SELECTION TABLE (No. 3 journals)
A
EM
K
JSBIA6021GB
MAIN BEARING GRADE TABLE (ALL JOURNALS)

L
Main bearing grade table (All journals) : Refer to EM-125, "Main Bearing".
USE UNDERSIZE BEARING USAGE GUIDE

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under- M
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard. N
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
O
Refer to EM-125, "Main Bearing".
P
PBIC3263J

Bearing undersize table : Refer to EM-125, "Main Bearing".

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [QR25DE]
SERVICE DATA AND SPECIFICATIONS (SDS) A

General Specification INFOID:0000000014267097
EM
GENERAL SPECIFICATIONS
C
Engine type QR25DE
Cylinder arrangement In-line 4
Displacement cm3 (cu in) 2,488 (151.82) D
Bore and stroke mm (in) 89.0 x 100.0 (3.504 x 3.937)
Valve arrangement DOHC
E
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 F
Compression ratio 10.0
Standard 1,410 (14.1, 14.4, 204.7)
Compression pressure G
Minimum 1,220 (12.2, 12.1, 176.3)
kPa (bar, kg/cm2, psi)/250 rpm
Differential limit between cylinders 100 (1.0, 1.0, 14)
Unit: degree H
J
Valve timing
PBIC4542E
a b c d e f L
212 224 8 (-12) 52 (32) 7 25
( ): Valve timing control “ON”
M
Drive belt INFOID:0000000014267098
DRIVE BELT N
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
O
Spark Plug INFOID:0000000014267099
SPARK PLUG P
Unit: mm (in)
Make DENSO
Standard type FXE20HE11
Spark plug gap (Nominal) 1.1 (0.043)

Exhaust Manifold INFOID:0000000014267100
EXHAUST MANIFOLD
Unit: mm (in)
Items Limit
Surface distortion Exhaust manifold 0.3 (0.012)
Camshaft INFOID:0000000014267101
CAMSHAFT
Unit: mm (in)
SEM671
Items Standard Limit

Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034) —
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal diameter
No. 2, 3, 4, 5 23.435 - 23.455 (0.9226 - 0.9234) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) —
Intake 45.865 - 46.055 (1.8057 - 1.8132)
Camshaft cam height “A” 0.2 (0.008)*1
Exhaust 44.175 - 44.365 (1.7392 - 1.7467)
Camshaft runout [TIR*2] Less than 0.02 mm (0.0008) —
Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)
*1: Cam wear limit

*2: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter hole diameter 34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter clearance 0.010 - 0.041 (0.0004 - 0.0016)
VALVE CLEARANCE
Unit: mm (in)
Items Cold Hot* (reference data)

Intake 0.24 - 0.32 (0.094 - 0.0126) 0.304 - 0.416 (0.0120 - 0.0164)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)
*: Approximately 80°C (176°F)
AVAILABLE VALVE LIFTER

Unit: mm (in)
A
EM
D
JPBIA0170ZZ
Thickness Identification (stamped)* mark

6.96 (0.2740) 696
E
6.98 (0.2748) 698
7.00 (0.2756) 700
F
7.02 (0.2764) 702
7.04 (0.2772) 704
7.06 (0.2780) 706 G
7.08 (0.2787) 708
7.10 (0.2795) 710
H
7.12 (0.2803) 712
7.14 (0.2811) 714
7.16 (0.2819) 716 I
7.18 (0.2827) 718
7.20 (0.2835) 720
J
7.22 (0.2843) 722
7.24 (0.2850) 724
7.26 (0.2858) 726 K
7.28 (0.2866) 728
7.30 (0.2874) 730
L
7.32 (0.2882) 732
7.34 (0.2890) 734
7.36 (0.2898) 736 M
7.38 (0.2906) 738
7.40 (0.2913) 740
7.42 (0.2921) 742 N
7.44 (0.2929) 744
7.46 (0.2937) 746
O
*: Always check with the Parts Department for the latest parts information.
Cylinder Head INFOID:0000000014267102

P
CYLINDER HEAD

Unit: mm (in)
PBIC0924E

Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 129.4 (5.09) —
VALVE DIMENSIONS
Unit: mm (in)
JSBIA1166ZZ
Valve head diameter “D” Intake 35.5 - 35.8 (1.398 - 1.409)

Exhaust 30.3 - 30.6 (1.193 - 1.205)
Intake 101.72 (4.0074)
Valve length “L”
Exhaust 102.78 (4.0464)
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 1.3 (0.0512)
Valve margin “T”
Exhaust 1.6 (0.0630)
Valve margin “T” limit 0.5 (0.020)
Valve stem end surface grinding limit 0.2 (0.008)
VALVE GUIDE

Unit: mm (in)
A
EM
D
SEM950E
Items Standard Oversize (Service) [0.2 (0.008)]

E
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)
F
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.003) G
Valve guide clearance
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.0035)
Projection length “L” Intake 10.1– -10.3 (0.398 - 0.405)

H
Exhaust 10.0 - 10.4 (0.394 - 0.409)
VALVE SEAT
Unit: mm (in) I
PBIC2745E
M
Intake 36.500 - 36.516 (1.4370 - 1.4376) 37.000 - 37.016 (1.4567 - 1.4573)
Cylinder head seat recess diameter “D”
Exhaust 31.500 - 31.516 (1.2402 - 1.2408) 32.000 - 32.016 (1.2598 - 1.2408) N
Intake 36.597 - 36.613 (1.4408 - 1.4415) 37.097 - 37.113 (1.4605 - 1.4611)
Valve seat outer diameter “d”
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Intake 0.081 - 0.113 (0.0032 - 0.0044) O
Valve seat interference fit
Exhaust 0.084 - 0.116 (0.0034 - 0.0046)
Intake 33.5 (1.319)
Diameter “d1”*1 P
Exhaust 28.0 (1.102)
Intake 34.8 - 35.3 (1.370 - 1.390)
Diameter “d2”*2
Exhaust 29.6 - 30.1 (1.165 - 1.185)
Intake 60°
Angle “α1”
Exhaust 60°

Intake 88°75′ - 90°25′
Angle “α2”
Exhaust 88°75′ - 90°25′
Intake 120°
Angle “α3”
Exhaust 120°
Intake 0.99 - 1.35 (0.0390 - 0.0531)
Contacting width “W”*3
Exhaust 1.19 - 1.55 (0.0469 - 0.0610)
Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.91 - 5.01 (0.1933 - 0.1972)
Depth “H” 6.0 (0.236)
*1: Diameter made by intersection point of conic angles “α1” and “α2”
*2: Diameter made by intersection point of conic angles “α2” and “α3”
*3: Machining data
VALVE SPRING
Items Intake Exhaust

Free height 47.02 (1.8512) 47.75 (1.8799)
Installation height 35.96 mm (1.4158 in) 35.96 mm (1.4158 in)
Installation load 153 – 173 N (15.6 – 17.6 kg, 34.4 – 38.9 lb) 153 – 173 N (15.6 – 17.6 kg, 34.4 – 38.9 lb)
Height during valve open 25.76 mm (1.0142 in) 27.46 mm (1.0811 in)
Load with valve open 337 – 381 N (34.4 – 39.1 kg, 75.8 – 86.1 lb) 302 – 340 N (30.8 – 34.7 kg, 67.9 – 76.4 lb)
Identification color White Light blue
Out- of- Square 1.0 mm (0.0394 in)
Cylinder Block INFOID:0000000014267103
CYLINDER BLOCK
Unit: mm (in)
PBIC0281E
Surface distortion Limit 0.1 (0.004)

Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Standard
Cylinder bore Inner diameter Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.2 (0.008)
Out-of-round (Difference between “X” and “Y”) 0.015 (0.0006)
Limit
Taper (Difference between “A” and “C”) 0.01 (0.0004)

Grade No. A 58.944 - 58.945 (2.3206 - 2.3207)
Grade No. B 58.945 - 58.946 (2.3207 - 2.3207) A
Grade No. C 58.946 - 58.947 (2.3207 - 2.3207)
Grade No. D 58.947 - 58.948 (2.3207 - 2.3208)
Grade No. E 58.948 - 58.949 (2.3208 - 2.3208)
Grade No. F 58.949 - 58.950 (2.3208 - 2.3209) EM
Grade No. G 58.950 - 58.951 (2.3209 - 2.3209)
Grade No. H 58.951 - 58.952 (2.3209 - 2.3209)
Grade No. J 58.952 - 58.953 (2.3209 - 2.3210)
Grade No. K 58.953 - 58.954 (2.3210 - 2.3210)
C
Grade No. L 58.954 - 58.955 (2.3210 - 2.3211)
Grade No. M 58.955 - 58.956 (2.3211 - 2.3211)
Main bearing housing inner diameter grade
Grade No. N 58.956 - 58.957 (2.3211 - 2.3211) D
Grade No. P 58.957 - 58.958 (2.3211 - 2.3212)
Grade No. R 58.958 - 58.959 (2.3212 - 2.3212)
Grade No. S 58.959 - 58.960 (2.3212 - 2.3213)
Grade No. T 58.960 - 58.961 (2.3213 - 2.3213) E
Grade No. U 58.961 - 58.962 (2.3213 - 2.3213)
Grade No. V 58.962 - 58.963 (2.3213 - 2.3214)
Grade No. W 58.963 - 58.964 (2.3214 - 2.3214)
Grade No. X 58.964 - 58.965 (2.3214 - 2.3215) F
Grade No. Y 58.965 - 58.966 (2.3215 - 2.3215)
Grade No. 4 58.966 - 58.967 (2.3215 - 2.3215)
Grade No. 7 58.967 - 58.968 (2.3215 - 2.3216)
G
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
AVAILABLE PISTON
Unit: mm (in) H
PBIC0188E
L
Grade No. 2 88.990 - 89.000 (3.5035 - 3.5039)
Piston skirt diameter “A” Standard Grade No. 3 89.000 - 89.010 (3.5039 - 3.5043)
Oversize (Service) [0.20 (0.008)] 89.180 - 89.210 (3.5110 - 3.5122) M
Piston height “H” dimension 37.5 (1.476)
Grade No. 0 19.993 - 19.999 (0.7871 - 0.7874)
Piston pin hole diameter
Grade No. 1 19.999 - 20.005 (0.7874 - 0.7876) N
Standard 0.010 - 0.030 (0.0004 - 0.0012)
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
O
PISTON RING
Unit: mm (in)
Items Standard Limit P
Top 0.040 - 0.080 (0.0016 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.1 (0.004)
Oil ring 0.045 - 0.125 (0.0018 - 0.0049) —

Top 0.21 - 0.31 (0.0083 - 0.0122) 0.53 (0.0209)
End gap 2nd 0.37 - 0.52 (0.0146 - 0.0205) 0.71 (0.0280)
Oil (rail ring) 0.20 - 0.45 (0.008 - 0.0177) 0.80 (0.0314)
PISTON PIN
Unit: mm (in)

Grade No. 0 19.989 - 19.995 (0.7870 - 0.7872) —
Piston pin outer diameter
Grade No. 1 19.995 - 20.001 (0.7872 - 0.7874) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
CONNECTING ROD
Unit: mm (in)
Center distance 143.00 – 143.10 (5.63 – 5.63)
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.3 (0.012)
Connecting rod small end inner diameter 21.980 – 22.000 (0.8654 – 0.8661)
Grade No. 0 20.000 – 20.006 (0.7874 – 0.7876)
Connecting rod bushing inner diameter*
Grade No. 1 20.006 – 20.012 (0.7876 – 0.7879)
Connecting rod big end inner diameter 48.000 - 48.013 (1.8898 - 1.8903)
Standard 0.20 – 0.35 (0.008 – 0.0138)
Side clearance
Limit 0.5 (0.020)
Grade No. 0 48.000 – 48.001 (1.8898 – 1.8898)
Grade No. 1 48.001 – 48.002 (1.8898 – 1.8898)
Grade No. 2 48.002 – 48.003 (1.8898 – 1.8899)
Grade No. 3 48.003 – 48.004 (1.8899 – 1.8899)
Grade No. 4 48.004 – 48.005 (1.8899 – 1.8900)
Grade No. 5 48.005 – 48.006 (1.8900 – 1.8900)
Connecting rod big end diameter Grade No. 6 48.006 – 48.007 (1.8900 – 1.8900)
Grade No. 7 48.007 – 48.008 (1.8900 – 1.8901)
Grade No. 8 48.008 – 48.009 (1.8901 – 1.8901)
Grade No. 9 48.009 – 48.010 (1.8901 – 1.8902)
Grade No. A 48.010 – 48.011 (1.8902 – 1.8902)
Grade No. B 48.011 – 48.012 (1.8902 – 1.8902)
Grade No. C 48.012 – 48.013 (1.8902 – 1.8903)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E
Center distance “r” 49.96 - 50.04 (1.9669 - 1.9701)

Out-of-round (Difference between “X” and “Y”) Limit 0.005 (0.0002)

Taper (Difference between “A” and “B”) Limit 0.005 (0.0002)
A
Runout [TIR*] Limit 0.05 (0.0020)
Standard 0.10 - 0.26 (0.004 - 0.0102)
Crankshaft end play
Limit 0.3 (0.012) EM
Grade No. A 44.974 - 44.973 (1.7706 - 1.7706)
Grade No. B 44.973 - 44.972 (1.7706 - 1.7705)
Grade No. C 44.972 - 44.971 (1.7705 - 1.7705)
Grade No. D 44.971 - 44.970 (1.7705 - 1.7705) C
Grade No. E 44.970 - 44.969 (1.7705 - 1.7704)
Grade No. F 44.969 - 44.968 (1.7704 - 1.7704)
Grade No. G 44.968 - 44.967 (1.7704 - 1.7704) D
Grade No. H 44.967 - 44.966 (1.7704 - 1.7703)
Grade No. J 44.966 - 44.965 (1.7703 - 1.7703)
Pin journal diameter grade. “Dp”
Grade No. K 44.965 - 44.964 (1.7703 - 1.7702)
Grade No. L 44.964 - 44.963 (1.7702 - 1.7702) E
Grade No. M 44.963 - 44.962 (1.7702 - 1.7702)
Grade No. N 44.962 - 44.961 (1.7702 - 1.7701)
Grade No. P 44.961 - 44.960 (1.7701 - 1.7701)
Grade No. R 44.960 - 44.959 (1.7701 - 1.7700) F
Grade No. S 44.959 - 44.958 (1.7700 - 1.7700)
Grade No. T 44.958 - 44.957 (1.7700 - 1.7700)
Grade No. U 44.957 - 44.956 (1.7700 - 1.7699)
G
Grade No. A 54.979 - 54.978 (2.1645 - 2.1645)
Grade No. B 54.978 - 54.977 (2.1645 - 2.1644)
Grade No. C 54.977 - 54.976 (2.1644 - 2.1644)
Grade No. D 54.976 - 54.975 (2.1644 - 2.1644) H
Grade No. E 54.975 - 54.974 (2.1644 - 2.1643)
Grade No. F 54.974 - 54.973 (2.1643 - 2.1643)
Grade No. G 54.973 - 54.972 (2.1643 - 2.1642)
Grade No. H 54.972 - 54.971 (2.1642 - 2.1642) I
Grade No. J 54.971 - 54.970 (2.1642 - 2.1642)
Grade No. K 54.970 - 54.969 (2.1642 - 2.1641)
Grade No. L 54.969 - 54.968 (2.1641 - 2.1641)
Grade No. M 54.968 - 54.967 (2.1641 - 2.1641) J
Main journal diameter grade. “Dm”
Grade No. N 54.967 - 54.966 (2.1641 - 2.1640)
Grade No. P 54.966 - 54.965 (2.1640 - 2.1640)
Grade No. R 54.965 - 54.964 (2.1640 - 2.1639)
K
Grade No. S 54.964 - 54.963 (2.1639 - 2.1639)
Grade No. T 54.963 - 54.962 (2.1639 - 2.1639)
Grade No. U 54.962 - 54.961 (2.1639 - 2.1638)
Grade No. V 54.961 - 54.960 (2.1638 - 2.1638) L
Grade No. W 54.960 - 54.959 (2.1638 - 2.1637)
Grade No. X 54.959 - 54.958 (2.1637 - 2.1637)
Grade No. Y 54.958 - 54.957 (2.1637 - 2.1637)
Grade No. 4 54.957 - 54.956 (2.1637 - 2.1636) M
Grade No. 7 54.956 - 54.955 (2.1636 - 2.1636)
*: Total indicator reading
N
MAIN BEARING
O

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

-3 1.964 - 1.967 (0.0773 - 0.0774) Blue - Green
-2 1.967 - 1.970 (0.0774 - 0.0776) Black - Green
-1 1.970 - 1.973 (0.0776 - 0.0777) Red - Red
0 1.973 - 1.976 (0.0777 - 0.0778) Black
1 1.976 - 1.979 (0.0778 - 0.0779) Brown
Grade and color are the same
2 1.979 - 1.982 (0.0779 - 0.0780) Green
for upper and lower bearings.
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow
4 1.985 - 1.988 (0.0781 - 0.0783) Blue
5 1.988 - 1.991 (0.0783 - 0.0784) Pink
6 1.991 - 1.994 (0.0784 - 0.0785) Purple
7 1.994 - 1.997 (0.0785 - 0.0786) White
UPR 1.964 - 1.967 (0.0773 - 0.0774) Blue - Green
-3-2
LWR 1.967 - 1.970 (0.0774 - 0.0776) Black - Green
UPR 1.967 - 1.970 (0.0774 - 0.0776) Red
-2-1
LWR 1.970 - 1.973 (0.0776 - 0.0777) Red
UPR 1.970 - 1.973 (0.0776 - 0.0777) Green - Brown
-10
LWR 1.973 - 1.976 (0.0777 - 0.0778) Black
UPR 1.973 - 1.976 (0.0777 - 0.0778) Black
01
LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown
UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown
12
LWR 1.979 - 1.982 (0.0779 - 0.0780) Green Grade and color are different
UPR 1.979 - 1.982 (0.0779 - 0.0780) Green for upper and lower bearings.
23
LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
34
LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue
UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue
45
LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink
UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink
56
LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple
UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple
67
LWR 1.994 - 1.997 (0.0785 - 0.0786) White
UNDERSIZE

Unit: mm (in)
Items Thickness Main journal diameter A

0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832) Grind so that bearing clearance is the specified value.
MAIN BEARING OIL CLEARANCE EM

Unit: mm (in)
No. 1 and 5 0.012 - 0.022 (0.0005 - 0.0009)

Standard No. 2 and 4 0.018 - 0.028 (0.0007 - 0.0011) C
Main bearing oil clearance
No. 3 0.030 - 0.040 (0.0012 - 0.0016)
Limit 0.1 (0.004)
D
CONNECTING ROD BEARING E

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

F
0 1.493 - 1.496 (0.0588 - 0.0589) Black - Black
1 1.496 - 1.499 (0.0589 - 0.0590) Brown - Brown
2 1.499 - 1.502 (0.0590 - 0.0591) Green - Green G
3 1.502 - 1.505 (0.0591 - 0.0593) Yellow - Yellow
4 1.505 - 1.508 (0.0593 - 0.0594) Blue - Blue
H
UPR 1.493 - 1.496 (0.0588 - 0.0589) Black - Black
01
LWR 1.496 - 1.499 (0.0589 - 0.0590) Brown - Brown
UPR 1.496 - 1.499 (0.0589 - 0.0590) Brown - Brown
12 Grade and color are different I
LWR 1.499 - 1.502 (0.0590 - 0.0591) Green - Green for upper and lower bearings.
UPR 1.499 - 1.502 (0.0590 - 0.0591) Green - Green
23
LWR 1.502 - 1.505 (0.0591 - 0.0593) Yellow - Yellow J
UPR 1.502 - 1.505 (0.0591 - 0.0593) Yellow - Yellow
34
LWR 1.505 - 1.508 (0.0593 - 0.0594) Blue - Blue
K
UNDERSIZE
Unit: mm (in)
Items Thickness Crank pin journal diameter L

CONNECTING ROD BEARING OIL CLEARANCE M

Unit: mm (in)

Connecting rod bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018) 0.1 (0.004) N

PRECAUTIONS
< PRECAUTION > [YD25DDTi]
PRECAUTION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
WARNING:
nance and repair be performed by an authorized NISSAN/INFINITI dealer.
see the SR section.
ness connectors.
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the
INFOID:0000000014267107
NOTE:
battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.
OPERATION PROCEDURE
NOTE:
Supply power using jumper cables if battery is discharged.
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-

PRECAUTIONS
A
windshield. EM
D
PIIB3706J

E
• Release fuel pressure before disconnecting and disassembly. F
DRAINING ENGINE COOLANT G

H
I
structed operations. J
check that dowel pins are installed in the original position. K
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used L
in the step.
ASSEMBLY AND INSTALLATION M

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, N
O
• After disassembling and opening the engine, change engine oil and replace oil filter with a new one. P
• For the final tightening of the following engine parts use Tool:

PRECAUTIONS
Tool number : KV10112100 (BT-8653-A)

- Cylinder head bolts
- Connecting rod cap bolts
ing)
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.

CAUTION:
• After removing the bolts and nuts, separate the mating surface and
Tool number (A) : KV10111100 (J-37228)

lightly tap (1) the cutter where the liquid gasket is applied. Use a
plastic hammer to slide (2) the cutter by tapping on the side.
AWBIA1249GB
LIQUID GASKET APPLICATION PROCEDURE

• Remove liquid gasket completely from the groove of the liquid
JPBIA0053ZZ
3. Attach liquid gasket tube to the suitable tool.

EMA0622D

PRECAUTIONS
holes. Occasionally, it should be applied outside the holes. A
(A) : Groove
EM
: Inside

ing component. C
D
engine oil and engine coolant. Refer to LU-25, "Changing Engine Oil" and CO-36, "Changing Engine
Coolant".
CAUTION:
If there are more specific instructions in the procedures contained in this manual concerning liquid E
Precaution for Diesel Equipment INFOID:0000000014267112
F
CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM G
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are: H
• Damage or destruction of the high pressure injection system and the engine
• Seizing or leaking of a component
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions. I
The cleanliness principle must be applied from the fuel filter to the fuel injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
J
Contamination is caused by:
• Metal or plastic chips
• Paint
• Fibers: K
- Boxes
- Brushes
- Paper L
- Clothing
- Cloths
• Foreign bodies such as hair
• Ambient air M
• Etc.
WARNING:
It is not possible to clean the engine using a high pressure fuel pump because of the risk of damaging N
connections. In addition, moisture may collect in the connectors and create electrical connection mal-
functions
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS-
TEM O
• Check that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan
part No. 16609 00Q0A, Renault part No. 77 01 209 062). Plugs are to be used once only. After use, they
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). P
Unused plugs must be thrown away.
• Check that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away.
• Lint-free towelettes to be used for fuel pump related service purpose. The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system.
Each lint-free cloth should only be used once.

PRECAUTIONS
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinners to clean the connections to be opened.
• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered.
• Wash your hands before and during the operation if necessary.
• When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Stores - Nissan part No. 16609 00Q0A, Renault part No.
77 01 209 062. They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con-
tamination.
• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted.
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system.
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle.
Instructions for Fitting the Plugs
Nissan part No. 16609 00Q0C

PRECAUTIONS
(Renault part No. 77 01 479 091)
A
EM
JPBIA0585ZZ
SPECIAL FEATURES P
CAUTION:
• The engine must not operate with:
- Use diesel fuel required by the regulations for cetane number. Refer to FL-22, "Inspection".
- Petrol, even in tiny quantities
• Before carrying out any work, check that the fuel rail is not under pressure and that the fuel temper-
ature is not too high. [The system can inject the diesel into the engine at a pressure up to 160,000
kPa (1,600 bar, 1,632 kg/cm2, 23,200 psi)].

PRECAUTIONS
• Respect the cleaning and safety advice specified in this document for any work on the high pressure
injection system.
• Remove of the interior of the fuel pump and fuel injectors is prohibited.
• For safety reasons, it is strictly forbidden to slacken an injection tube union when the engine is run-
ning.
• It is not possible to remove the fuel pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the fuel pressure sensor fails, the fuel pressure sensor, the fuel rail
and the fuel injection tubes must be replaced.
• It is strictly forbidden to remove the fuel pump pulley.
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Do not start the engine without the battery being connected correctly.
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there is no diesel leakage.
• Start the engine and check for fuel leak for one minute after starting.
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50°C (122°F) and provided there are no malfunctions
present, carry out a road test, taking the engine speed up to 4,000 rpm at least once to check that there is no
leakage.
• Perform a visual inspection after the road test to check that there is no high pressure leakage.
• Clean off the tracing fluid.

PREPARATION
< PREPARATION > [YD25DDTi]
PREPARATION A
PREPARATION
Special Service Tool INFOID:0000000014267113
EM
(RENAUT tool No.) C
Tool name
KV10115600 Installing valve oil seal
( — ) Use side A . D
Valve oil seal drift
: 20 (0.79) dia. : 8 (0.31) dia.
: 13 (0.51) dia. : 10.7 (0.421)
: 10.3 (0.406) dia. : 5 (0.20) E
: side B
Unit: mm (in)
JPBIA0396ZZ
F
KV10107902 Removing valve oil seal
( — )
Valve oil seal puller
KV10116100 G
( — )
Valve oil seal puller adapter
H
S-NT605
KV11103000 Removing crankshaft pulley

( — )
Pulley puller I
NT676
KV11300QAM Connecting compression gauge and glow K

(RENAUT tool No.: Mot.1772) plug hole
Compression gauge adapter
JPBIA0626ZZ
M
KV111063S0 Connecting compression gauge and com-
( — ) pression gauge adapter
Adapter set : φ 16.2 mm (0.64 in)
N
KV11106310 : φ 13.1 mm (0.52 in)
( — )
Adapter
KV11106320 O
( — )
Gasket
KV11106330 JPBIA6259ZZ
( — ) P
Gasket

PREPARATION
(RENAUT tool No.)
Tool name
KV101056S0 Preventing crankshaft from rotating
( — ) : 3 (0.12) : 6.4 (0.252)
Ring gear stopper
: 2.8 (0.110) : 6.6 (0.260)
KV10105630
: 107 (4.21) : 14 (0.55)
( — )
Adapter : 20 (0.79) : 14 (0.55) dia.
Unit: mm (in)
KV10105610
( — )
JSBIA5495ZZ
Plate
KV101151S0 Changing adjusting shim
( — )
Lifter stopper set
KV10115110
( — )
Camshaft pliers
KV10115120
( — )
NT041
Lifter stopper
ST16610001 Removing pilot converter
( — )
Pilot bushing puller
NT045
KV10111100 Removing oil pan (lower and upper), front and

( — ) rear timing chain case, etc.
Seal cutter
NT046
KV10112100 Tightening bolts for connecting rod bearing

( — ) cap, cylinder head, etc. at an angle
Angle wrench
NT014
EM03470000 Installing piston assembly into cylinder bore

( — )
Piston ring compressor
NT044

PREPARATION
(RENAUT tool No.) A
Tool name
KV11106010 Removing and installing chain tensioner
( — ) : 5 mm (0.20 in) (Face to face) EM
Hexagon wrench
: 20 mm (0.79 in)
JSBIA5496ZZ
KV11106020 Removing and installing slack guide D

( — ) : 6 mm (0.24 in) (Face to face)
Hexagon wrench
: 20 mm (0.79 in)
E
JSBIA5497ZZ F
KV11106030 Fixing fuel pump sprocket
( — ) : 6 mm (0.24 in) dia.
Positioning stopper pin G
: 80 mm (3.15 in)
H
JSBIA5498ZZ
KV11106040 Removing and installing fuel pump sprocket

( — ) nut I
Wrench : T70
: 26 mm (1.02 in)
J
JSBIA5499ZZ
K
KV11106050 Removing and installing fuel pump sprocket
( — ) : 6 mm (0.24 in) (Face to face)
Hexagonal wrench
: 42 mm (1.65 in)
L
M
JSBIA5500ZZ
KV11106060 Holding fuel pump sprocket

( — )
N
Sprocket holder
SBIA0225E

PREPARATION
Commercial Service Tool INFOID:0000000014267114

Tool name
— Pressing the tube of liquid gasket
Tube presser
NT052
— Loosening nuts, screws, and bolts

Power tool
PIIB1407E
KV10116200 Disassembling and assembling valve mecha-

Valve spring compressor nism
KV10115900 Part is a component of KV10116200 but
Attachment Part is not so.
KV10109220
Adapter
PBIC1650E
— Finishing valve seat dimensions

Valve seat cutter set
NT048
— Removing and installing piston ring

Piston ring expander
NT030
— : Reaming valve guide inner hole

Valve guide reamer
: Reaming hole for oversize valve guide
Intake and Exhaust:
: 6.0 mm (0.236 in) dia.
: 10.2 mm (0.402 in) dia.
JPBIA0401ZZ

PREPARATION
Tool name A
— Removing and installing valve guide
Valve guide drift Intake and Exhaust:
: 9.5 mm (0.374 in) dia. EM
: 5.5 mm (0.217 in) dia.
C
JPBIA0400ZZ
— Loosening and tightening fuel pump bolt

Socket Size: E10 D
NT807
F
— Loosening and tightening cylinder head bolt,
Cylinder head bolt wrench and used with angle wrench [SST:
KV10112100]
: 13 (0.51) dia. G
: 12 (0.47)
: 10 (0.39)
Unit: mm (in) H
JPBIA0398ZZ
— Loosening and tightening main bearing cap

Socket bolt
Size: E14 I
NT807
— Crankshaft pulley removing and installing K

Pulley holder
ZZA1010D M
N
O
ZZA1210D
Sealant or/and Lubricant INFOID:0000000014267115

P

PREPARATION
Name Description Note
Three bond 1215 Cylinder block Water drain plug
• Rocker cover
• Secondary timing chain
• Camshaft
Three bond 1217H • Cylinder head —
• Oil pan and oil strainer
• Primary timing chain
• Cylinder block

< BASIC INSPECTION > [YD25DDTi]
BASIC INSPECTION A
Inspection and Adjustment INFOID:0000000014267116
EM
INSPECTION
NOTE: C
• When the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the miss adjustment of the valve clearance,
inspect as follows.
• Inspect and adjust when the engine is cool (at normal temperature). D
2. Remove fuel injector. Refer to EM-174, "Exploded View".
E
3. Set the No. 1 piston to TDC on its compression stroke.
• Turn crankshaft pulley clockwise so that the cam nose (A) on
exhaust camshaft (1) faces straight above ( ). (No position
indicator, etc. is provided on the crankshaft pulley.) F
H
JPBIA4521ZZ
4. While referring to the figure, measure the valve clearance I

marked in the table below.
: Engine front J
Measuring position No.1 No.2 No.3 No.4

K
No. 1 cylinder at com- INT (A) (D)
pression TDC EXH (B) (C)
JPBIA3758ZZ
L
NOTE:
Use a feeler gauge (A), measure the clearance between valve M
lifter and camshaft.
JPBIA3759ZZ P
5. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)

6. While referring to the figure, measure the valve clearance
marked in the table below.
: Engine front
Measuring position No.1 No.2 No.3 No.4
No. 4 cylinder at com- INT (A) (D)

pression TDC EXH (B) (C)
JPBIA3787ZZ
7. If the valve clearance is outside the specification, adjust as follows.

ADJUSTMENTS
• Remove adjusting shim for parts which are outside the specified valve clearance.
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft (1) to face the camshaft for adjusting shims
that are to be removed upward.
(A) : Cam nose

: Facing straight above
JPBIA3883ZZ
3. Grip camshaft with the camshaft pliers (A) [SST: KV10115110],

then using camshaft as a support point, push adjusting shim
downward to compress valve spring. Then move the camshaft
pliers handle in the direction of arrow ( ).
CAUTION:
Do not damage camshaft, cylinder head and the outer cir-
cumference of valve lifter.
JPBIA3884ZZ
4. With valve spring in a compressed state, remove the camshaft

pliers (A) [SST: KV10115110] by securely setting the outer cir-
cumference of the valve lifter with the end of the lifter stopper (B)
[SST: KV10115120].
CAUTION:
Do not retrieve the camshaft pliers forcefully, as camshaft
will be damaged.
NOTE:
Hold the lifter stopper by hand until the shim is removed.
JPBIA3885ZZ
5. Move the round hole of adjusting shim to the front with the very thin screwdriver or like that.
NOTE:
When adjusting shim on valve lifter will not rotate smoothly, restart from step 3 to release the end of the
lifter stopper [SST: KV10115120] from touching adjusting shim.

6. Remove adjusting shim from valve lifter by blowing air through
the round hole (1) of the adjusting shim with the air gun (B). A
(A) : Lifter stopper

CAUTION: EM
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles.
C
JPBIA3886ZZ
D
7. Remove adjusting shim (1) by using the magnet hand (B).

E
G
JPBIA3887ZZ
8. Measure the thickness of adjusting shim using the micrometer.

• Measure near the center of the shim (the part that touches H
camshaft).
FEM032
K
9. Select the new adjusting shim from the following methods.
Calculation method of the adjusting shim thickness: L

R = Thickness of removed shim
N = Thickness of new shim
M
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0110 in)] N
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
O
• New adjusting shims have the thickness stamped (A) on the
rear side.
• Shims are available in 33 size from 2.10 mm (0.0827 in) to
2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in). Refer to P
EM-275, "Camshaft".
(B) : Thickness
JPBIA3912ZZ

10. Fit the selected adjusting shim to valve lifter.

(B) : Suitable tool
CAUTION:
Place the stamped side of adjusting shim to valve lifter.
JPBIA3888ZZ
11. Compress valve spring using the camshaft pliers [SST: KV10115110] and remove the lifter stopper [SST:
KV10115120].
12. Rotate crankshaft 2 to 3 turns by hand.
13. Confirm that the valve clearance is within the specification.
14. Install remaining parts in the reverse order of removal.
15. Warm up engine, and check for unusual noise and vibration.

A
CHECKING COMPRESSION PRESSURE EM

1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT, check no error codes are indicated for self-diagnosis items. Refer to EC-892, "Work
Flow". C
• Do not disconnect CONSULT until the end of this operation, it will be used to check engine rpm and for
error detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal. D
4. Remove the engine cover. Refer to EM-154, "Exploded View".
5. To prevent fuel from being injected during inspection, disconnect
all the connectors of the fuel injector. E
(A) : Connector
(B) : Injector F
JPBIA3881ZZ
H
6. Wind the insulating tape around the electrode of the discon-
nected connectors. Tie them together and fix them on the har-
ness side. I
(A) : Connector
J
K
PBIC4772E
7. Remove glow plugs from all the cylinders. Refer to EM-173, "Exploded View". L
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage. M
• Handle with care to avoid applying any shock to glow plugs.
8. Install compression gauge adapter [SST: KV11300QAM

(Mot.1772)] (A) to installation holes of glow plugs and connect N
compression gauge for diesel engine (Commercial service tools)
(B).
NOTE: O
If compression gauge for diesel engine cannot connect to the
compression gauge adapter, use the adapter [SST:
KV111063S0].
P
Compression : 20 N·m (2.0 kg-m, 15 ft-lb)
gauge adapter JPBIA6189ZZ
9. Connect the battery cable to the negative terminal.

10. Turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression
pressure and engine rpm. Perform these steps to check each cylinder.
• Always use a fully-charged battery to obtain specified engine speed.


• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
• If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
• If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
- If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
- If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
• If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be leak-
ing from gasket. In this case, replace cylinder head gasket.
11. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Connect all the connectors of the fuel injector.
e. Connect the battery cable to the negative terminal.
f. Check DTC. If DTC is displayed, erase it.

< SYMPTOM DIAGNOSIS > [YD25DDTi]
SYMPTOM DIAGNOSIS A
NVH Troubleshooting - Engine Noise INFOID:0000000014267118
EM
JSBIA3923GB

< SYMPTOM DIAGNOSIS > [YD25DDTi]
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000014267119


up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-141
gine clicking noise
Rocker
cover Camshaft
Camshaft oil clearance EM-195
Cylinder Rattle C A — A B C bearing
Camshaft runout EM-195
head noise
Piston to piston pin

Slap or Piston pin clearance EM-257
— A — B B —
knock noise Connecting rod bushing EM-257
oil clearance
Piston to cylinder bore
Crank- clearance
EM-257
Slap or Piston EM-257
ley A — — B B A ance
rap slap noise EM-257
Cylinder Piston ring end gap
EM-257
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-257
Knock A B C B B B
bearing Connecting rod bearing EM-257
noise oil clearance (Big end)
Main bearing oil clear-
Main bear- EM-257
Knock A B — A B C ance
ing noise EM-257
Crankshaft runout
Timing
chain and
engine Tapping or and wear
A A — B B B chain ten- *
Timing ticking Timing chain tensioner
sioner
chain case operation
noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-150
ping)
Front of
Drive belts Idler pulley bearing op-
(Slipping) eration
Water
Squall
Creak
noise
• *: Refer to the following list.
- Primary timing chain: Refer to EM-231, "Inspection".
- Secondary timing chain: Refer to EM-186, "Inspection".

DRIVE BELT
< PERIODIC MAINTENANCE > [YD25DDTi]
DRIVE BELT
EM
JPBIA6615ZZ
G
1. Generator 2. Idler pulley 3. Water pump

4. Drive belt auto-tensioner 5. P/S belt tensioner pulley 6. Power steering oil pump belt H
7. Power steering oil pump 8. Crankshaft pulley 9. A/C compressor or idler pulley
10. Drive belt A. Inspection position B. View (B)
C. Indicator D. Range when new belt is installed E. Possible use I
J
REMOVAL
1. Remove the air duct. Refer to EM-156, "Exploded View".
2. Remove the power steering belt as per the following procedures: K
• Loosen idler pulley lock nut (1).
• Loosen adjusting bolt (2), and remove power steering oil pump
belt. L
CAUTION:
Adjusting bolts are applied with grease. Do not allow the
grease to adhere to the belt.
M
N
JPBIA6190ZZ
3. Remove front under cover. Refer to EXT-30, "FRONT UNDER COVER : Exploded View". O
4. Remove the radiator lower hose connector pipe bolts. Refer to CO-40, "Exploded View".
5. Remove radiator fan shroud (lower). Refer to CO-45, "Exploded View".
P
6. Hold the hexagonal part in center of drive belt auto-tensioner pulley with a wrench securely. Then move
the wrench handle in the loosening direction of drive belt (clockwise).
CAUTION:
• Avoid placing hand in a location where pinching may occur if the holding tool accidentally
comes off.
• Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it
counterclockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be
replaced as a unit, including the pulley.

DRIVE BELT
7. Insert a stopper pin in diameter such as short-length screwdriver into the hole of the retaining boss to fix
drive belt auto-tensioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
NOTE:
Use approximately 5.0 mm (0.20 in) dia. hard metal pin as a stopper pin.
INSTALLATION
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
• Do not allow engine coolant to contact the drive belt.
3. Install power steering oil pump belt.
4. Adjust belt tension. Refer to EM-151, "Adjustment".
6. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-150, "Inspection".
JPBIA6615ZZ
1. Generator 2. Idler pulley 3. Water pump

4. Drive belt auto-tensioner 5. P/S belt tensioner pulley 6. Power steering oil pump belt
7. Power steering oil pump 8. Crankshaft pulley 9. A/C compressor or idler pulley
10. Drive belt A. Inspection position B. View (B)
Range when new drive belt is in-
C. Indicator D. E. Possible use range
stalled
WARNING:
Be sure to perform this step when the engine is stopped.
DRIVE BELT
• Check that the indicator (B) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(D).
NOTE:
ure.
POWER STEERING OIL PUMP BELT

DRIVE BELT
• Check the belt with the engine cold or after a lapse of 30 minutes or more after the engine is stopped.
• Measure belt tension at the position as shown in the figure with the A
tension gauge (A). If it is difficult to measure the tension at the
position, then a nearby position can be measured.
• Apply the force of 98.1 N (10kg) at the position (A) shown in the
EM
figure also when measuring by deflection amount.
CAUTION:
• To check belt tension right after belt installation, adjust belt
tension to the reference value and rotate the crankshaft C
twice or more to prevent variations in the tension between
pulleys. Measure belt tension again and adjust to the refer-
ence value. D
JPBIA0422ZZ
• Tighten Idler pulley lock nut by hand and measure tension in
backlash-free condition.
Auxiliary machine belt tension E

deflection amount of auxiliary : Refer to EM-274, "Drive belt".
machine belt
F
G
Portion Belt tightening method for adjustment
Drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Power steering oil pump belt Adjusting bolt of idler pulley. H
CAUTION:
• After replacing belt with a new one, adjust it to the value of "NEW" since new ones do not sufficiently
fit in with pulley grooves. I
• If the belt in use exceeds the value of "Limit of Retightening" adjust the belt to the value of "For
Adjustment"
• To check belt tension right after belt installation, adjust belt tension to the reference value and rotate J
the crankshaft twice or more to prevent variations in the tension between pulleys. Measure belt ten-
sion again and adjust to the reference value.
• After installing belt, check that it is completely fit into the pulley groove.
• Do not allow oil and coolant to adhere to the belt. K
• Do not twist or bend the belt.
POWER STEERING OIL PUMP BELT
L
1. Loosening idler pulley lock nut (1).
2. Adjust tension by turning adjusting bolt (2).
CAUTION: M
Adjusting bolts are applied with grease. Do not allow the
grease to adhere to the belt.
• For adjustment value, refer to EM-274, "Drive belt".
3. Tightening idler pulley lock nut. N
Tightening torque : 28.0 N·m (2.9 kg-m, 21 ft-lb)

O
JPBIA6190ZZ

AIR CLEANER FILTER
AIR CLEANER FILTER
AWBIA3139ZZ
1. Air duct 2. Blow-by hose 3. Clamp

4. Gasket 5. Mass air flow sensor 6. Air cleaner case (upper)
7. Air cleaner filter 8. Air cleaner case (lower) 9. Mounting rubber
10. Bracket 11. Retainer 12. Mounting rubber
13. Air duct (inlet) 14. Clip 15. Air duct
16. Retainer 17. Mounting rubber 18. Air duct
A. To rocker cover B. To turbocharger
REMOVAL
1. Unhook clips (A) and pull up the air cleaner body cover upward
(1).
JSBIA5599ZZ

AIR CLEANER FILTER
2. Remove air cleaner filter (1) from the air cleaner body assembly.
A
EM
JSBIA5600ZZ
D
INSTALLATION
E

ENGINE COVER
< REMOVAL AND INSTALLATION > [YD25DDTi]
REMOVAL AND INSTALLATION

ENGINE COVER
JSBIA4967GB
1. Engine cover (low grade models) 2. Mounting rubber 3. Bracket

4. Bracket 5. Bracket 6. Bracket
7. Bracket
REMOVAL
Remove engine cover.
CAUTION:
Do not damage or scratch engine cover when installing or removing.
INSTALLATION

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
A
EM
I
AWBIA2703ZZ
1. Idler pulley shaft 2. Idler pulley bracket 3. Idler pulley rear cover J
4. Collar 5. Pulley 6. Idler pulley front cover
7. Stopper 8. Collar 9. Idler pulley rear cover
10. Idler pulley 11. Idler pulley front cover 12. Drive belt auto-tensioner K
Front
Removal and Installation INFOID:0000000014267129 L
REMOVAL
1. Remove the radiator fan shroud (upper and lower). Refer to CO-40, "Exploded View". M
2. Remove drive belt and power steering oil pump belt. Refer to ST-35, "Exploded View - YD25DDTi".
NOTE:
To remove auto tensioner, insert a rod of 5.0 mm (0.20 in) dia. into the retaining boss. N
3. Remove drive belt auto-tensioner and idler pulleys.
CAUTION:
The disassemble prohibition part. Do not disassemble the drive belt auto-tensioner, because the O
worker shall injure by the spring jumped out.
NOTE:
Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.
P
INSTALLATION
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.

AWBIA3139ZZ
1. Air duct 2. Blow-by hose 3. Clamp

4. Gasket 5. Mass air flow sensor 6. Air cleaner case (upper)
7. Air cleaner filter 8. Air cleaner case (lower) 9. Mounting rubber
10. Bracket 11. Retainer 12. Mounting rubber
13. Air duct (inlet) 14. Clip 15. Air duct
16. Retainer 17. Mounting rubber 18. Air duct
A. To rocker cover B. To turbocharger
REMOVAL
2. Disconnect the harness connector from mass air flow sensor.
3. Remove the air cleaner body assembly with air cleaner filter.
4. Remove air duct.

5. Disconnect Blow-by hose (2) from air duct (1) and rocker cover
(3). A
: Front
EM
Air duct side : White paint mark (C) align with air
duct slot.
Rocker cover : White paint mark (B) faces upward di- C
side rection of the vehicle.
JSBIA5448ZZ
D
6. Disconnect air duct (2) from turbocharger (1).
• By matching with matching marks (A) of both parts align while
installation.
E
G
JSBIA5460ZZ
7. Remove mass air flow sensor from air cleaner case (if necessary).
CAUTION: H
• Do not shock mass air flow sensor.
• Do not disassemble mass air flow sensor.
• Do not touch mass air flow sensor element. I
INSTALLATION
• Align marks. Attach each joint. Screw clamps firmly. J
K
• If anything found, replace air duct and resonator assembly.
L

CHARGE AIR COOLER
CHARGE AIR COOLER
AWBIA2813ZZ
1. Clamp 2. Air inlet tube 3. Bracket

4. Air inlet hose 5. Mounting rubber (upper) 6. Bracket (RH upper)
7. Bracket (RH lower) 8. Mounting rubber (lower) 9. Clip
10. Charge air cooler seal (RH) 11. Charge air cooler cover 12. Charge air cooler
13. Bracket (LH upper) 14. Charge air cooler seal (LH) 15. Bracket (LH lower)
16. Air inlet hose 17. Air inlet tube 18. Air inlet hose
19. Clamp 20. Bracket 21. Turbocharger boost sensor
22. Vacuum hose A. To throttle chamber B. To turbocharger
C. View C D. View D
REMOVAL
Charge air cooler
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
CHARGE AIR COOLER
1. Remove engine under cover. Refer to EXT-31, "ENGINE UNDER COVER : Removal and Installation".
2. Remove the radiator lower hose connector pipe bolt. Refer to CO-40, "Exploded View". A
3. Remove charge air cooler cover.
4. Remove air inlet tube and air inlet hose.
• Add marks as necessary for easier installation. EM
• Remove quick joint as follows:
- Insert suitable tool between air inlet hose and retainer (1).
C
(A) : View (A)
(B) : Insert position
(C) : Movement direction of the retainer D
(D) : Projection
- Unlock the retainer and pull out hose.
5. Remove charge air cooler seal (RH) (LH). E
6. Remove vacuum hose in charge air cooler side.
7. Remove the bolt of (RH lower) bracket (LH lower) bracket, JPBIA6194ZZ
remove charge air cooler. F

Turbocharger boost sensor
1. Remove the front grille. Refer to EXT-24, "Removal and Installation".
G
2. Disconnect the harness connector from turbocharger boost sensor.
3. Remove turbocharger boost sensor bracket bolt.
4. Remove vacuum hose. H
INSTALLATION
• When installing hoses, insert hose all the way to the end. I
• When installing clamps, check that the screw (B) and band (A) of
clamp have no damage and permanent strain. Replace with a new
one if the clamp has damage of permanent strain. J
• When installing air inlet hose, align identification marks (color and
direction).
• Do not retighten clamp. K
CAUTION:
If it is necessary to retighten a clamp, loosen it and visually
check that there is no damage. After this, tighten the clamp to L
the specified torque.
JPBIA6197ZZ
M

Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary. N
CAUTION:
Be careful not to deform core fins.
O

INTAKE MANIFOLD
INTAKE MANIFOLD
AWBIA3140ZZ
1. Bracket 2. Gasket 3. Intake manifold

4. Gasket 5. Air intake temperature sensor 2 6. Intake manifold collector
7. Intake manifold support 8. Gasket 9. Throttle chamber
10. Plug 11. Bracket 12. Bracket
13. Mounting rubber 14. Gasket 15. Mounting rubber
16. Retainer 17. Resonator 18. Gasket
19. Blind plate A. To charge air cooler B. Refer to INSTALLATION
Front
REMOVAL
1. Remove engine cover. Refer to EM-154, "Exploded View".
2. Remove resonator.
3. Remove air duct. Refer to EM-156, "Exploded View".
4. Remove air cleaner case (lower). Refer to EM-152, "Exploded View".

INTAKE MANIFOLD
5. Remove engine harness connector (RH side).
6. Remove the harness connector and clamps around the intake manifold. A
7. Remove the (RH side) engine harness clamps and move engine harness to the position without interfere
of the work.
8. Remove air inlet tube. Refer to EM-158, "Exploded View". EM
9. Disconnect air inlet hose from throttle chamber unit. Refer to EM-158, "Exploded View".
10. Remove vacuum hoses and throttle chamber.
C
11. Remove intake manifold collector.
12. Remove oil level gauge guide bolts.
13. Remove fuel gallery. Refer to EM-174, "Exploded View". D
• To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
• Add marks as necessary for easier installation. E
14. Remove fuel hose.
15. Remove the harness connector from fuel filter.
F
16. Remove the fuel filter bolts, to move to the position does not interfere with the working of the fuel filter
assembly.
17. Remove oil filter. Refer to LU-27, "Removal and Installation".
G
18. Remove injection tube 5. Refer to EM-174, "Exploded View".
CAUTION:
19. Loosen bolts and nuts in reverse order shown then remove H
intake manifold and intake manifold gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials. I
K
E1BIA0282ZZ
INSTALLATION
Installation is in the reverse order of removal. L
1. Install intake manifold.
• If stud bolts were removed, tighten them to the specified torque.
M
Stud bolts : 10.8 N·m (1.1 kg-m, 8 ft-lb)
• Tighten fixing bolts and nuts in the order from 1 to 9 as shown
in the figure. N
CAUTION:
Do not reuse gasket.
Intake manifold bolts : 21.6 N·m (2.2 kg-m, 16 ft-lb) O

and nuts
E1BIA0282ZZ

INTAKE MANIFOLD
• After tightening bolts and nuts re-tighten 1-4 as shown.
Intake manifold bolt : 21.6 N·m (2.2 kg-m, 16 ft-lb)

and nuts
E1BIA0282ZZ
2. Before starting engine, bleed from fuel piping. Refer to FL-23, "Air Bleeding".

Surface Distortion
• Check distortion on the surface with a straightedge (B) and feeler
gauge (A).
Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace intake manifold.
JPBIA3715ZZ

Start engine and increase engine speed to check for fuel leak.
CAUTION:
Do not touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:

EGR SYSTEM
EGR SYSTEM
A
EM
AWBIA2645ZZ
N
1. Vacuum hose 1 2. Bracket 3. EGR cooler bypass valve control
solenoid valve
4. Vacuum hose 5 5. Vacuum hose 6 6. Connector
O
7. Vacuum hose 6 8. Vacuum hose 7 9. Bracket
10. Gasket 11. EGR guide tube 12. Gasket
EGR volume control valve as-
13. EGR spacer 14. Gasket 15.
sembly
P
16. Gasket 17. EGR tube 18. Gasket
19. Stud bolt 20. Bracket 21. Cover
22. Gasket 23. Stud bolt 24. EGR cooler
25. Vacuum hose 4 26. Vacuum hose 2 27. Connector
28. Vacuum hose 3 A. To air duct B. To vacuum pump
C. To water hose D. To water hose E. Refer to INSTALLATION

EGR SYSTEM
REMOVAL
CAUTION:
Perform this step when the engine is cold.
2. Remove engine cover. Refer to EM-154, "Removal and Installation".
4. Remove air inlet hose and air inlet tube.
5. Remove EGR tube.
6. Remove EGR volume control valve assembly harness connector.
7. Disconnect water hoses from EGR volume control valve assembly and remove EGR volume control valve
assembly.
8. Remove bracket.
9. Disconnect the vacuum hose.
10. Remove EGR cover.
11. Remove water hose from EGR cooler or water pipe.
12. Remove EGR guide tube (1).
(2) : EGR spacer

: Front
JPBIA6444ZZ
13. Remove EGR spacer.

14. Remove EGR cooler.
15. Remove EGR cooler bypass valve control solenoid valve, if necessary.
INSTALLATION
CAUTION:
• Clean each joint surface before installation.
• Make sure to install water outlet pipe and turbo charger after installing EGR cooler.
• Do not reuse gaskets
• Do not reuse stud, bolt and nut except for No. 1, 5, 6, 7, 11 and 12.
• Do not remove EGR cooler tube from EGR cooler.
1. Install EGR system using the following procedure.
ALBIA1325ZZ
• Install EGR cooler as follows.
Step 1 M10 nuts : No. 9, 10 Temporarily tighten

EGR SYSTEM
Step 2 M10 x 1.50 bolts : No. 1 Temporarily tighten
M10 x 1.25 bolts : No. 11, 12 Temporarily tighten A
Step 3 M10 nuts : No. 9, 10 48.5 N·m (4.9 kg-m, 36 ft-lb)
CAUTION: EM
• Make sure to install EGR cooler before installing EGR spacer.
• Make sure to install EGR cooler before installing the turbo charger inlet stud.
• Install EGR spacer as follows.
C
Step 1 M10 bolt : No. 7 Temporarily tighten
Step 2 M10 bolts : No. 5, 6 55 N·m (5.6 kg-m, 41 ft-lb)
D
Step 3 M10 bolt : No. 7 48.5 N·m (4.9 kg-m, 36 ft-lb)
• Install EGR guide tube as follows.
E
Step 1 M8 bolts : No. 3, 2 Temporarily tighten
Step 2 M8 bolts : No. 4, 8 22 N·m (2.2 kg-m, 16 ft-lb)
Step 3 M12 bolts : No. 3, 2 22 N·m (2.2 kg-m, 16 ft-lb) F
Step 4 M10 x 1.50 bolts : No. 1 55 N·m (5.6 kg-m, 41 ft-lb)
M10 x 1.25 bolts : No. 11, 12 55 N·m (5.6 kg-m, 41 ft-lb)
G
• Install cover.
Step 1 M6 bolt : No. 17 Temporarily tighten

H
Step 2 M10 x 1.50 bolts : No. 16, 13, 14, 15 7.8 N·m (0.80 kg-m, 69 in-lb)
Step 3 M6 bolt : No. 17 7.8 N·m (0.80 kg-m, 69 in-lb)
2. Install EGR volume control valve assembly using the following I

steps.
Step 1 M8 bolts : No. 1, 2, 3 Temporarily J

and nut tighten
Step 2 M8 nut : No. 2 22 N·m (2.2 kg-m,
16 ft-lb) K
Step 3 M8 bolt : No. 1 22 N·m (2.2 kg-m,
16 ft-lb)
Step 4 M8 nuts : No. 3 22 N·m (2.2 kg-m, L
ALBIA1326ZZ
16 ft-lb)
Step 5 M8 nut : No. 2 22 N·m (2.2 kg-m,
M
16 ft-lb)

EGR Volume Control Valve N
Perform “EGR Volume Control Valve Closed Position Learning Value Clear” and “EGR Volume Control Valve
Closed Position Learning” after repair when removing or replacing EGR volume control valve. Refer to EC-
900, "Work Procedure" and EC-901, "Work Procedure". O

CATALYST
CATALYST
JSBIA3951GB
1. Catalyst 2. Bracket 3. Bracket

4. Catalyst cover (upper) 5. Catalyst cover (lower) 6. Catalyst cover (lower)
7. Gasket
REMOVAL
1. Remove catalyst cover (upper).
2. Remove exhaust front tube. Refer to EX-12, "Exploded View".
3. Remove air inlet hose and air inlet tube. Refer to EM-158, "Exploded View".
4. Remove bracket.
5. Remove catalyst nut (turbo side).
6. Remove catalyst.
INSTALLATION
CAUTION:
• If stud bolts of turbocharger were removed, tighten them to the specified torque. Refer to EM-167, "Exploded
View".
• If stud bolts of catalyst were removed, tighten them to the specified torque.
Stud bolts : 18.0 N·m (1.8 kg-m, 13 ft-lb)

• While pushing bracket against the cylinder block and the catalyst, temporarily tighten the bolt, then tighten it
to the specified torque.

TURBO CHARGER
TURBO CHARGER
A
EM
L
AWBIA2664ZZ
1. Turbocharger 2. Exhaust manifold 3. Nut M

4. Gasket 5. Stud 6. Stud
7. Heat insulator 8. Clip 9. Turbocharger pressure sensor
10. Clamp 11. Hose 12. Bracket N
13. Bolt 14. Tube 15. Bolt
16. Gasket 17. Oil pipe 18. Eye-bolt
19. Gasket 20. Clamp 21. Oil connector O
22. Gasket 23. Clamp 24. Clamp
25. Clamp 26. Water pipe 27. Clamp
28. Water hose feed 29. Clamp 30. Gasket P
A. To air inlet hose B. To cylinder block C. To cylinder block
D. To Water outlet D. To water pipe E. To water pipe
F. To catalyst
REMOVAL
TURBO CHARGER
NOTE:
• After applying penetrative lubricant to the nuts, check for the penetration of the lubricant, and then loosen
the nuts to remove.
• When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from
spilling.
4. Remove air inlet hose and air inlet tube. Refer to EM-158, "Exploded View".
5. Remove catalyst. Refer to EM-166, "Exploded View".
6. Remove tube.
7. Remove heat insulator.
8. Remove eye bolts and water hose from water tube and oil feed tube and oil return tube.
9. Remove the turbocharger nuts.
10. Remove turbocharger with water tube and oil feed tube and oil return tube.
CAUTION:
• Be careful not to deform water tube and oil-feed-and-return tube.
• Do not disassemble or adjust the turbocharger.
• Be careful not to contact with the vehicle.
• Do not hold turbocharger boost control actuator and actuator rod.
11. Remove water tube and oil feed tube and oil return tube from turbocharger.
12. Remove turbocharger.
CAUTION:
Oil Tube and Water Tube
• Clean inside of oil feed tube and oil return tube and water tube, and check tubes for clogging.
• Replace oil feed tube and oil return tube and/or water tube if clogging still exists after cleaning.
INSTALLATION
CAUTION:
• When a stud bolt is pulled out, replace it with a new one and tighten it to the specified torque.
TROUBLE DIAGNOSIS OF TURBOCHARGER

Preliminary check:
• Check that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil amount is
more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbocharger is mis-
judged malfunction.)
• Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
• Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.

TURBO CHARGER
Symptom A
(when each inspection item meets each inspection result)
Inspection item Inspection result
Engine oil Insufficient power/accel-
Smoke Noise
leakage eration malfunction
EM
Engine oil leaks C A C C
Carbon is accumulated C A B B
Turbine wheel
Friction with housing C B A B C
Blades are bent or broken — — A A
Inside the air inlet is seriously contam-
B B — — D
inated by engine oil.
Compressor wheel
Friction with housing C B A B
Blades are bent or broken — — A A
E
There is resistance when the rotor
— C C B
shaft is rotated by your fingertips.
After checking both turbine and
compressor, inspect rotor shaft The rotor shaft sometimes does not F
— — — A
end play. rotate by your fingertips.
There is too much play in the bearing. C C B C
Carbon or sludge is accumulated in G
Oil return port C A C C
the waste oil hole.
A: Large possibility
B: Medium possibility H
C: Small possibility

I
E1BIA0289ZZ
N
1. Compressor housing 2. Turbocharger boost control actuator 3. Turbine housing
A. Check for charge air pressure leaks B. Check for exhaust gas leaks C. Check for engine coolant leaks
D. Check for engine oil leaks O
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction: P
Suction side : Between turbocharger and charge air cooler

Exhaust side : Between turbocharger and catalyst
Rotor Shaft Clearance

TURBO CHARGER
• Check that the rotor shaft (1) rotates smoothly without any resis-
tance when it is rotated by your fingertips.
• Check that the rotor shaft is not loose when it is moved vertically or
horizontally.
• Measure looseness with a dial gauge inserting its measuring rod
through oil drain hole of turbocharger.
Standard : 0.086 - 0.111 mm (0.0034 - 0.0044 in)

• Replace turbocharger if out of standard.
E1BIA0290ZZ
Rotor Shaft End Play

• Place a dial gauge (A) at the rotor shaft (1) end in the axial direc-
tion to measure the end play.
Standard : 0.030 - 0.111 mm (0.0012 - 0.0044 in)

• Replace turbocharger if out of standard.
E1BIA0292ZZ
Turbine Wheel
• Check that there is no engine oil adhesion.
• Check that there is no carbon accumulation.
• Check that blades of turbine wheel (1) are not bent or broken.
• Check that turbine wheel does not interfere with turbine housing
(2).
E1BIA0291ZZ
Compressor Wheel
• Check that there is no engine oil adhesion inside the air inlet.
• Check that compressor wheel (1) does not interfere with compres-
sor housing (2).
• Check that compressor wheel is not bent or broken.
E1BIA0293ZZ
Turbocharger Boost Control Actuator:

Inspect turbocharger boost control actuator. Refer to EC-1007, "DTC Description".

EXHAUST MANIFOLD
EXHAUST MANIFOLD
A
EM
I
AWBIA3141ZZ
1. Exhaust manifold cover 2. Exhaust manifold cover 3. Gasket J

4. Stud bolt 5. Exhaust gas temperature sensor 1 6. Exhaust manifold
7. Gasket 8. Blind plate A. Refer to INSTALLATION
K
REMOVAL L
2. Remove catalyst. Refer to EM-166, "Exploded View".
3. Remove turbocharger. Refer to EM-167, "Exploded View". M
4. Remove exhaust manifold cover.
5. Loosen exhaust manifold nuts in the order from 8 to 1 as shown
in the figure. N
E1BIA0272ZZ
6. Remove exhaust manifold.

7. Remove exhaust gas temperature sensor 1 (if necessary).
8. Remove stud bolt from cylinder head (if necessary).

EXHAUST MANIFOLD
INSTALLATION
NOTE:
If stud bolts were removed, replace them with new ones, and tighten them to the specified torque. Refer to
EM-171, "Exploded View".
1. Install gasket to cylinder head as shown in the figure.
CAUTION:
(A) : Identification
: Engine front
JPBIA6040ZZ
2. Tighten the nuts to specification in the order as shown.
Step Nuts Torque specification

1 :1–8 : 30.9 N·m (3.2 kg-m, 23 ft-lb)
2 :1– : 30.9 N·m (3.2 kg-m, 23 ft-lb)
E1BIA0272ZZ


Surface Distortion
• Use a reliable straight edge (B) and feeler gauge (A) to check the
flatness of exhaust manifold fitting surface.
Limit : Refer to EM-275, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.
JPBIA6041ZZ

Start engine and raise engine speed to check no exhaust gas and engine oil leaks.

GLOW PLUG
GLOW PLUG
A
EM
G
JPBIA3689GB
1. Glow plug Engine front

H
REMOVAL I
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Remove engine cover. Refer to EM-154, "Exploded View". J
2. Disconnect the harness connector from glow plug.
3. Remove glow plug.
CAUTION: K
• When removing or installing, do not use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.] L
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
M
2. Install glow plug.
N

INJECTION TUBE AND FUEL INJECTOR
AWBIA2706ZZ
1. Nozzle oil seal 2. Clip (Entry grade) 3. Injection tube No. 1 - 4

4. Protector 5. Cooper washer 6. Eye-bolt
7. Spill tube 8. Gasket 9. Fuel rail
10. Connector tube 11. Gasket 12. Clamp
13. Return hose 14. Injection tube No. 5 15. Rubber mounting
16. Clip 17. Spill tube retaining bolt 18. Clamp
19. Spill hose 20. Fuel gallery 21. Clamp
22. Fuel feed hose 23. Fuel pump 24. Clamp
25. Fuel return hose 26. Fuel injector 27. O-ring
28. Nozzle gasket 29. Nozzle support A. To fuel filter
REMOVAL
NOTE:
ing.

1. Remove protector (1).
A
EM
JPBIA6448ZZ
D
2. Remove injection tube clips.
3. Disconnect harness connector from fuel injector.
4. Remove spill hose. E
CAUTION:
5. Following steps below, remove injection tubes (No.1 - 4). F
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method.
b. Remove injection tubes in order of 3-2-1-4 individually. G
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator
H
clear of fuel.
JPBIA6042ZZ J
6. Remove injection tube (No.5)

7. Remove fuel hoses. K
8. Remove oil level gauge guide bolts.
9. Remove fuel rail.
L
10. Remove nozzle oil seal (1).
• Using the flat-bladed screwdriver (A), pry flange (B) to remove
oil seal.
NOTE: M
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required. N
O
JPBIA6195ZZ

P

12. Remove spill tube bolts and nut.
• Loosen bolts and nut to the order from 6 to 1 as shown in the
figure and remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with span-
ner.
(B) : Gasket position

(C) : Spill tube retaining bolt
: Engine front
JPBIA3889ZZ
13. Remove fuel injector as follows.
(1) : Fuel injector

(2) : O-ring
(3) : Nozzle gasket
(4) : Nozzle support
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION: PBIC4852E
• Handle fuel injector carefully without giving any impact.
• Do not disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
d. Remove O-ring from fuel injector.
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface when replacing fuel injector.
• Refer to EC-905, "Description".
JPBIA6043ZZ
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6

2. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.

b. Tighten injection tubes temporarily in the order of 1-2-3-4.
A
: Front
EM
JPBIA6449ZZ
D
c. Be sure to fit nozzle support and pin without looseness.
d. Tighten nozzle support bolts.
e. Loosen injection tubes in the order of 3-2-1-4. E
3. Connect spill tube.
• Tighten fixing bolts and nut in the order from 1 to 6 as shown in
the figure.
F
CAUTION:
When tightening nut, fix spill tube retaining bolt with
spanner.
NOTE: G
Connection of spill tube gasket may be broken, even if it is
tighten to the specified torque. It does not affect performance.
H
(B) : Gasket position
(C) : Spill tube retaining bolt
: Engine front I
JPBIA3889ZZ
L
4. Perform air tightness test for spill tube.
• Connect a handy vacuum pump (A) to spill hose (1). Check
that vacuum is retained while applying following vacuum. M
Standard:
–53.3 to –66.7 kPa (–533 to –667 bar, –400 to –500 N
mmHg, –15.75 to –19.69 inHg)
• If outside of standard, reconnect spill tube. (Replace gasket in
this case.) O
5. Install rocker cover. Refer to EM-179, "Removal and Installa-
tion". JPBIA6191ZZ
6. Install nozzle oil seal. P

• Apply engine oil to the rocker cover nozzle oil seal contact surface and the nozzle oil seal fuel injector
contact surface before installation.
• Insert it straight until its flange fully contacts rocker cover.
CAUTION:
Check gutter spring in nozzle oil seal on fuel injector for missing.

7. Connect injection tubes individually to each cylinder in order of
1-2-3-4.
JPBIA6042ZZ

9. Before start engine, bleed fuel piping. Refer to FL-23, "Air Bleeding".

• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing to the vehicle when replacing fuel injector.
Refer to EC-905, "Description".
JPBIA6043ZZ
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6

• Start engine and increase engine speed to check for fuel leak.
CAUTION:
• After any operation, check that there are no diesel leaks.
• Do not touch engine immediately after stopped as engine becomes extremely hot.

ROCKER COVER
ROCKER COVER
A
EM
I
JSBIA3953GB
1. Oil filler cap 2. Rocker cover 3. Gasket J

A. Refer to INSTALLATION B. To intake air duct 2

K
REMOVAL
1. Remove engine cover and brackets. Refer to EM-154, "Exploded View". L
2. Remove vacuum hoses and bracket. Refer to EM-233, "Exploded View".
3. Disconnect harness connector from fuel injector. Refer to EM-174, "Exploded View".
4. Following steps below, remove injection tubes (No.1 - 4). Refer to EM-174, "Removal and Installation". M
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method.
b. Remove injection tubes in order of 3-2-1-4 individually. N
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator O
clear of fuel.
JPBIA6042ZZ
5. Remove injection nozzle oil seal (1).

ROCKER COVER
• Using the flat-bladed screwdriver (A), pry flange (B) to remove
nozzle oil seal.
JPBIA6195ZZ
6. Remove rocker cover.

• Loosen bolts in the order from 12 to 1 as shown in the figure
and remove.
: Engine front
JPBIA3760ZZ
7. Remove gasket from rocker cover.

INSTALLATION
1. Install new gasket to rocker cover.
CAUTION:
2. Apply liquid gasket with tube presser (commercial service tool)
on locations shown in the figure.
(1) : Cylinder head

(2) : Cylinder head rear cover
(a) : 10 mm (0.394 in)
(b) : φ 3.0 mm (0.118 in)
: Engine front
• Use Genuine Liquid Gasket or equivalent.

JPBIA6044ZZ
3. Tighten bolts.
• Tighten all bolts in the order from 1 to 12 as shown in the fig-
ure.
: Engine front
Bolts : 7.8 N·m (0.8 kg-m, 69 in-lb)
JPBIA3760ZZ

ROCKER COVER
• Re-tighten to the same torque in the same order as shown.
A
: Engine front
Bolts : 7.8 N·m (0.8 kg-m, 69 in-lb) EM
AWBIA2665ZZ
D
4. Install nozzle oil seal.
• Insert it straight until flange fully contacts rocker cover.
5. Installation of remaining components is in the reverse order of removal. E
F
Start engine and increase engine speed to check for fuel leak and engine oil leak.
CAUTION: G
Do not touch the engine immediately after stopped as engine becomes extremely hot.

SECONDARY TIMING CHAIN
AWBIA2707ZZ
1. Chain tensioner 2 2. Slack guide 2 3. Front chain case

4. Tension guide 4 5. Gasket 6. Secondary timing chain
7. Tension guide 5 A. Oil pump housing side B. Refer to INSTALLATION
CAUTION:
• After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike
piston heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
REMOVAL
1. Remove drive belt. Refer to EM-149, "Exploded View".
2. Remove cooling fan. Refer to CO-45, "Removal and Installation".
3. Remove front chain case.
• Loosen bolts in the order from 11 to 1 as shown in the figure
and remove them.
CAUTION:
While front chain case is removed, cover openings to pre-
vent entry of foreign material into engine.
JPBIA6066ZZ

4. Set the No. 1 piston to TDC on its compression stroke.
• Turn crankshaft pulley clockwise so that the alignment mark A
(punched mark) (B) on each camshaft sprocket is positioned
as shown in the figure.
EM
(A) : Same angle
• No position indicator is provided on crankshaft pulley.
• When installing, color coded links on secondary timing
C
chain can be used as alignment marks. Marking may not
be necessary for removal, however, make alignment
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see. JPBIA6068ZZ D
5. Remove chain tensioner 2.

a. Push the plunger of chain tensioner 2 (1) and keep it pressed E
with a push pin (A).
(B) : Press
F
JPBIA6069ZZ H
b. Using the hexagon wrench [SST: KV11106010] (A), remove
bolts to remove chain tensioner 2 (1).
I
K
JPBIA6070ZZ
6. Remove slack guide 2. L

• Using the hexagon wrench [SST: KV11106020] (A), remove
bolt to remove slack guide 2 (1).
M
O
JPBIA6071ZZ

7. Remove tension guide 4 (2).
(1) : Secondary timing chain

8. Remove secondary timing chain.
• Timing chain alone can be removed without removing sprock-
ets.
JPBIA6072ZZ
INSTALLATION
1. Install secondary timing chain.
• When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the timing
chain.
(1) : Secondary timing chain

(2) : Chain tensioner 2
(3) : Slack guide 2
(4) : Fuel pump sprocket
(5) : Tension guide 4
(6) : Camshaft sprocket
(A) : Alignment mark (dark blue link)
(B) : Alignment mark (punched mark)
(C) : Alignment mark (yellow link)
2. Install tension guide 4.
• The upper bolt has a longer shank than the lower bolt.
PBIC4048E
3. Using the hexagon wrench [SST: KV11106020] (A), install slack

guide 2 (1).
JPBIA6071ZZ

4. Install chain tensioner 2 (1).
a. Push the plunger of chain tensioner 2. While holding it with a A
push pin, install chain tensioner 2.
b. Using the hexagon wrench [SST: KV11106010] (A), tighten bolts.
c. Pull out the push pin, etc. holding the plunger. EM
• Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned. C
JPBIA6070ZZ
D
5. Install front chain case.
a. Install tension guide 5 (1) on the back surface of front chain case
(2). E
• Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
F
JPBIA6067ZZ
H
b. Apply a continuous bead of liquid gasket on both ends of arched area (locations where rear chain case is
adjoined) as shown in the figure.
I
M
JPBIA6073ZZ
1. Oil pump housing 2. Rear chain case a. 10 mm (0.39 in) N

c. Primary coating d. 5 mm (0.20 in)
CAUTION:
• For (A), the overlap of the liquid gasket starting point and end-point must be minimized and O
faced outward.
c. Install front chain case. P
CAUTION:
• When installing, align dowel pin on oil pump housing with the pin hole.

d. Tighten bolts in the order shown.
Front chain : 7.8 N·m (0.08 kg-m, 69 ft-lb)

case bolts
JPBIA6066ZZ
e. After tightening all the bolts, re-tighten in the order shown.
Front chain : 7.8 N·m (0.08 kg-m, 69 ft-lb)

case bolts
AWBIA2666ZZ


Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
SEM984C

Inspection for Leakage
1. Check the engine oil level and adjust engine oil. Refer to LU-24, "Inspection".
2. Start engine, and check there is no leak of engine oil.
4. Check the engine oil level again. Refer to LU-24, "Inspection".
Inspection for Noise and Vibration
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The noise
will stop after hydraulic pressure rises.

FUEL PUMP
FUEL PUMP
A
REMOVAL EM
JPBIA5916GB
J
1. Sprocket nut 2. Adjusting shim 3. Coupling
4. Washer 5. Fuel pump bracket 6. Oil seal
7. O-ring 8. Spacer 9. Key K
10. Fuel pump 11. Spacer 12. Bracket
DISASSEMBLY L
JPBIA3755GB
1. Suction control valve 2. O-ring 3. O-ring

FUEL PUMP
CAUTION:
piston heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
• When fuel pump is replaced with new one or another one, perform fuel pump learning value clearing
before starting engine. Refer to EC-904, "Work Procedure".
NOTE:
ing.
REMOVAL
2. Remove fuel feed hose, fuel return hose. Refer to EM-174, "Exploded View".
CAUTION:
3. Disconnect harness connectors from fuel pump.
4. Remove injection tube (No.5), clip and insert rubber. Refer to EM-174, "Removal and Installation".
CAUTION:
5. Remove collector intake manifold. Refer to EM-160, "Exploded View".
6. Remove secondary timing chain. Refer to EM-182, "Exploded View".
7. Hold fuel pump sprocket and remove bolt.
a. Insert the positioning stopper pin [SST: KV11106030] (B) into the
hole 6 mm (0.24 in) in the diameter on the fuel pump sprocket.
b. Using the a wrench (T70) [SST: KV11106040] (A), turn pump
shaft little by little to adjust the position of fuel pump sprocket so
that the holes align.
c. Push the positioning stopper pin [SST: KV11106030] (B) through
fuel pump sprocket to fuel pump body to hold fuel pump
sprocket.
JPBIA6045ZZ
• Insert the positioning stopper pin [SST: KV11106030] (A) until

its flange contacts the fuel pump sprocket (2).
(1) : Coupling
(3) : Fuel pump
(B) : Wrench (T70) [SST: KV11106040]
JPBIA6046ZZ

FUEL PUMP
8. Using the hexagon wrench [SST: KV11106050] (B) remove tight-
ening bolts of fuel pump sprocket. A

(2) : Washer EM
(A) : Positioning stopper pin [SST: KV11106030]
JPBIA6047ZZ
G
JPBIA6048ZZ
9. Using the sprocket holder [SST: KV11106060], hold fuel pump sprocket to prevent falling. H
• Rework sprocket holder (A) to use, as shown in the figure.
(B) : Additional machining area

I
K
JPBIA6049ZZ
• When the sprocket holder [SST: KV11106060] (A) is installed,

L
if the positioning stopper pin [SST: KV11106030] (B) interferes,
pull out the positioning stopper pin approximately 10 mm (0.39
in), then install it.
• After the sprocket holder is installed temporarily, tighten the M
sprocket holder after making extension bar and socket (size:
E10) (commercial service tool) insert into the machined bore.
• The length of the sprocket holder bolts should be approxi-
N
mately 15 mm (0.59 in) (M6 thread length).
• Check that the (C) and (D) faces of the sprocket holder contact
the bottom side of the sprocket (small diameter side).
JPBIA6050ZZ
CAUTION: O
Do not remove the sprocket holder [SST: KV11106060] until fuel pump is installed.
• After the sprocket holder is installed, pull out the positioning stopper pin from fuel pump sprocket.
P

FUEL PUMP
10. Using the extension bar and a socket (size: E10) (commercial
service tool) (A), remove the tightening bolts.
(1) : Fuel pump

CAUTION:
Be careful not to drop the seal washer into the engine.
NOTE:
The seal washer of the tightening bolts cannot be reused.
JPBIA6051ZZ
11. Remove the fuel pump toward the rear of engine.

12. Remove adjusting shim.
13. Attach a suitable pulley holder (A) in the M8 bolt hole on cou-
pling (2).
(1) : Sprocket nut

(B) : Bolt (M8)
(C) : Wrench (T70) [SST: KV11106040]
14. Loosen sprocket nut with a wrench (T70) [SST: KV11106040].
JPBIA6052ZZ
15. Remove coupling (1) with a suitable puller (A).
JPBIA6053ZZ
16. Remove spacer from fuel pump.

17. Remove oil seal from spacer.
INSTALLATION
1. Install new oil seal (2) to spacer (1).
(A) : 2 - 2.5 mm (0.08 - 0.09 in)

: Spacer side
JPBIA6055ZZ
2. Install spacer to fuel pump.

FUEL PUMP
3. Install coupling (2) to fuel pump of spacer.
A
(1) : Sprocket nut
(A) : Pulley holder (suitable tool)
(B) : Bolt (M8) EM
(C) : Wrench (T70) [SST: KV11106040]
• Using the a wrench (SST), tighten the sprocket nut to fix the
coupling. C
JPBIA6052ZZ
D
4. Install adjusting shim.
• For shim adjustment, measure dimension (B) [Distance
between front surface of coupling (1) and spacer (2)] at two
E
opposing points near the coupling bolt center. Use the average
of these two measurements to select the shim grade that
marked on adjusting shim.
F
(A) : Measuring point
JPBIA6056ZZ
H
• The shim adjustment is required only when the fuel pump is
replaced.
I
K
PBIC3439E
L
Part No. of adjusting shim Grade number Measuring dimension B [mm (in)] Type
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657) A
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445) B M
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
N
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A+C
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B+B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C+B O
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D+B

FUEL PUMP
5. Before fuel pump is installed, check that spacer and the 6 mm
(0.24 in) dia. hole (a) on coupling (1) are aligned.
JPBIA6057ZZ
6. Insert fuel pump (1) into position from the rear side of the
engine, and install the tightening bolts with seal washer (2).
CAUTION:
• Be careful not to drop the seal washer into engine.
• Do not reuse seal washers.
JPBIA6058ZZ
7. Using the extension bar and a socket (size: E10) (commercial

service tool) (A), tighten the tightening bolts of fuel pump (1).
8. Remove the sprocket holder [SST: KV11106060].
JPBIA6051ZZ
9. Using a wrench (T70) [SST: KV11106040] (A), turn the pump

shaft gradually to adjust the position of fuel pump sprocket.
Then, insert the positioning stopper pin [SST: KV11106030] (B)
to the 6 mm (0.24 in) dia. hole of the fuel pump sprocket through
the pump body.
JPBIA6045ZZ
10. Using the hexagon wrench [SST: KV11106050] (B), tighten the
sprocket tightening bolt.

(2) : Washer
• When the washer of the fuel pump sprocket is removed, install
it with the marking “ ” facing the front of the engine.
JPBIA6047ZZ

FUEL PUMP
11. Pull out the positioning stopper pin [SST: KV11106030].
12. Install secondary timing chain. Refer to EM-182, "Exploded View". A
EM
CAUTION:
When fuel pump is replaced with new one or another one, perform fuel pump learning value clearing
before starting engine. Refer to EC-904, "Work Procedure".
C
DISASSEMBLY D
1. Disconnect harness connector from fuel pump suction control
valve (1).
E
G
E1BIA0297ZZ
2. Take note of the connector's orientation. The new valve will have to be fitted in the same way as the old H
one.
3. Clean the pump with brake cleaner around fuel pump suction control valve contact surface.
4. Remove fixating bolt of the suction valve, and remove the suction valve. I
CAUTION:
• The large O-ring says inside. Do not pull the valve with twisting or try prying it out with any tool.
Carefully pull the valve straight up.
J
• Do not use work gloves to prevent foreign substances entering the fuel injection pump.
5. Remove large O-ring (1).
CAUTION:
• Do not use any tool to remove the O-ring. K
• Do not allow any foreign substances to enter into the fuel
injection pump.
L
E1BIA0298ZZ
N
ASSEMBLY
CAUTION:
The seal washer of the tightening bolts cannot be reused.
O
1. Ensure that the groove of the pump side housing is contamina-
tion free, then place the large new O-ring (1) into the groove.
NOTE:
• Apply clean engine oil around the small O-ring, then fit it to the P
groove. Otherwise the O-ring may fall off.
E1BIA0299ZZ

FUEL PUMP
2. Apply clean engine oil around the small O-ring (1) on the new
suction control valve for sealing.
CAUTION:
Make sure the suction control valve is clean and no debris
sticks to the O-ring. Any contamination or damage to the O-
ring will cause the fuel injection pump not to work properly.
E1BIA0300ZZ
3. Insert the new suction control valve by hand until you feel a
click. Make sure the connector faces into the same direction as
before removal.
CAUTION:
Do not try to twist the suction control valve in, just push it
straight.
E1BIA0301ZZ
4. Tighten bolt by hand and then use the torque wrench. Refer to EM-187, "Exploded View".
5. Connect the suction control valve to the wiring harness.
6. Clean the suction control valve fitting area with a degreasing spray.
7. Bleed fuel lines.
8. Start engine and check there is no fuel leakage.

Start engine and increase engine speed to check for fuel leak.
CAUTION:
• After any operation, check that there are no diesel leaks.
• Do not touch engine immediately after stopped as engine becomes extremely hot.

CAMSHAFT
CAMSHAFT
A
EM
J
JPBIA5921GB
1. Camshaft bracket 2. Intake camshaft 3. Exhaust camshaft K

4. Adjusting shim 5. Valve lifter 6. Knock pin
7. Camshaft sprocket 8. Cylinder head 9. O-ring
10. Camshaft position sensor 11. Cylinder head rear cover 12. Signal plate L
A. Comply with the installation proce-
dure when tightening. Refer to EM-
195 M
N
REMOVAL
2. Remove the following parts: O
• Fuel injector. Refer to EM-174, "Exploded View".
• Rocker cover. Refer to EM-179, "Exploded View".
• Secondary timing chain. Refer to EM-182, "Exploded View".
P
4. Remove camshaft sprockets.

CAMSHAFT
• Loosen the camshaft sprocket bolts by fixing the hexagonal
portion of camshaft.
JEM159G
5. Remove camshaft.
• Place distinguishing marks on the right and left sides with paint.
• Loosen and remove the camshaft bolts in the order from 15 to
1 as shown in the figure.
: Engine front
JPBIA3771ZZ
6. Remove adjusting shim and valve lifter.

• Remove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion.
7. Loosen cylinder head rear cover bolts in the order from 6 to 1 as
shown in the figure.
8. Remove signal plate (if necessary).
JPBIA6074ZZ
INSTALLATION
CAUTION:
1. Install signal plate (if removed).
2. Install cylinder head rear cover (if removed).
a. Apply liquid gasket to cylinder head rear cover as shown in the
figure.
(a) : 4.0 - 5.6 mm (0.157 - 0.220 in)

(b) : φ 3.4 - 4.4 mm (0.134 - 0.173 in)
Use Genuine Liquid Gasket or Equivalent.
JPBIA6077ZZ

CAMSHAFT
b. Install cylinder head rear cover and tighten bolts in the order
from 1 to 6 as shown in the figure. A
M8 × 50 mm (1.97 in) : Bolt No. 1

M8 × 20 mm (0.79 in) : Bolt No. 2 - 6 EM
JPBIA6074ZZ
D
3. Install valve lifter and adjusting shim.
• Check that these are installed in the same position as before the removal process.
4. Install camshaft.
E
(1) : Intake camshaft
(2) : Exhaust camshaft
F
: Engine front
• Identify camshafts by the paint position.

G
(A) : White
(B) : Green
JPBIA3894ZZ
H
• When replace camshaft (2), install knock pin (1) shown in the
figure.
I
(a) : 3.6 - 4.2 mm (0.142 - 0.165 in)
: Engine front
J
JPBIA6075ZZ
L
• Install so that knock pins (A) are positioned in the directions
(B) : Intake camshaft M

(C) : Exhaust camshaft
(d) : Approx. 67.5°
(e) : Approx. 2.6° N
: Up
O
AWBIA3142ZZ
5. Install camshaft brackets.

• Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cylin- P
der head.

CAMSHAFT
• Install correctly, identifying brackets by the journal No. (A) and
front mark (B) on top surface.
: Engine front
JPBIA6076ZZ
6. Tighten camshaft bolts in the order from 1 to 15 as shown in the

figure according to the following procedure:
: Engine front
a. Tighten No. 13 to 15.
Camshaft bolts : 1.96 N·m (0.20 kg-m, 1 ft-lb)

• Check camshaft thrusting parts (on rear side) securely fit in
their mating parts on the cylinder head.
b. Tighten No. 1 to 12. JPBIA3771ZZ

c. Tighten all bolts.

d. Tighten all bolts.

7. Install camshaft sprockets.
• Camshaft sprockets are commonly used for right side and left side.
• Align camshaft sprocket and knock pin on camshaft, and install.
• Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprockets.
8. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to EM-141, "Inspection and Adjustment".

Visual Check of Camshaft
• Check the camshaft for one sided wear or scratches.
• Replace the camshaft if there are abnormalities.
Camshaft Runout

CAMSHAFT
• Prepare V-block on a flat surface and secure camshaft journals No.
2 and No. 5. A
• Set the dial gauge (A) vertically on journal No. 3.
• Rotate camshaft in one direction by hand, then read needle move-
ment on dial gauge. (Total indicator reading)
EM
• If it exceeds the limit, replace camshaft. C
JPBIA3895ZZ
D
Height of Cam Nose
• Measure the height of cam nose using the micrometer.
Standard : Refer to EM-275, "Camshaft". E
• If out of the standard, replace camshaft.

F
G
SEM549A
Camshaft Journal Oil Clearance H

CAMSHAFT JOURNAL OUTER DIAMETER
• Measure outer diameter of camshaft journal with micrometer.
I
SEM012A
L
CAMSHAFT BRACKET INNER DIAMETER
• Install camshaft bracket and tighten bolts to the specified torque. Refer to "INSTALLATION" for the tighten-
ing procedure. M
• Measure inner diameter of camshaft bracket using the inside
micrometer (A).
Standard : Refer to EM-275, "Camshaft". N
P
JPBIA6078ZZ
CAMSHAFT OIL CLEARANCE CALCULATIONS

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter)

• If out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head.

CAMSHAFT
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the camshaft
bracket.
Camshaft End Play
• Install dial gauge in thrust direction on front end of camshaft. Mea-
sure end play of dial gauge (A) when camshaft is moved forward/
backward (in direction to axis).

and limit
JPBIA6079ZZ
• Measure the following parts if out of the standard.

- Dimension “A” for camshaft
Standard : 6.882 - 6.930 mm (0.2709 - 0.2728 in)

- Dimension “B” for cylinder head
Standard : 7.000 - 7.030 mm (0.2756 - 0.2768 in)

• Refer to the standards above, and then replace camshaft and/or
cylinder head.
PBIC2320E
Camshaft Sprocket Runout

1. Install camshaft in cylinder head. Refer to EM-195, "Removal and Installation" for the tightening proce-
dure.
2. Install sprocket on camshaft. Refer to EM-195, "Removal and Installation".
3. Measure camshaft sprocket runout. (Total indicator reading)
(A) : Dial gauge

• If it exceeds the limit, replace camshaft sprocket.
JPBIA6080ZZ
Visual Inspection of Valve Lifter and Adjusting Shim

Check if surface of valve lifter and adjusting shim has any wear or
cracks.
• If anything above is found, replace valve lifter or adjusting shim.
SEM160D
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER

CAMSHAFT
• Measure the outer diameter of the valve lifter with the micrometer.
A
EM
SEM961E
D
VALVE LIFTER BORE DIAMETER
• Measure the bore diameter of the cylinder head valve lifter with the
inside micrometer (A). E

F
JPBIA6081ZZ
H
VALVE LIFTER CLEARANCE CALCULATIONS
• (Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)
Standard : Refer to EM-275, "Camshaft". I
• If out of standard, refer to the outer diameter and bore diameter standard values and replace valve lifter and/
or cylinder head.
J
K
The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-23, "Fluids and Lubricants". L
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points. M
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a N
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant. O
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary. P
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Transmission / AT & CVT Models Leakage Level / Leakage Leakage

transaxle fluid MT Models Level / Leakage Leakage Level / Leakage

CAMSHAFT
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

CYLINDER HEAD
CYLINDER HEAD
A
REMOVAL EM
JSBIA3954GB
J
1. Cylinder head assembly 2. Slinger 3. Engine coolant temperature sensor
4. Gasket A. Comply with the installation pro-
cedure when tightening. Refer to K
EM-204.
DISASSEMBLY
L

CYLINDER HEAD
JPBIA3699GB
1. Adjusting shim 2. Valve lifter 3. Valve collet

4. Valve spring retainer 5. Valve spring (intake) 6. Valve oil seal
7. Valve spring seat 8. Valve guide 9. Cylinder head
10. Valve seat 11. Valve (intake) 12. Valve (exhaust)
13. Valve spring (exhaust)
REMOVAL
1. Drain engine coolant from radiator and cylinder block. Refer to CO-36, "Changing Engine Coolant".
• Turbocharger. Refer to EM-167, "Exploded View".
• Exhaust manifold. Refer to EM-171, "Exploded View".
• Intake manifold. Refer to EM-160, "Exploded View".
• Glow plug. Refer to EM-173, "Exploded View".
• Injection tube and fuel injector. Refer to EM-174, "Exploded View".
• Rocker cover. Refer to EM-179, "Exploded View".
• Camshaft. Refer to EM-195, "Exploded View".
3. Remove cylinder head assembly.
a. Remove bolts between rear chain case and cylinder head. Refer to EM-219, "Exploded View".

CYLINDER HEAD
b. Remove cylinder head bolts in the order from 18 to 1 as shown
in the figure with the cylinder head bolt wrench (commercial ser- A
vice tool).
: Engine front EM
c. Lift up cylinder head assembly to avoid interference with dowel
pins located between the cylinder block and cylinder head, and
remove cylinder head assembly. C
CAUTION:
Remove glow plug in advance to avoid damage as the tip of
JPBIA3785ZZ
the glow plug projects from the bottom of cylinder head, or, D
place wood blocks beneath both ends of cylinder head to keep the cylinder bottom from any con-
tact.
4. Remove water temperature sensor (if necessary).
E
INSTALLATION
NOTE:
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts. F
1. Install cylinder head gasket.
CAUTION:
• Cylinder head gasket to be installed is selected by its thickness through the following procedure. G
- When replacing gasket alone:
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of ID marks on H
the front LH side.
: Engine front
I
Gasket thickness* [mm (in)] Number of grade Number of ID marks

J
0.900 (0.0354) 1 0
0.925 (0.0364) 2 1
0.950 (0.0374) 3 1+2 K
JPBIA3786ZZ
0.975 (0.0384) 4 1+2+3

1.000 (0.0394) 5 1+2+3+4
1.025 (0.0404) 6 1+2+3+4+5 L
*: Measured with head bolts tightened
M
• Heater return tube is omitted for explanation.
NOTE:
- When the following parts have been repaired/replaced: N
• With cylinder block upper surface and/or crankshaft pin journal ground.
• With cylinder block, pistons, connecting rods, and/or crankshaft replaced.
a. Set piston at a point close to TDC. O

CYLINDER HEAD
b. Set the dial gauge (A) at the location as shown in the figure.
Turning crankshaft gradually, set the gauge scale to “0” where
the piston protrusion is maximized.
(B) : Measuring point

(C) : Front mark
(d) : 39.5 mm (1.555 in)
c. Move the dial gauge stand so that the tip of dial gauge can con-
tact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each JPBIA6096ZZ
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.
Identification
Piston protrusion [mm (in)] Gasket thickness* [mm (in)]
Number of ID marks
0.161 - 0.186 (0.0063 - 0.0073) 0.900 (0.0354) 0
0.186 - 0.211 (0.0073 - 0.0083) 0.925 (0.0364) 1
0.211 - 0.236 (0.0083 - 0.0093) 0.950 (0.0374) 1+2
0.236 - 0.261 (0.0093 - 0.0103) 0.975 (0.0384) 1+2+3
0.261 - 0.286 (0.0103 - 0.0113) 1.000 (0.0394) 1+2+3+4
0.286 - 0.331 (0.0113 - 0.0130) 1.025 (0.0404) 1+2+3+4+5
*: Measured with head bolts tightened
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure.
(b) : φ 2.6 - 3.6 mm (0.102 - 0.142 in)

: Engine front
• Apply bead so that it does not protrude into oil passage (A).
JPBIA6097ZZ
3. Install cylinder head assembly.

• Tighten bolts in the order from 1 to 18 as shown in the figure
according to the following procedure:
: Engine front
a. Apply engine oil to bolt threads and seat surfaces.

b. Tighten all bolts.
Bolts : 39.2 N·m (4.0 kg-m, 29 ft-lb)
JPBIA3785ZZ

CYLINDER HEAD
c. Tighten all cylinder head bolts (clockwise).
A
Angle tightening : 180 degrees
CAUTION:
When the angle wrench [SST: KV10112100] (A) is not used, EM
paint an alignment mark on the head of cylinder head bolt
and cylinder head surface before tightening. Check the
angle with a protractor. C
d. Loosen completely in the reverse order of that shown in the fig-
ure.
JPBIA6098ZZ
D
e. Tighten all bolts.
E
Bolts : 39.2 N·m (4.0 kg-m, 29 ft-lb)
f. Tighten all cylinder head bolts (clockwise).
F
g. Tighten all cylinder head bolts (clockwise). G

CAUTION: H
When the angle wrench [SST: KV10112100] is not used, paint an alignment mark on the head of
cylinder head bolt and cylinder head surface before tightening. Check the angle with a protractor.
4. Tighten bolts between rear chain case and cylinder head. Refer to EM-219, "Exploded View". I
5. After installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head (If rear
chain case is removed). J
(A) : Vernier caliper
K
Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in)
• If out of the standard, check fitting of dowel pins and cylinder
head. L
JPBIA6099ZZ
6. Install glow plug. M

CAUTION:
• To avoid damage, glow plugs should be removed only when required.
• Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one. N
• Before installing, remove carbon depositing on hole of glow plug with a reamer.
7. Install engine coolant temperature sensor (if removed). Refer to EM-203, "Exploded View".
8. Installation of remaining components is in the reverse order of removal. O
P
DISASSEMBLY
1. Remove adjusting shims and valve lifters.
• Check the installation positions, and keep them to avoid being confused.

CYLINDER HEAD
• Using the valve spring compressor [Commercial Service Tool]
(A), compress valve spring. Using magnet hand, remove valve
collets.
(B) : Adapter
(C) : Attachment
JPBIA6100ZZ
3. Remove valve spring retainers and valve springs.

4. Remove valves as pressing valve stems toward combustion chamber.
• Before removing valve, check the valve guide clearance. Refer to EM-209, "Inspection".
5. Remove valve oil seals using the valve oil seal puller [SST:
KV10107902] (A).
(B) : Adapter [SST: KV10116100]

6. Remove valve spring seats.
7. Remove valve seats.
• Before removing valve seats, perform valve seat contact
check. Refer to EM-209, "Inspection".
8. Remove valve guides.
JPBIA6101ZZ
ASSEMBLY
1. Install valve guides. Refer to EM-209, "Inspection".
2. Install valve seats. Refer to EM-209, "Inspection".
3. Using the valve oil seal drift [SST: KV10115600] (A), install valve
oil seals referring to the dimension shown in the figure.
(b) : 12.1 - 12.7 mm (0.476 - 0.500 in))

4. Install valve spring seats.
JPBIA6102ZZ
5. Install valves.
• Install the valves with bigger outer diameter to intake valve side.
6. Install valve spring.
7. Install valve spring retainers.
8. Using the valve spring compressor [Commercial Service Tool]
(A), compress valve springs.
(B) : Adapter
(C) : Attachment
Then install valve collets using magnet hand.
• After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
JPBIA6100ZZ

CYLINDER HEAD
9. Install valve lifters and adjusting shims to the same positions as before.
A

EM
Cylinder Head Bolt Deformation
• Using micrometer, measure the outer diameters (A) and (B) of bolt
thread as shown in the figure. C
(c) : 65 mm (2.56 in)
(d) : 11 mm (0.43 in)
D
• If the necking point can be identified, set it as measuring point (A).
• Calculate the difference between (A) and (B).
E
Limit : 0.15 mm (0.0059 in)
• If it exceeds the limit, replace cylinder head bolt. JPBIA6196ZZ
Cylinder Head Distortion F

1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water. G
measure distortion in six directions (A - F).
H
• If it exceeds the limit, replace cylinder head.
I
J
JPBIA0176ZZ
INSPECTION AFTER DISASSEMBLY K

Valve Dimension
• Check dimensions of each valve. For dimensions, refer to EM-277,
"Cylinder Head". L
• If dimensions are out of the standard, replace valve.
JSBIA1166ZZ
Valve Guide Clearance O
Valve Stem Diameter

P

CYLINDER HEAD
• Measure diameter of valve stem with micrometer (A).
Standard : Refer to EM-277, "Cylinder

Head".
JPBIA0183ZZ

• Measure inner diameter of valve guide with inside micrometer.
Standard : Refer to EM-277, "Cylinder

Head".

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Standard and limit : Refer to EM-277, "Cylinder

Head".
• If it exceeds the limit, replace valve and/or valve guide.
Valve Guide Replacement
When removing valve guide, replace it with oversized [0.2 mm (0.008 in)] valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
JPBIA0184ZZ
2. Using the valve guide drift (commercial service tool), tap valve
guides out from the combustion chamber side.
WARNING:
SEM931C

CYLINDER HEAD
3. Ream cylinder head valve guide hole with the valve guide
reamer (commercial service tool) (A). A
Valve guide hole diameter : Refer to EM-277, "Cylinder

(for service parts) Head". EM
JPBIA0185ZZ
D
heated oil (A).
E
G
JPBIA0184ZZ
5. Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension H
Projection (L) : Refer to EM-277, "Cylinder Head". I

WARNING:
equipment to avoid getting burned. J
PBIC2497E
K
6. Using the valve guide reamer (commercial service tool) (A), per-
form reaming to the press-fitted valve guides.
L
Reaming specifications : Refer to EM-277, "Cylin-
der Head".
M
N
JPBIA0185ZZ
Valve Seat Contact

O
• Before starting this check, confirm that the dimension of valve
guide and valves are as specified.
(A) : OK P
(B) : NG
• Apply red lead primer on contacting surfaces of valves seat and of
valve face to examine the conditions of contacting surfaces.
• Check that the paint on contacting surfaces is continuous along the
entire circumference.
JPBIA0187ZZ

CYLINDER HEAD
• If there are abnormal indications, grind the valve and check the contact again. If malfunction indications still
persist, replace valve seat.
Valve Spring Square
• Position the try square (A) to valve spring, turn the spring, and
measure the maximum clearance value between top surface of
spring and the try square.
(B) : Contact

• If it exceeds the limit, replace valve spring.
PBIC3219J
Valve Seat Replacement

When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-274, "General Specification".
2. Ream cylinder head recess diameter (a) for service valve seat.
Oversize [0.5 mm : Refer to EM-277, "Cylinder

(0.020 in)] Head".
• Be sure to ream in circles concentric to the valve guide center.
• This will enable valve seat to fit correctly.
JPBIA0188ZZ

heated oil (A).
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
WARNING:
CAUTION:
Do not touch the cooled valve seats directly by hand.
JPBIA0184ZZ
5. Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or
repeatedly, the valve seat surface may be damaged.
SEM934C
6. Using compound, perform valve fitting.

7. Check again to check that contacting status is satisfactory.
For details, refer to "Valve Seat Contact".

CYLINDER HEAD
8. Use the depth gauge to measure the distance between the sur-
face of cylinder head spring seat and the valve stem end. If the A
distance is shorter than specified, repeat step 5 above to adjust
it. If it is longer, replace valve seat with a new one.
EM
Valve seat resurface : Refer to EM-277, "Cylinder
limit (L) Head".
C
JEM253G
D
Valve Spring Dimensions and Valve Spring Pressure Load
• Using intake valve spring tester, check the following.
Standard : Refer to EM-277, "Cylinder Head". E
• If out of the standard, replace the valve spring.

F
G
SEM113
INSPECTION AFTER INSTALLATION H

The following are procedures for checking fluid leakage, lubricant leakage. I
required quantity, fill them to the specified level. Refer to MA-23, "Fluids and Lubricants".
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, J
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. K
NOTE:
noise will stop after hydraulic pressure rises. L
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system. M
the specified level, if necessary.
Summary of the inspection items: N
Engine oil Level Leakage Level O
P

JSBIA5567GB
1. Oil level gauge 2. Oil level gauge guide 3. Oil level sensor
4. O-ring 5. O-ring 6. Cap
7. Clamp 8. O-ring 9. Oil pan (upper)
10. Crankshaft position sensor 11. O-ring 12. Rear plate
13. Rear plate cover 14. Oil strainer 15. Oil pan drain plug
16. Drain plug washer 17. Oil pan (lower)
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
NOTE:
ing.

2. Remove oil pan (lower) bolts. Loosen bolts in the order from 10
to 1 as shown in the figure. A
: Front
EM
AWBIA2658ZZ
D
3. Remove oil pan (lower).
a. Insert the seal cutter (SST) between oil pan (upper) and oil pan
(lower). E
CAUTION:
• Be careful not to damage aluminum mating surface.
• Do not insert screwdriver, or oil pan flange will be
deformed. F
b. Slide the seal cutter by tapping on the side of the seal cutter with
a hammer.
G
c. Remove oil pan (lower).
SEM365EA
H
4. Remove oil strainer.
5. Remove power steering oil pump belt. Refer to ST-35, "Exploded View - YD25DDTi".
6. Remove power steering oil pump bracket and move power steering oil pump aside with its piping con- I
nected. Temporarily secure it on the vehicle side with a rope to avoid putting load on it.
7. Remove the oil level gauge guide.
8. Remove A/T oil cooler tube bracket and harness clips (A/T models). Refer to TM-313, "Exploded View". J
9. Remove A/C compressor bracket bolts (A).
(1) : Oil pan upper K

(2) : A/C compressor bracket
: Front
L
M
PBIC3426E
10. Remove the drive belt. Refer to EM-155, "Removal and Installation" N
11. Remove the crankshaft pulley. Refer to EM-250, "Exploded View".
12. Remove the front cross member.
13. Remove the oil level sensor. O
CAUTION:
• Avoid impacts such as a dropping.
• Do not disassemble. P
• Keep it away from metal particles.
• Do not place sensor close to magnetic materials.
14. Remove front propeller shaft. Refer to DLN-137, "Removal and Installation".
15. Remove RH and LH front drive shaft.
16. Remove front final drive assembly.
17. Remove rear plate cover and transmission joint bolts.

18. Remove oil pan (upper) bolts. Loosen bolts in the order from 17
to 1 as shown in the figure.
: Front
AWBIA2659ZZ
19. Remove oil pan (upper).

• Insert the seal cutter (SST) between oil pan (upper) and cylin-
der block. Slide the seal cutter by tapping on the side of the
seal cutter with a hammer. Remove oil pan (upper).
CAUTION:
• Be careful not to damage aluminum mating surface.
• Do not insert screwdriver, or oil pan flange will be
deformed.
SEM365EA
INSTALLATION
• Install oil pan (upper) with the following procedure.
- Use the scraper (A) to remove old liquid gasket from mating sur-
face of oil pan (upper) (1).
CAUTION:
• Also remove old liquid gasket from mating surface of cylin-
der block and rear chain case.
• Remove old liquid gasket from the bolt hole and thread.
PBIC3432E
- Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to areas shown in the figure.
(a) : φ 4.5 - 5.5 mm (0.177 - 0.217 in)

(b) : φ 3.5 - 4.5 mm (0.138 - 0.177 in)
: Engine front

CAUTION:
• At the 2 bolt holes marked , liquid gasket should be
applied outside holes. JPBIA2177ZZ
• Attaching should be done within 5 minutes after coating.
- Install oil pan (upper).
CAUTION:
Install avoiding misalignment of O-ring.

• Tighten bolts in the order from 1 to 17 as shown in figure with the
specified torque. A
: Engine front
• Bolt dimensions vary depending on the installation location. Refer EM

to the following and use appropriate bolts.
M6 x 30 mm (1.18 in) : Bolt No. 16, 17 C

M8 x 25 mm (0.98 in) : Bolt No. 6, 7, 10, 11, 13, 14, 15
M8 x 60 mm (2.36 in) : Bolt No. 1, 2, 3, 4, 5, 8, 9, 12, AWBIA2659ZZ
D
• The shank length under the bolt neck above is the length of the threaded part (pilot portion not included).
• Install oil pan (lower) with the following procedure.
- Use a scraper (A) to remove old liquid gasket from mating surface
of oil pan (lower) (1). E
CAUTION:
• Also remove old liquid gasket from mating surface of oil pan
(upper). F
• Remove old liquid gasket from bolt hole and thread.
PBIC3430E
H
- Apply a continuous bead of liquid gasket with the tube presser
I
(a) : φ 3.5 - 4.5 mm (0.138 - 0.177 in)
: Engine front
J
CAUTION:
Attaching should be done within 5 minutes after coating.
K
JPBIA2178ZZ
L
- Install oil pan (lower).
• Tighten bolts in the order from 1 to 10 as shown in figure with the
specified torque.
M
:Engine front
NOTE:
Pour engine oil or start engine at least 30 minutes after oil pan is N
installed.
AWBIA2658ZZ
Inspection INFOID:0000000014267173 P

Clean oil strainer if any object attached.
1. Check engine oil level and add engine oil. Refer to LU-24, "Inspection".
2. Check for leakage of engine oil when engine is warmed.
4. Check engine oil level again. Refer to LU-24, "Inspection".

PRIMARY TIMING CHAIN
A
With balancer unit EM
L
JPBIA6622GB
1. O-ring 2. O-ring 3. O-ring M

4. O-ring 5. Rear chain case 6. O-ring
7. Oil jet 8. Fuel pump sprocket 9. Spacer
10. Key 11. Crankshaft sprocket 12. Tension guide 1 N
13. Tension guide 2 14. Primary timing chain 15. Tension guide 3
16. Slack guide 1 17. Chain tensioner 1 18. Crankshaft gear
19. Oil jet * 20. Oil pump housing * 21. Cover O
22. Front oil seal 23. Crankshaft pulley 24. Balancer unit
A. Comply with the installation proce-
dure when tightening. Refer to EM- P
220.
*: When the oil pump replacement or the oil jet damage, change both parts for a new. When damage occurred in press fitting, replace
both parts.

Without balancer unit
JSBIA3956GB
1. O-ring 2. O-ring 3. O-ring

4. O-ring 5. Rear chain case 6. O-ring
7. Oil jet 8. Fuel pump sprocket 9. Spacer
10. Key 11. Crankshaft sprocket 12. Tension guide 1
13. Tension guide 2 14. Primary timing chain 15. Tension guide 3
16. Slack guide 1 17. Chain tensioner 1 18. Spacer
19. Oil jet * 20. Oil pump housing * 21. Front oil seal
22. Crankshaft pulley 23. Cover A. Comply with the installation proce-
dure when tightening. Refer to EM-
220.
*: When the oil pump replacement or the oil jet damage, change both parts for a new. When damage occurred in press fitting, replace
both parts.
CAUTION:
piston heads.
• When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
REMOVAL

2. Remove the following parts: A
• Drive belt auto-tensioner and idler pulley. Refer to EM-155, "Exploded View".
• Oil pan (upper and lower). Refer to EM-214, "Exploded View". EM
3. Remove crankshaft pulley.
a. Hold crankshaft pulley (1) with the pulley holder (commercial
service tool) (A). C
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).
D
JPBIA6082ZZ
F
c. Using the pulley puller [SST: KV11103000] (B), remove crank-
shaft pulley.
• Use two M6 bolts (A) with approx. 60 mm (2.36 in) shank
length for securing crankshaft pulley. G
I
JPBIA6083ZZ
4. Remove oil pump housing.

• Loosen bolts in the order from 11 to 1 as shown in the figure J
and remove them.
• Use the seal cutter [SST: KV10111100] etc. for removal.
K
M
JPBIA6084ZZ
5. Remove front oil seal from oil pump housing.

• Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver. N
CAUTION:
Be careful not to damage oil pump housing.
O

6. Remove crankshaft gear (1) with the following procedure. (with
balancer unit)
a. Check that No.1 piston is TDC on its compression stroke.
b. Turn the idler sub gear (3) counterclockwise with snap ring pliers
(B) or suitable tool for aligning idler sub gear and idler main gear
(2).
• If idler gear rotates, hold the flat faces on balancer drive shaft
front end (1).
c. Install internal mechanism securing bolt and plate (Service part:
13012 EB30A and 13013 EB30A) (A) and tighten to the speci-
fied torque.
Securing bolt : 4.0 N·m (0.41 kg-m, 35 in-lb)

CAUTION:
• Do not loosen idler gear bolt (5).
• Only use the genuine internal mechanism securing bolt
and plate, or the idler gear and will be damaged.
• Do not remove internal mechanism securing bolt and
plate from idler gear and until crankshaft gear and all of
the parts in connection have been installed.
• If internal mechanism securing bolt and plate is not
installed, internal mechanism of idler gear and will disen- JPBIA3914ZZ
gage after crankshaft gear is removed. This will prohibit

the balancer unit from being reusable.
d. Apply mating marks (C) to crankshaft gear and idler sub gear.
e. Remove crankshaft gear.
7. Remove chain tensioner 1 (2).
(1) : Slack guide 1

• When removing chain tensioner, push the plunger of chain
tensioner and keep it pressed with a push pin (A).
8. Remove slack guide 1.
JPBIA6085ZZ
9. Hold fuel pump sprocket and remove bolt.

a. Insert positioning stopper pin [SST: KV11106030] (A) on fuel
pump sprocket (1).
(2) : Fuel pump

(B) : Hexagon wrench [SST: KV11106050]
JPBIA6048ZZ

b. Using the wrench (T70) [SST: KV11106040] (B), turn pump shaft
little by little to adjust the position of fuel pump sprocket (1) so A
that the holes align.
(A) : Positioning stopper pin [SST: KV11106030] EM

c. Push positioning stopper pin [SST: KV11106030] through fuel
pump sprocket to fuel pump body to hold fuel pump sprocket.
C
JPBIA6086ZZ
D
10. Remove primary timing chain (2) with fuel pump sprocket (1)
and crankshaft sprocket (3).
E
G
JPBIA6087ZZ
11. Remove tension guide 1 (1), tension guide 2 (3) and tension
H
guide 3 (2).
JPBIA6089ZZ
K
12. Remove fuel pump. Refer to EM-187, "Exploded View".
13. Remove vacuum pump. Refer to EM-233, "Exploded View".
L
14. Remove camshaft sprockets. Refer to EM-195, "Exploded View".

15. Remove rear chain case.
• Loosen fixing bolts in the order from 22 to 1 as shown in the
figure and remove them.
• Use the seal cutter [SST: KV10111100] for removal.
JPBIA6090ZZ
16. Remove balancer unit. (with balancer unit)

• Loosen bolts in the order from 6 to 1 as shown in the figure.
: Engine front
PBIC4049E
INSTALLATION
CAUTION:
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.
JPBIA6091ZZ

1. Secondary timing chain 2. Chain tensioner 2 3. Slack guide 2 A

4. Fuel pump sprocket 5. Tension guide 3 6. Primary timing chain
7. Vacuum pump sprocket 8. Slack guide 1 9. Chain tensioner 1
10. Crankshaft sprocket 11. Tension guide 1 12. Tension guide 2 EM
13. Tension guide 4 14. Camshaft sprocket 15. Tension guide 5
16. Front chain case A. Alignment mark (dark blue link) B. Alignment mark (yellow link)
C. Alignment mark (punched mark) D. Alignment mark (punched mark) C
CAUTION:
Before starting work, check that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten bolts in the order from 1 to 6 as D
shown in the figure. (with balancer unit)
: Engine front E
CAUTION:
If bolts are re-used, check their outer diameter before instal-
lation. Refer to "Balancer Unit Bolt Outer Diameter". F
a. Apply new engine oil to threads and seat surfaces of bolts.
b. Tighten all bolts.
PBIC4049E
G
Bolts : 29.4 N·m (3.0 kg-m, 22 ft-lb)
c. Turn all bolts 65 degrees clockwise (angle tightening). H
(1) : Balancer unit

CAUTION: I
Check tightening angle with an angle wrench [SST:
KV10112100] (A) or a protract. Do not make judgement by
visual check alone.
J
d. Completely loosen.

PBIC3474E K
CAUTION:
In this step, loosen bolts in the reverse order as shown in the figure.
e. Tighten all bolts. L
Bolts : 29.4 N·m (3.0 kg-m, 22 ft-lb)
f. Turn them another 65 degrees clockwise (angle tightening). M

CAUTION:
Check tightening angle with an angle wrench [SST: KV10112100] or a protractor. Do not make
judgment by visual check alone. N
2. Install rear chain case.

a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) on locations shown in the figure.
CAUTION:
• Do not reuse O-ring.
• Do not allow liquid gasket to stick out to the oil passage
(E).
• For area (B), the overlap of the liquid gasket starting point
and end-point must be minimized and faced outward.
• For area (C), the starting point and the end-point of the liq-
uid gasket must stick out from the case rim.
(a) : φ3.4 - 4.4 mm (0.13 - 0.17 in)
JSBIA3957ZZ
b. Install new O-rings to the grooves.
(1) : For fuel pump

(2) : For vacuum pump
(3) : For slack guide 1
(4) : For main gallery
CAUTION:
JPBIA6093ZZ
c. Install rear chain case.

• When installing, align the dowel pin with the pin hole.

d. Tighten bolts in the order from 1 to 22 as shown in the figure.
• Install the following two types of bolts, referring to the figure. A
M8 × 16 mm (0.63 in) : No. 1, 2, 8 - 13, 17, 18

M8 × 20 mm (0.79 in) : No. 3 - 7, 14 - 16, 19 - 22 EM
• The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order. C
G
JPBIA6090ZZ
3. Install fuel pump. Refer to EM-187, "Exploded View".

• Before installing, check that spacer and the hole 6 mm (0.24 in) in diameter on coupling are aligned. H
4. Install tension guide 1 (1), tension guide 2 (3) and tension guide
3 (2).
I
K
JPBIA6089ZZ
5. Install crankshaft sprocket, aligning it with crankshaft key on the far side. L
6. Install primary timing chain (2) with fuel pump sprocket (1).
(3) : Crankshaft sprocket M

• When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on primary timing
chain. N
• Install fuel pump sprocket washer with the surface marked
“ ” (front mark) facing the front of the engine.
O
JPBIA6087ZZ

7. Use the positioning stopper pin [SST: KV11106030] (A) to hold
the fuel pump sprocket (1) and install the bolt.
(2) : Washer
(B) : Hexagon wrench [SST: KV11106050]
JPBIA6047ZZ
a. Using the wrench (T70) [SST: KV11106040] (B), turn the fuel
pump shaft little by little to adjust the position of the fuel pump
sprocket (1).
JPBIA6086ZZ
b. Insert positioning stopper pin [SST: KV11106030] into the hole 6 mm (0.24 in) in diameter on fuel pump
sprocket so that the stopper pin goes through the fuel pump body. While the stopper pin is in place, install
the bolt.
8. Install timing chain slack guide 1.
9. Install chain tensioner 1 (2).
(1) : Slack guide 1

• Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin (A), install chain ten-
sioner.
• After installation, pull out the push pin holding the plunger.
CAUTION:
Check again that the alignment marks on sprockets and the
colored alignment marks on timing chain are aligned.
JPBIA6085ZZ
10. Install crankshaft gear. (with balancer unit)

• Align crankshaft gear (1) mating mark and idler sub gear (3)
mating mark (C). A
(2) : Idler main gear

(4) : Balancer drive shaft front end EM
(5) : Idler gear bolt (do not loosen)
(B) : Snap ring pliers
• Remove internal mechanism securing bolt and plate (Service C
part: 13012 EB30A and 13013 EB30A) (A).
G
JPBIA3914ZZ
- If new balancer unit (2) is used, align matching marks (B) of H

each gear as shown in the figure.
- Remove securing-bolt-and-plate (A) and securing pin (C) after
installing crankshaft gear (1).
I
N
PBIC3475E
11. Install front oil seal (1) to oil pump housing (2). O
• Using the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION:
P
Do not touch lips of oil seal. Check seal surfaces are free of
foreign materials.
PBIC3448E

12. Install oil pump housing.
a. Apply a continuous bead of liquid gasket with the tube presser
• Leave the start and end areas (A) of the bead slightly protrud-
ing from the surface.
• Apply liquid gasket along upper end surface of oil pump hous-
ing.
(C) : φ 3.4 - 4.4 mm (0.13 - 0.17 in)

(D) : 4.0 - 5.6 mm (0.16 - 0.22 in)
(E) : 0.5 - 2.1 mm (0.02 - 0.08 in)
JPBIA6094ZZ
b. Install new O-ring (1) into the groove of rear chain case.
CAUTION:
JPBIA6193ZZ
c. Install oil pump housing.

• When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
• When installing, align the dowel pin with the pin hole.
d. Tighten fixing bolts in the order from 1 to 11 as shown in the fig-
ure.
e. After tightening all the bolts, re-tighten in the same order.
JPBIA6084ZZ

13. Check gaps on oil pan upper surface.
A
(1) : Cylinder block
(2) : Rear chain case
(3) : Oil pump housing EM
• Using straightedge (A) and feeler gauge (B), measure gaps
between the locations of the following parts:
C
Oil pump housing and rear chain case:
Standard : (–0.09) – (+0.09) mm [(–0.0035) – (+0.0035) JPBIA6095ZZ
in] D
Rear chain case and cylinder block:
Standard : (–0.19) – (+0.07) mm [(–0.0075) – (+0.0028)
in] E
• If the measured value is out of the standard, install again.

14. Install crankshaft pulley, refer to the following: F
CAUTION:
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
G
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
c. Hold crankshaft pulley (1) with the pulley holder (commercial
service tool) (A).
H
d. Tighten crankshaft pulley fixing bolt.
Bolt : 75.0 N·m (7.7 kg-m, 55 ft-lb) I

e. Completely loosen.
Bolt : 0 N·m (0 kg-m, 0 ft-lb) J

f. Tighten crankshaft pulley bolt. JPBIA6082ZZ
K
Bolt : 75.0 N·m (7.7 kg-m, 55 ft-lb)
g. Put an alignment mark (B) on crankshaft pulley that aligns with
one of the punched marks on the bolt. L
h. Turn another 120 degrees clockwise (angle tightening).
(A) : Indicate embossments

M
(B) : Alignment mark
• Check the tightening angle with movement of one angle mark
(A). N
PBIC3476E
O
P
Timing Chain

Check for cracks (A) and excessive wear (B) at roller links.
Replace timing chain if necessary.
JPBIA6054ZZ
Balancer Unit Mounting Bolt Outer Diameter

in the figure.
• If reduction appears in “A” range, regard it as “d2”.
Limit (“d1 ” - “d2 ”) : 0.15 mm (0.0059 in)

• If it exceeds the limit (large difference in dimensions), replace it
with a new one.
PBIC1137E

VACUUM PUMP
VACUUM PUMP
A
EM
I
AWBIA2655ZZ
1. O-ring 2. Vacuum pump 3. Bracket J

4. Oil feed tube 5. Copper washer 6. Eye-bolt
A. Refer to INSTALLATION Front
K
REMOVAL L
NOTE:
ing.
M
1. Remove primary timing chain. Refer to EM-219, "Exploded View".
2. Remove fuel pump. Refer to EM-187, "Exploded View".
3. Remove oil feed tube. N
4. Remove bracket.
5. Remove vacuum pump and O-ring.
INSTALLATION O
CAUTION:
Do not reuse O-ring or washer. P
Bracket

VACUUM PUMP
Temporarily tighten bolts, then tighten bolts to specification in the
order shown.
Bolts : 22.0 N·m (2.2 kg-m, 16 ft-lb)
: Cylinder block side
PBIC4907E
INSPECTION BEFORE REMOVAL

1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-
tor.
2. Start engine and measure generated vacuum at idle speed.
Standard:
–93.3 to –101 kPa (–933 to –1010 mbar, –700 to –760 mmHg, –27.55 to –29.83 inHg)
• If out of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump.

DRIVE PLATE
DRIVE PLATE
A
EM
I
JPBIA5919GB
1. Pilot converter 2. Drive plate 3. Reinforcement plate J

4. Crankshaft position sensor (POS) 5. O-ring A. Chamfered
B. Installed on transmission Crankshaft side
K
REMOVAL L
1. Remove transmission assembly. Refer to TM-35, "4WD : Removal and Installation" (M/T models) or TM-
318, "Removal and Installation" (A/T models).
2. Before removing the drive plate, put a match mark (A) on the M
crankshaft and drive plate for alignment during installation.
ALBIA0522ZZ P
3. Remove drive plate as par the following procedure.

DRIVE PLATE
a. Set the ring gear stopper [SST: KV10105630] (C) as shown in
the figure.
(A) : Plate [SST: KV10105610]

(B) : Spacer (suitable one)
b. Loosen the bolts diagonally, and then pull drive plate with both
hands to remove it.
CAUTION:
• Do not disassemble them.
• Do not place them with signal plate facing down.
• When handling signal plate, take care not to damage or JPBIA6202ZZ
scratch them.
• Handle signal plate in a manner that prevents them from becoming magnetized.
• Take care not to damage the periphery of the sensing area.
• Any dropped drive plate shall not be used. (The drive plate to which the sensing area shall not
be placed on the floor.)
• Do not touch drive plate with bare hands. Always use urethane coating gloves or skin gloves
when removing these parts.
• Do not use torn glove.
4. Remove pilot converter (1) using the pilot bush puller [SST:
ST16610001] (A) (if necessary).
PBIC3229J
INSTALLATION
1. Install pilot converter to the crankshaft using suitable tool (if
removed).
• With a drift of the following outer diameter, press-fit as far as it
will go.
Pilot converter : Approx. 33 mm (1.30 in)
EMP0569D
• Press-fit pilot converter with its chamfering side facing crank-

shaft shown in the figure.
: Crankshaft side
JPBIA0210ZZ
2. Install drive plate.

DRIVE PLATE
• Install drive plate (4) and reinforcement plate (3) as shown in
the figure. A
(1) : Crankshaft
(2) : Pilot converter EM
(A) : Rounded
: Engine front
• When installing drive plate to crankshaft, be sure to correctly C

align crankshaft side dowel pin and drive plate side dowel pin
hole. JSBIA3959ZZ
CAUTION: D
If these are not aligned correctly, engine runs roughly and “MIL” illuminates.
• Holding ring gear with the ring gear stopper [SST: KV101056S0].
• Tighten the bolts crosswise over several times.
E
F
DRIVE PLATE DEFLECTION
• Check drive plate and signal plate (A) for deformation or damage.
G
(B) : Ring gear
: Engine front
CAUTION: H
• Do not disassemble drive plate.
• Do not place drive plate with signal plate facing down.
• When handling signal plate, take care not to damage or I
scratch it.
• Handle signal plate in a manner that prevents it from becom-
ing magnetized. JSBIA3960ZZ
• If damage is found, replace drive plate. J

• Measure the deflection of drive plate contact surface to torque con-
verter with a dial indicator (A).
• Measure the deflection at the area (B). K
(B) : φ 11.0 - 20.6 mm (0.43 - 0.81 in)
L
• If measured value is out of the standard, replace drive plate.
M
JPBIA6064ZZ

FLYWHEEL
FLYWHEEL
JPBIA5920GB
1. Pilot bush 2. Flywheel 3. Crankshaft position sensor (POS)

4. O-ring A. Installed on transmission
REMOVAL
1. Remove transmission assembly. Refer to TM-35, "4WD : Removal and Installation" (M/T models) or TM-
318, "Removal and Installation" (A/T models).
2. Before removing the flywheel, put a match mark (A) on the
crankshaft and flywheel for alignment during installation.
ALBIA0522ZZ
3. Remove flywheel as par the following procedure.

FLYWHEEL
a. Set the ring gear stopper [SST: KV10105630] (C) as shown in
the figure. A
(A) : Plate [SST: KV10105610]

(B) : Spacer (suitable one) EM
b. Loosen the bolts diagonally, and then pull flywheel with both
hands to remove it.
CAUTION: C
• Do not disassemble them.
• Do not place them with signal plate facing down.
• When handling signal plate, take care not to damage or JPBIA6203ZZ
D
scratch them.
• Take care not to damage the periphery of the sensing area.
• Any dropped flywheel shall not be used. (The flywheel to which the sensing area shall not be E
placed on the floor.)
• Do not touch flywheel with bare hands. Always use urethane coating gloves or skin gloves when
removing these parts.
F
• Do not use torn glove.
4. Remove pilot bush (1) using the pilot bush puller [SST:
ST16610001] (A) (if necessary).
G
PBIC3229J
INSTALLATION J
1. Install pilot bush to the crankshaft using suitable tool.
• With a drift of the following outer diameter, press-fit as far as it
will go. K
Pilot bush : Approx. 20.6 mm (0.81 in)

L
M
EMP0569D
2. Installation of remaining components is in the reverse order of removal. N

CAUTION:
Be careful not to damage or scratch and contact surface for clutch disc of flywheel.
Inspection INFOID:0000000014267185 O
FLYWHEEL DEFLECTION
P

FLYWHEEL
• Measure the deflection of flywheel contact surface to torque with a
dial indicator (A).
• Measure the deflection at 225 mm (8.86 in) diameter (B).

• If measured value is out of the standard, replace flywheel.
• If a trace of burn or discoloration is found on the surface, repair it
with sandpaper.
JPBIA6065ZZ

OIL SEAL
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000014267186
EM
REMOVAL
1. Remove camshafts. Refer to EM-195, "Exploded View".
C
2. Remove valve lifters. Refer to EM-203, "Exploded View".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
D
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
• Compress valve spring with the valve spring compressor E
[commercial service tool] (A), the attachment [commercial ser-
vice tool] (C), and the adapter [commercial service tool] (B).
Remove valve collet with magnet hand. F
H
JPBIA1365ZZ
CAUTION:
• Be careful not to damage valve lifter holes. I
• Install attachment (A) in the center of valve spring retainer
to press it.
J
(1) : Valve spring retainer
L
JSBIA3390ZZ
5. Remove valve spring retainer and valve spring (with valve spring seat). M
CAUTION:
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902] (A) and attachment [SST: KV10116100] (B). N
JPBIA6101ZZ
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.

OIL SEAL
2. Press in valve oil seal to the height (H) shown in the figure with
the valve oil seal drift [SST: KV10115600] (A).
(b) : 12.1 - 12.7 mm (0.476 - 0.500 in)
JPBIA6102ZZ

FRONT OIL SEAL
REMOVAL
• Drive belt. Refer to EM-149, "Removal and Installation".
• Crankshaft pulley. Refer to EM-219, "Exploded View".
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
JPBIA6103ZZ
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
CAUTION:
Do not reuse front oil seal.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
(A) : Oil seal lip

(B) : Dust seal lip
: Engine inside
: Engine outside
JPBIA0054ZZ

OIL SEAL
• Using the suitable drift [62 mm (2.44 in) dia.] (A), press fit the
oil seal (2) so that the dimension is as specified in the figure. A
(1) : Oil pump housing
EM
(b) : 0 - 0.5 mm (0 - 0.020 in)
CAUTION:
Do not touch lips of oil seal. Check seal surfaces are free C
of foreign materials.
G
JPBIA6104ZZ

H
REAR OIL SEAL
I
REMOVAL
1. Remove transmission. Refer to TM-35, "4WD : Removal and Installation" (M/T models) or TM-318,
"Removal and Installation" (A/T models). J
2. Remove drive plate or flywheel. Refer to EM-235, "Exploded View" (drive plate) or EM-238, "Exploded
View" (flywheel).
K
3. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
L
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
CAUTION:
M
Do not reuse rear oil seal.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
N
(A) : Oil seal lip
(B) : Dust seal lip
: Engine inside O
: Engine outside
JPBIA0054ZZ

OIL SEAL
• Press in rear oil seal (2) to rear oil seal retainer (1) as shown in
the figure.
(b) : 0 - 0.5 mm (0 - 0.020 in)

• Using the drift [105 mm (4.13 in) dia.] (A), press fit so that the
dimension is as specified in the figure.
• Avoid inclined fitting. Force fit perpendicularly.
CAUTION:
Do not touch lips of oil seal. Check seal surfaces are free of
foreign materials.
JPBIA6105ZZ

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [YD25DDTi]
UNIT REMOVAL AND INSTALLATION A

ENGINE ASSEMBLY
EM
JPBIA2163GB J
1. RH engine mounting insulator 2. RH engine mounting bracket 3. LH engine mounting bracket

4. Heat insulator 5. LH engine mounting insulator 6. Transmission cross member
K
7. Engine mounting insulator (rear)

L
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels. M
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
N
• Do not start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine main body section, refer to the applicable
sections. O
able reasons, support at the rear axle jacking point with transmission jack or similar tool before P
• For supporting points for lifting and jacking point at rear axle, refer to GI-29, "Garage Jack and
Safety Stand".
NOTE:
ing.
REMOVAL

ENGINE ASSEMBLY
Description of work
Remove transmission assembly from vehicle downward. Then hoist the engine from vehicle upward.
Preparation
1. Disconnect battery cable from negative terminal.
• Front undercover. Refer to EXT-30, "FRONT UNDER COVER : Exploded View".
LIGENT KEY SYSTEM).
• Front grille. Refer to EXT-24, "Exploded View".
• Engine cover: Refer to EM-154, "Exploded View".
• Resonator: Refer to EX-12, "Exploded View".
• Air duct and air cleaner case: Refer to EM-156, "Exploded View".
• Brake pipe lines, fuel pipe lines brackets:
• Radiator hose (upper and lower): Refer to CO-40, "Exploded View".
4. Discharge refrigerant from A/C circuit. Refer to HA-74, "Recycle Refrigerant".
Engine room front
1. Remove power steering reservoir tank bolt and move power steering reservoir tank to the position without
interfere of the work.
2. Remove the radiator shroud (upper and lower). Refer to CO-40, "Exploded View".
3. Remove power steering belt and driver belt. Refer to EM-149, "Exploded View".
4. Remove the cooling fan assembly. Refer to CO-45, "Exploded View".
5. Remove the water pump pulley. Refer to EM-155, "Exploded View".
6. Separate the cooler pipe (HI) (LOW) from condenser side. Refer to HA-86, "Exploded View".
7. Remove the refrigerant pressure sensor harness connector.
8. Separate A/T oil cooler from the condenser (A/T models). Refer to TM-314, "Removal and Installation: A/
T Fluid Cooler".
9. Separate A/T oil cooler hose from the radiator (A/T models). Refer to TM-315, "Removal and Installation:
A/T Fluid Cooler Tubes and Hoses".
10. Remove radiator assembly along with condenser.
11. Remove air inlet hose. Refer to EM-158, "Exploded View".
12. Remove power steering oil pump bolt, move to the position which does not interfere the work of power
steering oil pump. Refer to ST-35, "Exploded View - YD25DDTi".
Engine room RH
1. Disconnect fuel feed hose and return hose, and plug it to prevent fuel from draining. Refer to EM-174,
"Exploded View".
2. Disconnect fuel filter harness connector.
3. Remove fuel filter bracket bolt and move fuel filter assembly to the position without interfere of the work.
Refer to FL-24, "Exploded View".
4. Remove brake booster hose in engine side.
5. Remove the engine ground cable in engine side.
Engine room LH
1. Disconnect A/C piping from heater unit. Refer to HA-95, "Exploded View".
2. Disconnect heater hose, and install plug it to prevent engine coolant from draining.
Vehicle underbody
1. Remove exhaust front tube. Refer to EX-12, "Exploded View".
2. Remove front propeller shaft. Refer to DLN-137, "Exploded View".
3. Remove rear propeller shaft. Refer to DLN-158, "Exploded View".

ENGINE ASSEMBLY
4. Separate the lower joint from the steering gear assembly. Refer to ST-30, "Exploded View".
5. Remove clutch operating cylinder from transmission, and move it aside (M/T models). Refer to CL-25, A
"YD25DDTi : Exploded View".
6. Remove starter motor. Refer to STR-34, "YD25DDTi : Exploded View".
7. Remove A/T oil cooler pipe. Refer to HA-86, "Exploded View". EM
8. Remove transmission assembly. Refer to TM-35, "4WD : Exploded View" (M/T models) or TM-318,
"Exploded View" (A/T models).
C
Removal
1. In order to attach the (rear) engine slinger, remove the engine cover bracket.
2. Install engine slingers into front right of cylinder head (A) and D
rear left of cylinder head (B).
(1) : Engine slinger (front)

E
(2) : Engine slinger (rear)
: Engine front
F
Slinger bolts : 22.0 N·m (2.2 kg-m, 16 ft-lb)
PBIC3480E
G

4. Loosen LH and RH engine mounting insulator nuts. H
5. Remove engine.
CAUTION:
I
body side.
J
K
SEM896G
INSTALLATION
Installation is in the reverse order of removal. L
• Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
• When installation directions are specified, install parts according to the direction marks on them referring to
figure of components. M
• Check that each mounting insulator is seated properly, and tighten bolts and nuts.
• Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stopper
is provided at vacuum gallery.
• Insert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery. N
O
P
The following are procedures for checking fluid leakage, lubricant leakage.
required quantity, fill them to the specified level. Refer to MA-23, "Fluids and Lubricants".
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
ENGINE ASSEMBLY
NOTE:
noise will stop after hydraulic pressure rises.
engine coolant.
the specified level, if necessary.


< UNIT DISASSEMBLY AND ASSEMBLY > [YD25DDTi]

EM
NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc. C
1. Remove engine from the vehicle. Refer to EM-245, "Exploded View".
2. Install engine to engine stand as follows.
D
a. Remove drive plate or flywheel. Refer to EM-235, "Exploded View" (A/T models) or EM-238, "Exploded
View" (M/T models).
b. Hoist engine and install it to the engine stand (A) (commercial
service tool). E
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and F
rear plate removed.
JSBIA2481ZZ
H
4. Drain engine coolant by removing drain plug from inside of
engine. I

: Engine front J
Tightening torque : Refer to EM-251, "Disassembly

K
and Assembly".
JPBIA3768ZZ
L

CYLINDER BLOCK
CYLINDER BLOCK
JPBIA5925GB
1. Cylinder block 2. Copper washer 3. Oil jet relief valve

4. Drain plug 5. Top ring 6. Second ring
7. Oil ring 8. Snap ring 9. Piston
10. Piston pin 11. Connecting rod 12. Connecting rod bearing
13. Connecting rod cap 14. Main bearing cap 15. Main bearing lower
16. Crankshaft 17. Key 18. Main bearing upper
19. Thrust bearing 20. Oil jet 21. Rear oil seal retainer
22. Rear oil seal 23. Oil pressure switch 24. Dowel pin
A. Comply with the installation proce- B. Comply with the installation proce-
dure when tightening. Refer to EM- dure when tightening. Refer to EM-
251. 251.

CYLINDER BLOCK
A
DISASSEMBLY
1. Remove fuel pump bracket. Refer to EM-187, "Exploded View".
EM
2. Remove rear oil seal retainer.
• Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
3. Remove rear oil seal from rear oil seal retainer. Refer to EM-243, "REAR OIL SEAL : Removal and Instal-
lation". C
• Punch out with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage rear oil seal retainer. D
4. Remove piston and connecting rod assembly.
• Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-257, "Inspection". E
a. Move crankshaft pin to be removed to approximately BDC.
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod F
assembly out to cylinder head side.
CAUTION:
• Be careful not to damage the cylinder wall and crankshaft G
pin, resulting from an interference of the connecting rod
big end. JEM195G
• When removing piston and connecting rod assembly, pre-

vent the big end of connecting rod from interfering with H
oil jet (1).
JPBIA3896ZZ
K
5. Remove connecting rod bearings from connecting rods and caps.
CAUTION:
• Be careful not to drop connecting rod bearing, and to scratch the surface. L
6. Remove piston rings from pistons using the piston ring expander
(commercial service tool) (A). M
CAUTION:
• When removing, prevent pistons from being damaged.
• Do not expand piston rings excessively. This may damage N
piston rings.
PBIC3233J
P

CYLINDER BLOCK
7. Remove pistons from connecting rods.
a. Using the snap ring pliers (A), remove snap rings.
PBIC3230J
b. Using the industrial use dryer (A), heat pistons up to 60 to 80°C

(140 to 176°F).
PBIC3231J
c. Using rod with outer diameter of 26 mm (1.02 in), press piston

pins out.
EMM0072D
8. Loosen and remove main bearing cap bolts in the order form 10
to 1 as shown in the figure.
: Engine front
• Use socket (size: E14) (commercial service tool).

• Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-280, "Cylinder Block".
JPBIA3788ZZ
9. Remove main bearing caps.

• Insert bolts (A) into bolt holes, and then remove main bearing
cap (1) by lifting up and shaking forward and backward.
JPBIA6214ZZ

CYLINDER BLOCK
10. Remove crankshaft.
11. Remove main bearings and thrust bearings from cylinder block and main bearing caps. A
CAUTION:
Check the correct installation locations of removed parts. Store them so they do not get mixed up.
12. Remove oil jet. EM
13. Remove oil jet relief valve.
ASSEMBLY C
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION: D
Use a goggles to protect your eye.
2. Install drain plug to cylinder block (1).
• Apply liquid gasket to drain plug (2).
Use Genuine Liquid Gasket or equivalent E
• Tighten drain plug.
Drain Plug : 46.6 N·m (4.8 kg-m, 34 ft-lb) F
PBIC3483E
H
3. Install oil jet relief valve.
4. Install oil jet (A).
• Align (B) knock pin on back of oil jet with hole on block when
installing oil jet. I
JPBIA6108ZZ
L
5. Install main bearings and thrust bearings.
a. Remove contamination, dust and engine oil from bearing posi-
tions on cylinder block and main bearing caps.
M
b. Install thrust bearings on both sides of No. 3 housing (B) on cyl-
inder block.
• Install thrust bearings with oil groove (A) facing to crankshaft
arm (outside). N
: Engine front
O
JPBIA6109ZZ

CYLINDER BLOCK
c. Being careful with the direction, install main bearings.
• Install main bearings with the oil holes (C) and grooves (B)
onto the cylinder block side (A), and those without oil holes
and grooves onto the main cap side (D).
• While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
• Align stopper notches on bearings to install them.
• Check that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
6. Install crankshaft to cylinder block. JPBIA6110ZZ
• Check crankshaft rotates smoothly by hand.
7. Install main bearing caps.
• Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap (A) and the
journal with the front mark (B) facing forward.
: Engine front
• Main bearing caps are commonly processed with the cylinder

block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer to EM-
257, "Inspection".
JPBIA6111ZZ
9. With the socket (size: E14) (commercial service tool), tighten the
main bearing cap bolts according to the following procedure:
: Engine front
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in the order from 1 to 10 as shown in the figure.
Bolts : 27.0 N·m (2.8 kg-m, 20 ft-lb)

c. Put alignment marks (with paint) on each bolt and the main JPBIA3788ZZ
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90 degrees. (angle tightening)

CAUTION:
Always use either the angle wrench [SST: KV10112100] or
protractor during angular tightening. Avoid tightening
based on visual checks alone.
• After tightening bolts to specified torque, check that crankshaft
rotates smoothly.
• Check crankshaft end play. Refer to EM-280, "Cylinder Block".
10. Check the outer diameter of connecting rod bolts. Refer to EM-
280, "Cylinder Block".
11. Install piston to connecting rod. JEM226G
a. Using the snap ring pliers, install snap rings to groove on piston
rear side.
• Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.

CYLINDER BLOCK
• Using the industrial use dryer (A), heat pistons up to approx.
60 to 80°C (140 to 176°F) until piston pin can be pressed A
down by finger touch. Then insert piston pin into piston and
connecting rod from front side of piston toward rear.
EM
PBIC3231J
D
• Assemble piston and connecting rod with front mark (A) of pis-
ton head and cylinder No. (C) stamped on connecting rod
being positioned as shown in the figure. E
(B) : Oil hole

: Engine front F
c. Install snap ring to front side of piston.
• Refer to above step a for precaution on snap ring installation.
• After installation, check connecting rods for smooth move- G
ment. JPBIA6112ZZ
12. Use the piston ring expander (commercial service tool) to install piston rings. H
CAUTION:
When installing, prevent piston from being damaged.
• Install top ring (1) and second ring (3) with punched mark (A)
I
surfaces facing upward.
(2) : Oil ring

J
Punched mark:
Top ring : RTOP
K
Second ring : R2ND
• Install rings so that three closed gap position 120 degrees (b)
apart one another. JPBIA6113ZZ
L
• Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart.
13. Install connecting rod bearing to connecting rod and cap. M
(A : Oil hole
(B) : Cut−out area N
(C) : Cylinder No.
(D) : Protrusions
• While installing connecting rod bearing, apply engine oil to O
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
• Align protrusions on connecting rod bearings with connecting P
JPBIA6114ZZ
rod cut-outs to install connecting rod bearings.

CYLINDER BLOCK
14. Install piston and connecting rod assembly to crankshaft.
• Move crankshaft pin to be assembled to BDC.
• Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
• Using the piston ring compressor [SST: EM03470000] (A) or
suitable tool, install piston and connecting rod assembly with
front mark on piston head facing toward the front side of
engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
JPBIA6115ZZ
oil jet.
15. Install connecting rod caps and nuts.

• Align cylinder No. stamped (C) on connecting rod with that on
cap to install connecting rod cap.
(B) : Oil hole

: Engine front
• Check that the front mark (A) on piston faces towards the front
of the engine.
JPBIA6112ZZ
16. Tighten connecting rod nuts according to the following procedure:

a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.
Bolts : 29.4 N·m (3.0 kg-m, 22 ft-lb)

c. Loosen completely.
Bolts : 0 N·m (0 kg-m, 0 in-lb)

d. Tighten bolts.
Bolts : 19.6 N·m (2.0 kg-m, 14 ft-lb)

e. Tighten bolts.

• Always use either the angle wrench [SST: KV10112100] or
protractor during angular tightening. Avoid tightening
based on visual checks alone.
• After tightening nuts, check that crankshaft rotates smoothly.
• Check connecting rod side clearance. Refer to EM-280, "Cyl-
inder Block".
JEM231G

CYLINDER BLOCK
17. Press fit rear oil seal (1) into rear oil seal retainer (2).
A
(b) : 0 − 0.5 mm (0 − 0.020 in)
• Using the drift [105 mm (4.13 in) dia.] (A), press fit so that the
dimension is as specified in the figure. EM
• Avoid inclined fitting. Force fit perpendicularly.
JPBIA6116ZZ
D
18. Install rear oil seal retainer to cylinder block.
CAUTION:
Do not reuse rear oil seal. E
• Apply new engine oil to the oil and dust seal lips.
• Apply liquid gasket (1) to rear oil seal retainer using the tube
presser (commercial service tool) as shown in the figure. F
(a) : φ 2.0 − 3.0 mm (φ 0.079− 0.118 in)

G
CAUTION:
For the area (B), the starting point and the end-point of the
liquid gasket must stick out from the rear oil seal retainer
rim. H
JPBIA6192ZZ
I
19. Install fuel pump bracket (2).
• Align the bracket with the dowel pins (1) on cylinder block to
install.
J
L
JPBIA6117ZZ

M
CRANKSHAFT END PLAY N

• Using dial gauge (A), measure crankshaft travel amount by moving
the crankshaft forward or backward.
O
Block".
• If the value exceeds the limit, replace thrust bearings with new P
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
JPBIA6118ZZ

CYLINDER BLOCK
• Using feeler gauge (A), measure side clearance between connect-
ing rod and crankshaft arm.

Block".
• If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
JPBIA6119ZZ
PISTON TO PISTON PIN CLEARANCE

Piston Pin Bore Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
JPBIA0217ZZ

JPBIA0218ZZ
Calculation of Piston to Piston Pin Clearance

(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)

• If out of the standard, replace piston/piston pin assembly.
NOTE:
Piston is available together with piston pin as assembly.
• Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C).

CYLINDER BLOCK
(A) : NG A
(B) : OK
Standard and limit : Refer to EM-280, "Cylinder EM

Block".
JPBIA2276ZZ
D
• Align top ring (1) and external surface of piston. Measure lower
side clearance of top ring (a) with top ring pressed onto upper side
of ring groove. E
• If side clearance exceeds the limit, replace piston ring.
• Check clearance again. If side clearance still exceeds the limit,
replace piston.
F
G
JPBIA6120ZZ
PISTON RING END GAP

H
• Check that the cylinder bore inner diameter is within the specifica-
tion.
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert piston ring until middle of cylinder with piston, and mea- I
sure the piston ring end gap with a feeler gauge (B).
(A) : Press-fit
J

Block". K
JPBIA2277ZZ
measure again. If it still exceeds the limit, re-bore cylinder and use oversize piston and piston rings.
CONNECTING ROD BEND AND TORSION L

CYLINDER BLOCK
• Check with a connecting rod aligner.
(A) : Bend
(B) : Torsion
(C) : Feeler gauge
Bend limit : Refer to EM-280, "Cylinder Block".

Torsion limit
• If it exceeds the limit, replace connecting rod assembly.
JPBIA0221ZZ

• Install connecting rod bearing cap without installing connecting rod
bearing, and tighten connecting rod bolts to the specified torque.
Refer to EM-251, "Disassembly and Assembly" for the tightening
procedure.
(1) : Connecting rod

• Measure the inner diameter of connecting rod big end with an
inside micrometer.

JPBIA0222ZZ
• If out of the standard, replace connecting rod assembly.
micrometer (A).
JPBIA0223ZZ

CYLINDER BLOCK
A
EM
JPBIA0218ZZ
D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
Standard and limit : Refer to EM-280, "Cylinder Block".
• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly. F
• If replacing piston and piston pin assembly, refer to EM-268, "Description".
• If replacing connecting rod assembly, refer to EM-269, "Connecting Rod Bearing" to select the connecting
rod bearing. G
CYLINDER BLOCK DISTORTION
other contamination. H
CAUTION:
• Measure the distortion on the cylinder block upper face at some I
different points in six directions (C), (D), (E), (F), (G) and (H) with a
straightedge (A) and a feeler gauge (B).
Limit : Refer to EM-280, "Cylinder Block". J
• If it exceeds the limit, replace cylinder block.

K
JPBIA0224ZZ L
• Install main bearing cap (2) without installing main bearings, and
tighten main bearing cap bolts to the specified torque. Refer to EM- M
251, "Disassembly and Assembly" for the tightening procedure.

N
gauge.
O
• If out of the standard, replace cylinder block and main bearing cap JPBIA0225ZZ
as assembly. P
NOTE:
Cylinder block cannot be replaced as a single part, because it is machined together with main bearing cap.

CYLINDER BLOCK
• Using a bore gauge, measure the cylinder bore for wear, out-of
round and taper at six different points on each cylinder. [(A) and (B)
directions at (C), (D) and (E)] [(A) is in longitudinal direction of
engine]
(f) : 10 mm (0.39 in)

(g) : 85 mm (3.35 in)
(h) : 160 mm (6.30 in)

Block". JPBIA2059ZZ
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or bore the inner wall.
• Oversize piston is provided. When using oversize piston, hone the cylinder so that the clearance between
piston and cylinder satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with oversize piston rings.
Oversize (O/S) : Refer to EM-280, "Cylinder

Block".
Piston Outer Diameter
Measurement position : Refer to EM-280, "Cylinder

Standard Block".
JPBIA0227ZZ

• Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].
(A) : Direction A
(C) : Position C
(E) : Position E
(f) : 10 mm (0.39 in)
(g) : 85 mm (3.35 in)
(h) : 160 mm (6.30 in)
(Clearance) = (Cylinder bore inner diameter) − (Piston outer diam- JPBIA2059ZZ
eter)

Block".
• If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-268, "Description".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Re-bore size calculation:

D=A+B–C

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

• If out of the standard, measure the main bearing oil clearance. H
Then use the under size bearing. Refer to EM-271, "Main Bearing".
JPBIA6121ZZ
J
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).
K
• If out of the standard, measure the connecting rod bearing oil
clearance. Then use under size bearing. Refer to EM-269, "Con- L
necting Rod Bearing".
JPBIA0228ZZ
CRANKSHAFT OUT-OF-ROUND AND TAPER N

• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in the dimensions
O
between (d) and (c) at (a) and (b).
• Taper is indicated by the difference in the dimensions between.
Out-of-round (Difference : Refer to EM-280, "Cylin- P

between c and d) der Block".
Taper (Difference between
a and b)
• If the measured value exceeds the limit, correct or replace crank- JPBIA0229ZZ
shaft.

CYLINDER BLOCK
• If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to EM-271, "Main Bearing" and/or EM-269, "Connecting Rod Bear-
ing".
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on
both ends of crankshaft.
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on a
dial indicator. (Total indicator reading)
Standard and limit : Refer to EM-280, "Cylinder Block".

• If it exceeds the limit, replace crankshaft.
SEM346D

• Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-251, "Disassembly and Assembly" for the
tightening procedure.
JPBIA0230ZZ
• Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)
Standard and limit : Refer to EM-269, "Connecting Rod Bearing".

• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-268, "Description".
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
holes.
• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-251, "Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
• Remove connecting rod bearing cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
JPBIA0231ZZ

CYLINDER BLOCK
A
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-251, "Disassembly and Assembly" for the tightening EM
procedure.
• Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main C
journal diameter)
Standard and limit : Refer to EM-282, "Main Bearing".

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

E
Refer to EM-268, "Description".
• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely. F
holes.
• Install main bearing to cylinder block and main bearing cap, and tighten main bearing cap bolts with main
bearing cap to the specified torque. Refer to EM-251, "Disassembly and Assembly" for the tightening proce- G
dure.
CAUTION:
Do not rotate crankshaft. H
• Remove main bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the I
K
JPBIA0231ZZ
MAIN BEARING CRUSH HEIGHT

• When main bearing cap is removed after being tightened to the L
specified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-251, "Disassembly and
Assembly" for the tightening procedure. M
(A) : Crush height
N
• If the standard is not met, replace main bearings.
JPBIA0233ZZ O
CONNECTING ROD BEARING CRUSH HEIGHT
P

CYLINDER BLOCK
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-251, "Disassem-
bly and Assembly" for the tightening procedure.
(A) : Crush height

• If the standard is not met, replace connecting rod bearings.
JPBIA0233ZZ
MAIN BEARING CAP BOLT DEFORMATION

• Measure the outer diameter of threaded area, (B) and (A), at the
points specified in the figure.
(c) : 35 mm (1.38 in)

(d) : 5 mm (0.20 in)
• When the necked point is identified at a point other than where
specified, measure at the point as (A).
• Calculate the difference between (B) and (A).
Limit : 0.13 mm (0.0051 in)

JPBIA6196ZZ
• If it exceeds the limit, replace main bearing cap bolt.
CONNECTING ROD BOLT DEFORMATION
• Install nuts to connecting rod bolts (1). Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on the
bolt.
(a) : 19 mm (0.75 in)

• If the nut does not screw in smoothly, measure the outer diameter
of the bolt thread at the point specified in the figure.
• If a necked point is identified, measure at that point.
Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.

JPBIA6122ZZ
Limit : 8.75 mm (0. 3445 in) dia.
• If it exceeds the limit, replace connecting rod bolts and nuts.
OIL JET
• Check nozzle (A) for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
Standard : No deformation and no damage.

• If out of the standard, replace oil jet.
JPBIA6123ZZ
OIL JET RELIEF VALVE

CYLINDER BLOCK
• Using clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force. A
Standard:
Valve moves smoothly with proper reaction force. EM
• If out of the standard, replace oil jet relief valve.
JEM222G


Piston and piston pin assembly
Between cylinder block to pis- Piston grade (piston outer diam- Piston grade = cylinder bore
The piston is available together
ton eter) grade (inner diameter of bore)
with piston pin as an assembly.
Combining service grades for
connecting rod big end diame-
Between crankshaft to connect- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
ing rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Determined by match of cylin-
der block bearing housing
Between cylinder block to Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
selective fitting parts, refer to the text.
WHEN NEW CYLINDER BLOCK IS USED

1. Identify the cylinder bore grade (No. 1, 2, or 3) (B) on LH surface
at the rear of cylinder block.
(A) : Crank journal grade

(C) : Control code
: Engine front

• The part No. of piston is specified together with piston pin as
an assembly.
JPBIA6128ZZ
WHEN CYLINDER BLOCK IS REUSED

1. Measure cylinder bore inner diameter. Refer to EM-257, "Inspection".
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
(A) : Identification code

(B) : Front mark
(C) : Piston grade number
JPBIA3910ZZ

Unit: mm (in)
Grade (punched) 1 2 3 A
Cylinder bore in-
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
ner diameter
Piston outer di- EM
88.806 - 88.820 (3.4963 - 3.4968) 88.816 - 88.830 (3.4967 - 3.4972) 88.826 - 88.840 (3.4971 - 3.4976)
ameter
NOTE:
C
Piston is available together with piston pin as an assembly.
D
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED
1. Identify connecting rod big end diameter grade stamped (B) on
connecting rod side face to the row in the “CONNECTING ROD E
BEARING SELECTION TABLE”.
(A) : Front mark

F
(D) : Cylinder No.
JPBIA6219ZZ
H
2. Identify pin journal diameter grade stamped (from left No. 1 to 4)
(E) on crankshaft front side (A) to the column in the “CONNECT-
ING ROD BEARING SELECTION TABLE”.
I
(1) : Key
(B) : Journal grade No. (From left No. 1 to 5)
(C) : Identification code J
(D) : Lot No.
K
JPBIA6124ZZ
3. Select connecting rod bearings of the same grade.

NOTE: L
There is no grading for the inner diameter of the big end of the connecting rod.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
M
1. Measure the inner diameter of the big end of connecting rod and check it is within the specified range.
Refer to EM-257, "Inspection".
2. Measure the outer diameter of the crankshaft pin. Refer to EM-257, "Inspection".
N
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
O

JPBIA3907GB
UNDERSIZE BEARING USAGE GUIDE

• If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under size
bearings.
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.
Connecting rod bearing under size : Refer to EM-283, "Connecting Rod Bearing".
CAUTION:
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.
Standard dimension R : 1.5 - 1.7 mm (0.059 - 0.067 in)
JEM216G

A
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED
1. Identify the crank journal grade (from bottom No. 1 to 5) (A) on
LH surface at the rear of the cylinder block, and locate the appli- EM
cable grade on the “Grade” row in the “Main Bearing Grade
Table”.
C
(B) : Bore grade No. (From bottom No. 1 to 4)
(C) : Control code
: Engine front D
JPBIA6128ZZ
E
2. Identify the journal grade on the front surface of crankshaft (A),
and locate the applicable grade under the “Grade” column in the
“Main Bearing Grade Table”. F
(1) : Key
(B) : Journal grade No. (From left No. 1 to 5)
G
(C) : Identification code
(D) : Lot No.
(E) : Pin grade No. (From left No. 1 to 4)
H
JPBIA6124ZZ
3. The main bearing to be used can be located in the cell where the row and column cross.
I
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-257, "Inspection".
2. Locate the applicable cell where the measurement falls, on “Cylinder block main bearing housing inner J
diameter” row in the “MAIN BEARING SELECTION TABLE”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-257, "Inspection".
4. Locate the applicable cell where the measurement falls, under “Crankshaft main journal diameter” column K
in the “MAIN BEARING SELECTION TABLE”.
5. The main bearing to be used can be located in the cell where the row and column cross.
L

MAIN BEARING SELECTION TABLE
JPBIA3906GB
MAIN BEARING GRADE TABLE (ALL JOURNALS)
Main bearing grade table (All journals) : Refer to EM-282, "Main Bearing".
UNDERSIZE BEARING USAGE GUIDE

• If bearing clearance is out of the specifications for main bearings in standard size, use under size bearings.
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft journals to adjust clearance to the specification.
Main bearing under size : Refer to EM-282, "Main Bearing".

CAUTION:

When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals) A
Standard dimension R : 1.5 - 1.7 mm (0.059 - 0.067 in)

EM
JEM216G

< SERVICE DATA AND SPECIFICATIONS (SDS) [YD25DDTi]

GENERAL SPECIFICATION

Displacement 3 2,488 (151.82)
Unit: cm (cu in)
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Compression 2
Oil 1
Number of main bearings 5
Compression ratio 15
Standard 2,800 (28, 28.56, 406)
Compression pressure
Minimum 2,200 (22, 22.44, 319)
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 450 (4.5, 4.59, 65.3)
Valve Timing
Unit: degree
Valve timing
: Intake valve
: Exhaust valve
JSBIA3273GB
a b
c d e f
EXH valve open- INT valve open-
INT open INT close EXH close EXH open
ing angle ing angle
2 30 2 46
224 212
BTDC ABDC BTDC BBDC
Drive belt INFOID:0000000014267201
Belt Tension and Frequency
Tension adjustment * Unit: N (kg) Frequency adjustment * Unit: Hz

Location Used belt Used belt
New belt New belt
Limit After adjusted Limit After adjusted
Drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
532 - 588 760 - 840
Power steering oil pump belt 240 (24.5) 162 245 290
(54.3 - 60.0) (77.5 - 85.7)
*: When engine is cold.

Intake Manifold INFOID:0000000014267202
A
Unit: mm (in)
Items Limit
Intake manifold 0.1 (0.004)
EM
Surface distortion
Collector intake manifold 0.1 (0.004)
Exhaust Manifold INFOID:0000000014267203 C
Unit: mm (in)
Items Limit D
Surface distortion Exhaust manifold 0.3 (0.012)
E
CAMSHAFT
Unit: mm (in) F
Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034)
No.1 30.500 - 30.521 (1.2008 - 1.2016) G
Camshaft bracket inner diameter
No. 2, 3, 4, 5 24.000 - 24.021 (0.9449 - 0.9457) —
No. 1 30.435 - 30.455 (1.1982 - 1.1990) H
Camshaft journal outer diameter
No. 2, 3, 4, 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.02 (0.0008)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059) I
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
M
SEM671
Intake 39.505 - 39.695 (1.5553 - 1.5628)

Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785) N
VALVE LIFTER
Unit: mm (in)
O
Items Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801) P
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)
VALVE CLEARANCE

Unit: mm (in)
Items Cold Hot* (Reference data)

Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
AVAILABLE VALVE LIFTER
Stamped mark (A) Thickness (B) mm (in)

210 D 2.10 (0.0827)
212 D 2.12 (0.0835)
214 D 2.14 (0.0843)
216 D 2.16 (0.0850)
218 D 2.18 (0.0858)
220 D 2.20 (0.0866)
222 D 2.22 (0.0874)
224 D 2.24 (0.0882)
226 D 2.26 (0.0890)
228 D 2.28 (0.0898)
230 D 2.30 (0.0906)
232 D 2.32 (0.0913)
234 D 2.34 (0.0921)
236 D 2.36 (0.0929)
238 D 2.38 (0.0937)
240 D 2.40 (0.0945)
242 D 2.42 (0.0953)
244 D 2.44 (0.0961)
246 D 2.46 (0.0969)
248 D 2.48 (0.0976)
250 D 2.50 (0.0984)
252 D 2.52 (0.0992)
254 D 2.54 (0.1000)
256 D 2.56 (0.1008)
258 D 2.58 (0.1016)
260 D 2.60 (0.1024)
262 D 2.62 (0.1031)
264 D 2.64 (0.1039)
266 D 2.66 (0.1047)
268 D 2.68 (0.1055)
270 D 2.70 (0.1063)
272 D 2.72 (0.1071)

Stamped mark (A) Thickness (B) mm (in)
A
274 D 2.74 (0.1079)
EM
JPBIA3912ZZ
E
CYLINDER HEAD F
Unit: mm (in)
Cylinder head distortion Less than 0.04 (0.0016) 0.1 (0.004) G
Cylinder head height 153.9 - 154.1 (6.059 - 6.067) —
JPBIA6139ZZ
K
VALVE DIMENSIONS
Unit: mm (in) L
JSBIA1166ZZ
Intake 28.4 - 28.7 (1.1181 - 1.1299) P

Valve head diameter “D”
Exhaust 25.8 - 26.1 (1.0157 - 1.0276)
Intake 105.93 (4.1705)
Valve length “L”
Exhaust 105.48 (4.1527)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)

Valve seat angle “α” Intake and exhaust 45 degrees 15′ - 45 degrees 45′
Intake 1.08 (0.0425)
Exhaust 1.38 (0.0543)
Valve margin “T” limit More than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
VALVE GUIDE
Unit: mm (in)
JPBIA6140ZZ
Items Standard Service

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) 0.2 (0.008)
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.2 (0.008)
Projection length 10.4 - 10.6 (0.409 - 0.417)
VALVE SEAT

Unit: mm (in)
A
EM
E1BIA0294ZZ
JEM253G
M
Cylinder head seat (1) recess diame- Intake 30.4 - 30.416 (1.1968 - 1.1975) 30.9 - 30.916 (1.2165 - 1.2165)
ter (D) Exhaust 28.200 - 28.216 (1.1102 - 1.1109) 28.7 - 28.716 (1.1299 - 1.1305) N
Intake (A) 30.48 - 30.5 (1.2 - 1.2008) 30.98 - 31.0 (1.2197 - 1.2205)
Valve seat outer diameter (d)
Exhaust (B) 28.28 - 28.296 (1.1134 - 1.1140) 28.78 - 28.796 (1.1331 - 1.1337)
O
Intake (A) 0.064 - 0.100 (0.0025 - 0.0039)
Exhaust (B) 0.064 - 0.096 (0.0025 - 0.0038)
Intake (A) 27.7 - 28.2 (1.0689 - 1.0886) 27.7 - 28.2 (1.0689 - 1.0886) P
Diameter (d1)
Exhaust (B) 25.1 - 25.6 (0.9882 - 1.0079) 25.1 - 25.6 (0.9882 - 1.0079)
Angle (α) 89.5°±45′
Intake (A) 6.40 - 6.90 (0.252 - 0.272) 6.40 - 6.90 (0.252 - 0.272)
Height (h1)
Exhaust (B) 6.19 - 6.69 (0.244 - 0.263) 6.19 - 6.69 (0.244 - 0.263)

Intake (A) 2.25 - 2.45 (0.089 - 0.096) 2.15 - 2.55 (0.085 - 0.1004)
Height (h2)
Exhaust (B) 2.9 - 3.1 (0.1142 - 0.1220) 2.8 - 3.2 (0.1102 - 0.1260)
Intake 8.85 - 9.15 (0.3484 - 0.3602)
Depth (H)
Exhaust 9.29 - 9.59 (0.3657 - 0.3776)
Intake 36.18 - 36.78 (1.4382 - 1.4559)
Projection (L)
Exhaust 36.16 - 36.96 (1.4236 - 1.4551)
VALVE SPRING
Valve spring square mm (in) 1.8 (0.071)

Intake 44.8 (1.764)
Free height mm (in)
Exhaust 49.0 (1.929)
Intake 138 - 152 (14.08 - 15.50, 31.0 - 34.2) at 32.8 (1.29)
Pressure N (kg, lb) at height mm (in)
Exhaust 186 - 206 (18.97 - 21.01, 41.8 - 46.3) at 32.8 (1.29)
Intake 24.95 (0.982)
Height during valve open mm (in)
Exhaust 24.66 (0.971)
Intake 250 - 274 (25.5 - 27.9, 56.2 - 61.6)
Load with valve open N (kg, lb)
Exhaust 308 - 336 (31.4 - 34.3, 69.2 - 75.5)
CYLINDER BLOCK
Unit: mm (in)
JPBIA6141ZZ
Standard Less than 0.03 (0.0012)

Top surface distortion
Limit 0.1 (0.004)
Grade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Cylinder bore Inner diameter
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.07 (0.0028)
Out-of-round (Difference between X and Y) 0.015 (0.0006)
Limit
Taper (Difference between (A) and (C)) 0.010 (0.0004)
Main bearing housing inner diameter (Without bearing) 66.656 - 66.680 (2.6242 - 2.6252)
Difference in inner diameter between cylinders Limit Less than 0.05 (0.0020)
AVAILABLE PISTON

Unit: mm (in)
A
EM
D
E1BIA0295ZZ
Grade No. 1 88.806 - 88.820 (3.496 - 3.4968)

E
Grade No. 2 88.816 - 88.830 (3.4967 - 3.4972)
Piston outer diameter “A” Standard Grade No. 3 88.826 - 88.840 (3.4971 - 3.4976)
Oversize (Service) [0.25] 89.066 - 89.080 (3.5065 - 3.5071)
F
Oversize (Service) [0.5] 89.316 - 89.330 (3.5164 - 3.5169)
“a” dimension 43.0 (1.63)
Piston pin bore diameter 28.008 - 28.013 (1.1027 - 1.1029) G
Piston to cylinder bore clearance 0.18 - 0.204 (0.0071 - 0.008)
PISTON RING H
Unit: mm (in)

Top 0.04 - 0.06 (0.0016 - 0.0024) 0.17 (0.007) I
Side clearance 2nd 0.08 - 0.12 (0.0031 - 0.0047) 0.13 (0.005)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) -
J
Top 0.18 - 0.28 (0.0071 - 0.0110)
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217) K
PISTON PIN
Unit: mm (in)
L
Piston pin outer diameter 27.995 - 28.000 (1.1022 - 1.1024)
Piston to piston pin clearance 0.008 - 0.018 (0.0003 - 0.0007)
Standard 0.026 - 0.043 (0.0010 - 0.0017) M
Connecting rod bushing clearance
Limit 0.057 (0.0022)
CONNECTING ROD N
Unit: mm (in)
Center distance 154.47 - 154.53 (6.0815 - 6.0838)

Bend [per 100 (3.94)] Limit 0.35 (0.0138) O
Torsion [per 100 (3.94)] Limit 0.25 (0.0098)
Connecting rod bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
P
Connecting rod big end inner diameter* 55.000 - 55.013 (2.1654 - 2.1659)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.40 (0.0157)
*: After installing in connecting rod
CRANKSHAFT

Unit: mm (in)
SEM645 JPBIA0229ZZ
Main journal dia. “Dm” 62.951 - 62.975 (2.4784 - 2.4793)

Pin journal dia. “Dp” 51.956 - 51.974 (2.0455 - 2.0462)
Center distance “r” 49.97 - 50.03 (1.9673 - 1.9697)
Standard 0.003 (0.0001)
Out-of-round (Difference between (c) and (d))
Limit 0.005 (0.0002)
Standard 0.003 (0.0001)
Taper (Difference between (a) and (b))
Limit 0.005 (0.0002)
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.085 - 0.25 (0.0033 - 0.0098)
End play
Limit 0.30 (0.0118)
MAIN BEARING
Unit: mm (in)
Grade number Thickness Width Identification color Remarks

0 1.812 - 1.809 (0.0713 - 0.0712) Black
A
1 1.815 - 1.812 (0.0715 - 0.0713) Brown
2 1.818 - 1.815 (0.0716 - 0.0715) Green
3 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are the
same for upper and
EM
4 1.824 - 1.821 (0.0718 - 0.0717) Blue lower bearings.
5 1.827 - 1.824 (0.0719 - 0.0718) Pink
6 1.830 - 1.827 (0.0720 - 0.0719) Purple C
7 1.833 - 1.830 (0.0722 - 0.0720 Red
UPR 1.812 - 1.809 (0.0715 - 0.0712) Black
01 D
LWR 1.815 - 1.812 (0.0715 - 0.0713) Brown
UPR 1.815 - 1.812 (0.0715 - 0.0713) 19.9 - 20.1 Brown
12
LWR 1.818 - 1.815 (0.0716 - 0.0715) (0.783 - 0.791) Green E
UPR 1.818 - 1.815 (0.0716 - 0.0715) Green
23
LWR 1.821 - 1.818 (0.0717 - 0.0716) Yellow
F
UPR 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are dif-
34 ferent between upper
LWR 1.824 - 1.821 (0.0718 - 0.0717) Blue and lower bearings.
UPR 1.824 - 1.821 (0.0718 - 0.0717) Blue G
45
LWR 1.827 - 1.824 (0.0719 - 0.0718) Pink
UPR 1.827 - 1.824 (0.0719 - 0.0718) Pink
56 H
LWR 1.830 - 1.827 (0.0720 - 0.0719) Purple
UPR 1.830 - 1.827 (0.0720 - 0.0719) Purple
67
LWR 1.833 - 1.830 (0.0722 - 0.0720 Red I
UNDERSIZE
Unit: mm (in)
J
Size Thickness Main journal diameter “Dm”
MAIN BEARING OIL CLEARANCE K

Unit: mm (in)

L
Main bearing oil clearance * 0.066 (0.0026)
0.056 - 0.066 (0.0022 - 0.0026)
*: Actual clearance
M
CONNECTING ROD BEARING

N
Grade number Thickness mm (in) Width Identification color Remarks

0 1.488 - 1.485 (0.0586 - 0.0585) Green
1 1.491 - 1.488 (0.0585 - 0.0587) Yellow
2 1.494 - 1.491 (0.0588 - 0.0585) Blue
3 1.497 - 1.494 (0.0589 - 0.0588) Pink
4 1.500 - 1.497 (0.0591 - 0.0589) Purple
UPR 1.488 - 1.485 (0.0586 - 0.0585) Green
01 22.9 - 23.1
LWR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
(0.902 - 0.909)
UPR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
12
LWR 1.494 - 1.491 (0.0588 - 0.0585) Blue Grade and color are different
between upper and lower
UPR 1.494 - 1.491 (0.0588 - 0.0585) Blue bearings.
23
LWR 1.497 - 1.494 (0.0589 - 0.0588) Pink
UPR 1.497 - 1.494 (0.0589 - 0.0588) Pink
34
LWR 1.500 - 1.497 (0.0591 - 0.0589) Purple
UNDERSIZE
Unit: mm (in)
Size Thickness Crank pin journal diameter “Dp”

UPR 1.534 - 1.542 (0.0604 - 0.0607)
0.08 (0.0031)
LWR 1.536 - 1.540 (0.0605 - 0.0606)
UPR 1.554 - 1.562 (0.0612 - 0.0615)
0.12 (0.0047) Grind so that bearing clearance is the specified value.
LWR 1.556 - 1.560 (0.0613 - 0.0614)
UPR 1.619 - 1.627 (0.0637 - 0.0641)
0.25 (0.0098)
LWR 1.621 - 1.625 (0.0638 - 0.0640)

Unit: mm (in)

Connecting rod bearing oil clearance 0.051 - 0.061 (0.002 - 0.0024)* 0.061 (0.0024)
*: Actual clearance

PRECAUTIONS
< PRECAUTION > [YS23DDT/YS23DDTT (M9T)]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
WARNING: D
nance and repair be performed by an authorized NISSAN/INFINITI dealer. E
see the SR section.
F
ness connectors.
G
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the I
INFOID:0000000014267210
J
NOTE:
K
battery cables.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If L
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. M
OPERATION PROCEDURE N
NOTE:
Supply power using jumper cables if battery is discharged. O
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon- P

PRECAUTIONS
windshield.
PIIB3706J

• Release fuel pressure before disconnecting and disassembly.
DRAINING ENGINE COOLANT



structed operations.
check that dowel pins are installed in the original position.
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
ASSEMBLY AND INSTALLATION

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
• After disassembling, or exposing any internal engine parts, change engine oil and replace oil filter with a new
one.

PRECAUTIONS
A
• For the final tightening of the following engine parts use Tool:
Tool number : KV10112100 (BT-8653-A) EM

- Cylinder head bolts
- Connecting rod cap bolts C
ing)
• The torque value for these parts are for a preliminary step. D
• Ensure thread and seat surfaces are clean and coated with engine oil.
E

CAUTION:
F
• After removing the bolts and nuts, separate the mating surface and
G
Tool number (A) : KV10111100 (J-37228)
lightly tap (1) the cutter where the liquid gasket is applied. Use a H
plastic hammer to slide (2) the cutter by tapping on the side.
I
AWBIA1249GB
LIQUID GASKET APPLICATION PROCEDURE J

• Remove liquid gasket completely from the groove of the liquid K
L
M
JPBIA0053ZZ
3. Attach liquid gasket tube to the suitable tool. N

O
P
EMA0622D

PRECAUTIONS
holes. Occasionally, it should be applied outside the holes.
(A) : Groove
: Inside

ing component.
engine oil and engine coolant. Refer to LU-44, "Draining" and CO-63, "Changing Engine Coolant".
CAUTION:
If there are more specific instructions in the procedures contained in this manual concerning liquid
Precaution for Diesel Equipment INFOID:0000000014267215
CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
• Damage or destruction of the high pressure injection system and the engine
• Seizing or leaking of a component
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the fuel filter to the fuel injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
• Metal or plastic chips
• Paint
• Fibers:
- Boxes
- Brushes
- Paper
- Clothing
- Cloths
• Foreign bodies such as hair
• Ambient air
• Etc.
WARNING:
It is not possible to clean the engine using a high pressure fuel pump because of the risk of damaging
connections. In addition, moisture may collect in the connectors and create electrical connection mal-
functions
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS-
TEM
• Check that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan
part No. 16609 00Q0A, Renault part No. 77 01 209 062). Plugs are to be used once only. After use, they
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.
• Check that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away.
• Lint-free towelettes to be used for fuel pump related service purpose. The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system.
Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT

PRECAUTIONS
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle.
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles). A
• Use a brush and thinners to clean the connections to be opened.
• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered.
EM
• Wash your hands before and during the operation if necessary.
• When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION
• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. C
The plugs to be used are available from the Parts Stores - Nissan part No. 16609 00Q0A, Renault part No.
77 01 209 062. They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con- D
tamination.
• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted.
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been E
opened. These items are likely to allow impurities to enter the system.
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle. F
Instructions for Fitting the Plugs
Nissan part No. 16609 00Q0C

PRECAUTIONS
(Renault part No. 77 01 479 091)
JPBIA0585ZZ
SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Use diesel fuel required by the regulations for cetane number. Refer to GI-28, "Fuel".
- Petrol, even in tiny quantities
• Before carrying out any work, check that the fuel rail is not under pressure and that the fuel temper-
ature is not too high. [The system can inject the diesel into the engine at a pressure up to 160,000
kPa (1,600 bar, 1,632 kg/cm2, 23,200 psi)].

PRECAUTIONS
• Respect the cleaning and safety advice specified in this document for any work on the high pressure
injection system. A
• Remove of the interior of the fuel pump and fuel injectors is prohibited.
• For safety reasons, it is strictly forbidden to slacken an injection tube union when the engine is run-
ning.
EM
• It is not possible to remove the fuel pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the fuel pressure sensor fails, the fuel pressure sensor, the fuel rail
and the fuel injection tubes must be replaced.
• It is strictly forbidden to remove the fuel pump pulley. C
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Never start the engine without the battery being connected correctly. D
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there is no diesel leakage.
• Start the engine and check for fuel leak for one minute after starting. E
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50°C (122°F) and provided there are no malfunctions
present, carry out a road test, taking the engine speed up to 4,000 rpm at least once to check that there is no F
leakage.
• Perform a visual inspection after the road test to check that there is no high pressure leakage.
• Clean off the tracing fluid.
G

PREPARATION
< PREPARATION > [YS23DDT/YS23DDTT (M9T)]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000014267216
(RENAULT tool No.)
Tool name
— Installing piston assembly into cylinder bore
(Mot. 1979)
Piston ring compressor
KV10111100 Removing oil pan and front cover. etc
( — )
Seal cutter
NT046
KV10112100 Tightening bolts for bearing cap, cylinder

( — ) head, etc. in angle
Angle wrench
NT014
KV10114400 Loosening or tightening air fuel ratio sensor

( — ) a: 22 mm (0.87 in)
Heated oxygen sensor wrench
JPBIA0397ZZ
— To lock engine at TDC

(Mot. 1970)
TDC set pin
JPBIA0629ZZ
— To lock camshaft when changing timing chain

(Mot. 1969)
Camshaft timing tool
JPBIA0628ZZ

PREPARATION
(RENAULT tool No.) A
Tool name
— To lock crankshaft pulley
(Mot. 1770) EM
Crankshaft pulley locking tool
JPBIA0630ZZ
— Connecting compression gauge and glow D

(Mot. 1772) plug hole
Compression gauge adapter • : G1/4
• : M10×1.0 E
• : 64 mm
• : φ8.5 mm
JSBIA5512ZZ F
— To position the gear and apply for the right
(Mot. 1773) clearance (wear compensation gear)
Positioning tool G
H
JPBIA0625ZZ
— Removing and installing drive plate or fly-

(Mot. 1959) wheel I
TORX Socket Size: T55+
E1BIA0349ZZ
K
— Installing oil jet (9.5 degree orientation)
(Mot. 1972)
Piston cooler fitting tool
L
— Removing oil jet
(Mot. 1485-01)
Piston cooler removing tool
— To lock flywheel M
(Mot. 1431)
Flywheel locking tool
N
JMAIA0431ZZ O
— Pin extractor tool
(Emb. 880)
Piston cooler fitting tool P
Commercial Service Tools INFOID:0000000014267217

PREPARATION
(RENAULT tool No.)
Tool name
KV113B0040 Gauge stand used with KV113B0050 (Mot.
(Mot. 251-01) 252-01)
Dial indicator stand set
MBIB0360E
KV113B0050 Thrust plate for measuring the protrusion of

(Mot. 252-01) piston used with KV113B0040 (Mot. 251-01)
Dial indicator stand set
MBIB0361E
KV113B0090 Tool for removing valve oil seals

(Mot. 1335)
Valve seal remover
MBIB0370E
KV113B0180 Tool for installing valve oil seals

(Mot. 1511-01)
Valve seal drift
MBIB0378E
KV113B0200 Cylinder head and cylinder head housing sup-

(Mot. 1573) port
Cylinder head stand
MBIB0380E
— Pressing the tube of liquid gasket

( — )
Tube presser
NT052
— Disassembling valve mechanism

( — )
Valve spring compressor
JPBIA0770ZZ

PREPARATION
(RENAULT tool No.) A
Tool name
( — ) EM
ZZA1210D
— Loosening nuts, screws, and bolts D

( — )
Power tool
E
PIIB1407E F
— Removing and installing piston ring
( — )
Piston ring expander G
H
NT030

< BASIC INSPECTION > [YS23DDT/YS23DDTT (M9T)]
BASIC INSPECTION
1. PREPARATION OPERATION FOR CHECK

• Remove the grow plugs. Refer to EM-332, "Removal and Installation".
• Disconnect all the connectors of the fuel injector.
• Set the compression gauge adapter [SST: — (Mot. 1772)] in place of one of the removed grow plugs.
• Moderately tighten the compression gauge adapter [SST: — (Mot. 1772)] using an open-jawed spanner.
• Screw the conversion compression gauge adapter [SST: — (Mot. 1772)] of the diesel compression
gauge onto the hose.
• NOTE:
If compression gauge for diesel engine cannot connect to the compression gauge adapter, use the
adapter [SST: KV111063S0 ( — )].
Compression gauge adapter : 20 N·m (2.0 kg-m, 15 ft-lb)

• Put the vehicle under the starting conditions with the gear lever in neutral.
2. TEST OPERATION
• Turn the engine ignition key to trigger the engine starting phase.
NOTE:
The engine will be driven for 20 s without starting.
• Check the compression of cylinder no. 1.

NOTE:
• Put the vehicle back in forced + after ignition feed as soon as the starter has stopped (in order to main-
tain engine start inhibition and to measure the compression of the other cylinders).
• It is necessary to wait for at least 10 seconds before starting the engine each time (the starter will not
run due to its thermal protection).
• Measure the compression of the other cylinders.
3. FINAL OPERATION
• Proceed in the reverse order to removal.
• Install the glow plugs. Refer to EM-332, "Removal and Installation".

< SYMPTOM DIAGNOSIS > [YS23DDT/YS23DDTT (M9T)]
SYMPTOM DIAGNOSIS A
NVH Troubleshooting - Engine Noise INFOID:0000000014267219
EM
JSBIA6121GB

< SYMPTOM DIAGNOSIS > [YS23DDT/YS23DDTT (M9T)]
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000014267220


up up ing
Hydraulic
Ticking or
Top of en- A C — B B — tappet Out of oil EM-362
clicking
gine noise
Cylinder Camshaft
head Camshaft journal oil
Rattle C A — A B C bearing EM-358
clearance
noise
Piston to piston pin oil
Slap or Piston pin clearance
— A — B B — EM-416
knock noise Connecting rod bushing
Crank- oil clearance
ley Slap or Piston
A — — B B A ance EM-416
Cylinder rap slap noise
Piston ring end gap
block
(Side of Connect- Connecting rod bushing
engine) ing rod oil clearance
Knock A B C B B B EM-421
Oil pan bearing Connecting rod bearing
noise oil clearance
Main bear- Main bearing oil clear-
Knock A B — A B C EM-420
ing noise ance
Timing
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-352
Front cov- ticking Timing chain tensioner
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-306
ping)
Front of
Drive belt Idler pulley bearing op-
(Slipping) eration
Water
Squall
Creak
noise

DRIVE BELT
< PERIODIC MAINTENANCE > [YS23DDT/YS23DDTT (M9T)]
DRIVE BELT
EM
JPBIA7099ZZ
1. Generator 2. Water pump pulley 3. Crankshaft pulley

G
4. A/C compressor 5. Drive belt auto-tensioner 6. Power steering oil pump pulley
7. Idler pulley 8. Drive belt 9. Air compressor belt
H
Range when new drive belt is in-
A. View B. Indicator C.
stalled
D. Possible use range
I
CAUTION: J
• Replace the drive belt that has been removed with a new one.
• Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
• Do not run the engine without the drive belt to avoid damaging the crankshaft pulley. K
REMOVAL
1. Remove engine front under cover. Refer to EXT-30, "FRONT UNDER COVER : Exploded View". L
2. Remove radiator hose (lower) bolt (A) from charge air cooler
cover (1).
M
: Front
O
JSBIA6336ZZ
3. Remove charge air cooler cover. Refer to EM-309, "Exploded View".

P

DRIVE BELT
4. Remove compressor belt by cutting it with an appropriate tool
(A).
JSBIA6146ZZ
5. Hold the hexagonal part (A) in center of drive belt auto-tensioner

pully with a box wrench securely. Then move the wrench handle
in the direction of arrow (loosening direction arrow)
JSBIA6147ZZ
6. Insert a stopper pin (A) in diameter such as short-length screw-

driver into the hole of the retaining boss to fix drive belt auto-ten-
sioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed.
JSBIA6148ZZ
7. Remove drive belt.

INSTALLATION
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
• Do not allow engine coolant to contact the drive belt.
4. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-301, "Inspection".
5. Set A/C compressor belt (1) on A/C compressor pulley (2).
6. Install stretch belt service tool (A) to A/C compressor belt as shown in the figure.
JSBIA6378ZZ

DRIVE BELT
CAUTION:
• Stretch belt service tool (A) A
(B) : Correct
(C) : Incorrect EM
• Check that belt is properly placed in the groove of pulley.
JSBIA6379ZZ D
7. Rotate stretch belt service tool (A) installation direction.

8. Since the lower part of belt (B) becomes warped, rotate crank E
shaft pulley by holding the belt by hand.
JSBIA6380ZZ
H
9. If stretch belt service tool comes off check if the belt is properly placed in the groove of eachpulley.
I
M
JPBIA7099ZZ
1. Generator 2. Water pump pulley 3. Crankshaft pulley N

4. A/C compressor 5. Drive belt auto-tensioner 6. Power steering oil pump pulley
7. Idler pulley 8. Drive belt 9. Air compressor belt
A. View B. Indicator C.
Range when new drive belt is in- O
stalled
D. Possible use range
WARNING: P
Be sure to perform this step when the engine is stopped.
• Check that the indicator (B) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
.
NOTE:
ure.

DRIVE BELT
CAUTION:
Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
Refer to EM-413, "Drive Belts".

AIR CLEANER FILTER
AIR CLEANER FILTER
A
EM
I
AWBIA2671ZZ
1. Mass air flow sensor 2. Air cleaner cover 3. Air filter J

4. Grommet 5. Retainer 6. Bracket
7. Clip 8. Air duct (inlet) 9. O-ring
10. Air duct 2 11. Collar 12. Air cleaner body K
13. Clamp 14. Air duct 1 15. Gasket
A. To turbocharger Front
L
REMOVAL M
1. Unhook clips (A) and pull up the air cleaner body cover upward
(1).
N
P
JSBIA5599ZZ

AIR CLEANER FILTER
2. Remove air cleaner filter (1) from the air cleaner body assembly.
JSBIA5600ZZ
INSTALLATION
Inspection (Dry Paper Type) INFOID:0000000014267227

Examine with eyes that there is no stain, clogging, or damage on air cleaner element.
• Remove dusts (such as dead leafs) on air cleaner element surface and inside cleaner case.
• To clean air cleaner element, blow it from intake manifold side towards air intake side to remove trash or
dust.
• If clogging or damage is observed, replace the air cleaner element.
MAINTENANCE INTERVAL
Refer to MA-14, "EXCEPT MEXICO AND BRAZIL : Periodic Maintenance".

ENGINE COVER
< REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT (M9T)]
REMOVAL AND INSTALLATION A

ENGINE COVER
EM
JPBIA7101GB J
1. Engine cover 2. Grommet 3. Bracket

4. Bracket 5. Grommet 6. Bracket
K
REMOVAL L
Remove engine cover.
CAUTION:
Do not pull out the engine cover forcibly. M
INSTALLATION
installation is in the reverse order of removal.
N

JPBIA7105GB
1. Idler pulley 2. Cover 3. Drive belt auto-tensioner
CAUTION:
• Replace the drive belt that has been removed with a new one.
• Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
• Do not run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
1. Remove the radiator fan shroud (upper and lower). Refer to CO-66, "Exploded View".
2. Loosen drive belt. Refer to EM-299, "Removal and Installation".
3. Remove drive belt auto-tensioner and idler pulley.
CAUTION:
The disassemble prohibition part. Never disassemble the drive belt auto-tensioner, because the
worker shall injure by the spring jumped out.
NOTE:
Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.
INSTALLATION
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.

A
EM
I
AWBIA2671ZZ
1. Mass air flow sensor 2. Air cleaner cover 3. Air filter J

4. Grommet 5. Retainer 6. Bracket
7. Clip 8. Air duct (inlet) 9. O-ring
10. Air duct 2 11. Collar 12. Air cleaner body K
13. Clamp 14. Air duct 1 15. Gasket
A. To turbocharger Front
L
REMOVAL M
2. Remove reservoir tank and move to aside.
3. Disconnect harness connector from mass air flow sensor. N
4. Remove the air cleaner assembly with air cleaner filter.
5. Remove air duct 1.
O
6. Remove air duct 2.
7. Remove mass air flow sensor from air cleaner case (if necessary).
CAUTION:
• Do not shock mass air flow sensor. P
• Do not disassemble mass air flow sensor.
• Do not touch mass air flow sensor element.
INSTALLATION


• If anything found, replace air duct and resonator assembly.

CHARGE AIR COOLER
CHARGE AIR COOLER
A
YS23DDT EM
L
JSBIA7236GB
1. Air inlet tube (silencer) 2. Air inlet hose 3. Bracket (RH upper) M
4. Mounting rubber (upper) 5. Bracket (RH lower) 6. Clip
7. Charge air cooler seal (RH) 8. Mounting rubber (lower) 9. Charge air cooler
10. Charge air cooler cover 11. Charge air cooler seal (LH) 12. Bracket (LH lower) N
13. Air inlet hose 14. Clamp 15. Air inlet tube
16. O-ring 17. Intake air temperature sensor
A. To turbocharger B. To electric throttle control actuator C. View O
: Front

CHARGE AIR COOLER
YS23DDTT
JSBIA7237GB
1. Air inlet tube (silencer) 2. Air inlet hose 3. Bracket (RH upper)
4. Mounting rubber (upper) 5. Bracket (RH lower) 6. Clip
7. Charge air cooler seal (RH) 8. Mounting rubber (lower) 9. Charge air cooler
10. Charge air cooler cover 11. Charge air cooler seal (LH) 12. Bracket (LH lower)
13. Air inlet hose 14. Clamp 15. Air inlet tube
16. O-ring 17. Intake air temperature sensor
A. To turbocharger B. To electric throttle control actuator C. View
: Front
REMOVAL
Air inlet hose 1 and air inlet tube (silencer)
1. Remove front under cover. Refer to EXT-30, "FRONT UNDER COVER : Exploded View".

CHARGE AIR COOLER
cover (1). A
: Vehicle front
EM
JSBIA6336ZZ
D
5. Remove air cleaner assembly Refer to EM-307, "Removal and Installation". E
6. Remove reservoir tank and move to aside. Refer to CO-66, "Exploded View".
7. Remove air inlet hose with the following procedure:
a. Insert suitable tool between air inlet hose and retainer (1). F
A. : View
B. : Insert position G
C. : Movement direction of the retainer
D. : Projection
H
b. Unlock the retainer and pull out air inlet hose 2.
JPBIA6194ZZ
I
8. Remove air inlet tube (silencer).

J
Air inlet hose and air inlet tube
2. Remove radiator hose (lower) bolt (A) from charge air cooler K
cover (1).
: Vehicle front
L
JSBIA6336ZZ N
O
5. Remove air inlet hose with the following procedure:

CHARGE AIR COOLER
a. Insert suitable tool between air inlet hose and retainer (1).
A. : View
B. : Insert position
C. : Movement direction of the retainer
D. : Projection
b. Unlock the retainer and pull out air inlet hose.
6. Separate air inlet tube from mounting part.
7. Disconnect air inlet tube. (Charge air cooler side)
JPBIA6194ZZ
8. Disconnect radiator hose (upper). (Radiator side)
9. Disconnect air inlet tube. (Electric throttle control actuator side)
10. Remove air inlet tube.
Charge air cooler
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
cover (1).
: Vehicle front
JSBIA6336ZZ

4. Remove air inlet hose, air inlet tube and air inlet tube (silencer).
5. Remove charge air cooler seal (RH) (LH).
6. Remove vacuum hose in charge air cooler side.
7. Remove the mounting bolt of (RH lower) bracket (LH lower) bracket, remove charge air cooler.
INSTALLATION
CAUTION:
Do not reuse air inlet hose and clamp.
• When installing hoses, insert hose all the way to the end.
• When installing new clamps (1), check that clamps are positioned
between air inlet hose marks (A).
• When installing air inlet hose, align identification marks (color and
direction).
• Do not retighten clamp.
CAUTION:
If there is any issue with the clamp or the air inlet hose,
replace the air inlet hose and clamp.
JSBIA7229ZZ

CHARGE AIR COOLER
1. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry. A
2. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Do not deform core fins. EM

INTAKE MANIFOLD
INTAKE MANIFOLD
JPBIA7123GB
1. Gasket 2. Intake manifold 3. Thermo management valve control valve

4. O-ring 5. Electric throttle control actuator 6. Hose
7. Clamp 8. Intake manifold pressure sensor 9. EGR valve manifold duct
10. Gasket 11. EGR valve 12. Gasket
13. EGR temperatue sensor 14. EGR valve inlet pipe 15. Gasket
16. Clamp 17. Water hose 18. O-ring
A. To vaccum pump B. To Thermo management valve C. To water pipe
REMOVAL
1. Remove generator. Refer to CHG-53, "YS23DDT/YS23DDTT (M9T) : Removal and Installation".
2. Remove generator bracket. Refer to CHG-53, "YS23DDT/YS23DDTT (M9T) : Exploded View".
3. Remove air inlet hose 2 and air inlet tube. Refer to EM-309, "Exploded View".
4. Disconnect intake manifold pressure sensor harness connector.
5. Disconnect solenoid valve harness connector.
6. Disconnect electric throttle control actuator harness connector.
7. Remove electric throttle control actuator.
8. Remove intake manifold with the following procedure:

INTAKE MANIFOLD
a. Loosen mounting bolts in the order from 9 to 1 as shown in the
figure. A
EM
JSBIA6383ZZ
D
b. Remove intake manifold and gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
E
INSTALLATION
CAUTION: F
• Replace intake manifold stud if loosened.
• Do not reuse O-ring and gasket.
G
Intake Manifold
1. Install intake manifold.
• Tighten mounting bolts in the order from 1 to 9 as shown in the H
figure.
JSBIA6383ZZ
K
2. Perform "Throttle valve position learning". Refer to EC-558, "Description".

3. Perform "EGR volume control valve position learning". Refer to EC-559, "Description". when removing or L
replacing EGR volume control valve.
M
Surface Distortion N
• Check the surface distortion of the intake manifold mating surface with a straightedge and a feeler gauge.
Standard : Refer to EM-413, "Intake Manifold".

O
• If it exceeds the standard, replace intake manifold.

EGR SYSTEM
EGR SYSTEM
Exhaust manifold side
JPBIA7113GB
1. Vacuum hose 2. Vacuum hose 3. Clamp

4. Water hose 5. O-ring 6. Water pipe
7. Water pipe cover 8. EGR heat shield 9. Gasket
10. EGR intercooler inlet duct 11. Stud bolt 12. EGR cooler
13. Gasket 14. EGR intercooler outlet duct 15. Gasket
16. Vacuum hose 17. EGR cooler solenoid valve 18. Bracket
To turbocharger with exhaust manifold
A. To solenoid valve B. To water pipe center C. (YS23DDT)
To exhaust manifold (YS23DDTT)
Front

EGR SYSTEM
Intake manifold side
A
EM
H
JPBIA7123GB
1. Gasket 2. Intake manifold 3. Thermo management valve control valve

4. O-ring 5. Electric throttle control actuator 6. Hose I
7. Clamp 8. Intake manifold pressure sensor 9. EGR valve manifold duct
10. Gasket 11. EGR valve 12. Gasket
13. EGR temperature sensor 14. EGR valve inlet pipe 15. Gasket J
16. Clamp 17. Water hose
A. To vacuum pump B. To Thermo management valve C. To water pipe
K
REMOVAL L
NOTE:
ing. M
EGR volume control valve
2. Remove engine cover. Refer to EM-305, "Removal and Installation". N
3. Remove radiator upper hose 2. Refer to CO-66, "Exploded View".
4. Remove air inlet hose 2 and air inlet tube. Refer to EM-309, "Exploded View".
O
5. Remove fuel filter from bracket and move to aside.
6. Remove fuel filter bracket. Refer to FL-44, "Exploded View".
7. Remove water pipe. Refer to CO-73, "Exploded View". P
8. Remove EGR valve manifold duct.
9. Disconnect EGR volume control valve harness connector.
10. Remove EGR volume control valve.
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Do not disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.

EGR SYSTEM
11. Remove EGR volume control valve inlet pipe.
EGR cooler
CAUTION:
2. Remove turbocharger (YS23DDTT). Refer to EM-326, "Exploded View".
3. Remove exhaust manifold and turbocharger. Refer to EM-322, "Removal and Installation".
4. Remove EGR cooler bypass valve control solenoid valve.
5. Remove water pipe from EGR cooler.
6. Remove EGR cooler
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Do not disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.
INSTALLATION
CAUTION:
• Do not reuse gasket.
1. Perform “EGR volume control valve position learning”. Refer to EC-559, "Description" when removing or
replacing EGR volume control valve.

DPF (DIESEL PARTICULATE FILTER)
A
EM
I
JPBIA7122GB
1. Exhaust gas temperature sensor 2. Bracket 3. Outlet tube J

4. Inlet tube 5. Clamp 6. DPF (diesel particulate filter)
7. Bracket 8. Mounting rubber 9. Bracket
10. Mounting bracket A. To turbocharger B. To main muffler K
To turbochargerTo DPF (diesel par-
C.
ticulate filter) pressure sensor
Removal and installation INFOID:0000000014267244

L
CAUTION:
• Perform the operation with the exhaust system fully cooled down because the system is still hot just M
after engine stops.
• Be careful not to cut your hand on the insulator edge.
REMOVAL N
1. Remove the wheel and tire (RH) using a power tool. Refer to WT-10, "Exploded View".
2. Remove fender protector (RH). Refer to EXT-29, "Exploded View".
3. Remove main muffler. Refer to EX-18, "Exploded View". O
4. Disconnect DPF pressure sensor hose from outlet tube and inlet tube.
5. Disconnect exhaust gas temperature sensor harness connector.
P
6. Remove mounting bracket from transmission cross member.
Remove from parts. Refer to EM-366, "Exploded View".
7. Remove clamp between DPF (diesel particulate filter) and turbocharger.
8. Remove nuts of bracket (DPF side).
9. Remove DPF (diesel particulate filter)
10. Remove exhaust gas temperature sensor.
CAUTION:
Be careful not to impact or damage exhaust gas temperature sensor.
11. Remove DPF (diesel particulate filter) differential pressure tube assembly.
CAUTION:
Be careful not to impact or damage DPF (diesel particulate filter) differential pressure sensor.
INSTALLATION
CAUTION:
• Be careful not to impact or damage particle filter sensor.
• When installing never use such tools as an air impact wrench.
1. Perform “Diesel particulate filter data clear”. Refer to EC-564, "Description". when replacing diesel partic-
ulate filter.

EXHAUST MANIFOLD AND TURBOCHARGER ASSEMBLY
A
YS23DDT EM
I
JPBIA7119GB
Exhaust gas temperature sensor 1 Connector bracket A/F sensor J

Heat shield Turbocharger air outlet pipe Pipe bracket
Clamp Exhaust manifold and turbocharger Turbocharger air inlet pipe
K
Gasket Eye bolt Oil feed pipe
Exhaust manifold and turbocharger
Eye bolt Oil return pipe
bracket
L
Gasket Exhaust gas pressure sensor Bracket
Vacuum hose Oil return end pipe Gasket
Stud bolt M
Comply with the installation procedure
when tightening. Refer to EM-322, "Re- To DPF (diesel particulate filter) To EGR intercooler inlet duct
moval and Installation" N
To turbocharger boost control solenoid
To air duct 2 To air inlet tube (silencer)
valve
: N·m (kg-m, ft-lb) O
: N·m (kg-m, in-lb)
: Always replace after every disassembly.

P
, , : Indicates that the parts is connected at points with same symbols in actual vehicle.

YS23DDTT
JSBIA6465GB
Exhaust manifold and turbocharg-

Heat shield (right) Gasket
er (HP)
Bracket Eye bolt Heat shield (left)
Heat shield Oil feed pipe Eye bolt
High pressure compressor bypass
Bracket Vacuum hose
valve control solenoid valve
Gasket Oil return pipe O-ring
Exhaust gas temperature sensor 1 Eye bolt Exhaust gas pressure sensor
Oil return end pipe Stud bolt
Comply with the installation procedure
when tightening. Refer to EM-322, "Re- To turbocharger duct To turbocharger
moval and Installation"
: N·m (kg-m, ft-lb)
, , , , , : Indicates that the parts is connected at points with same symbols in actual vehicle.
REMOVAL
NOTE:
ing.
YS23DDT
1. Remove the front wheel and tire (RH) using a power tool. Refer to WT-10, "Removal and Installation".
3. Remover main muffler. Refer to EX-18, "Exploded View".

4. Remove DPF (diesel particulate filter). Refer to EM-319, "Removal and installation"
5. Remove air cleaner assembly. Refer to EM-307, "Exploded View". A
6. Remove air duct 1 and air duct 2. Refer to EM-307, "Exploded View".
7. Remove air inlet tube (silencer) and air inlet hose 1. Refer to EM-309, "Exploded View".
EM
8. Disconnect O2 sensor harness connector.
9. Remove O2 sensor.
10. Remove heat insulator. C
11. Remove water pipe cover. Refer to CO-73, "Exploded View".
12. Remove engine oil level gauge tube.
13. Remove EGR intercooler outlet duct insulator. Refer to EM-316, "Exploded View". D
14. Disconnect exhaust gas temperature sensor harness connector.
15. Remove turbocharger air inlet pipe.
16. Remove exhaust gas pressure sensor. E
17. Remove oil return pipe and oil feed pipe.
CAUTION:
Be careful not to deform water tube and oil-feed-and-return tube. F
18. Remove exhaust manifold and turbo charger bracket.
19. Loosen exhaust manifold and turbo charger nuts in the order
from 8 to 1 as show in the figure. G
: Engine front
H
JSBIA6389ZZ
J
20. Remove exhaust manifold and turbo charger.
CAUTION:
• Be careful not to contact with the vehicle. K
21. Remove gasket.
L
22. Remove exhaust gas temperature sensor, if necessary.
23. Remove stud bolt from cylinder head, if necessary.
Oil Tube and Water Tube M
YS23DDTT N
1. Remove turbo charger. Refer to EM-326, "Removal and Installation".
2. Remove heat insulator RH and LH.
3. Remove oil feed pipe and oil return pipe. O
CAUTION:
Be careful not to deform water tube and oil-feed-and-return tube.
4. Disconnect exhaust gas temperature sensor harness connector. P
5. Remove exhaust gas pressure sensor.

6. Loosen exhaust manifold and turbocharger nuts in the order
from 8 to 1 as show in the figure.
: Engine front
JSBIA6390ZZ
7. Remove exhaust manifold and turbo charger.

CAUTION:
• Be careful not to contact with the vehicle.
8. Remove gasket.
9. Remove exhaust gas temperature sensor, if necessary.
10. Remove stud bolt from cylinder head, if necessary.
Oil Tube and Water Tube
INSTALLATION
NOTE:
If stud bolts were removed, replace them with new ones.
1. Install gasket to cylinder head.
CAUTION:
2. Tighten exhaust manifold and turbo charger nuts in the order from 1 to 8 as shown in the figure.
• YS23DDT
: Engine front
Step 1 : 10.0 N·m (1.0 kg-m, 7 ft-lb)

Step 2 : 20.0 N·m (2.0 kg-m, 15 ft-lb)
Step 3 : 30.0 N·m (3.1 kg-m, 22 ft-lb)
JSBIA6389ZZ
• YS23DDTT
: Engine front
Step 1 : 10.0 N·m (1.0 kg-m, 7 ft-lb)

Step 2 : 20.0 N·m (2.0 kg-m, 15 ft-lb)
Step 3 : 30.0 N·m (3.1 kg-m, 22 ft-lb)
JSBIA6390ZZ

A
Turbocharger
EM
G
E1BIA0653ZZ
Check there is no leakage on the different side of the turbocharger (exhaust gas and oil)
H
CAUTION:
When the compressor wheel, turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction: I
Suction side: Between turbocharger and air cleaner

J
Between turbocharger and charge air cleaner
Exhaust side: Between turbocharger and diesel particle filter
Between turbocharger and exhaust manifold K
Turbocharger Boost Control
• Connect the handy vacuum pump (A) to the actuator, and check
that the rod strokes smoothly in compliance with the following L
pressure.
Standard (value of vacuum/value of rod moving): M

Refer to EM-414, "Turbocharger".
JPBIA0665ZZ
O
Start engine and raise engine speed to check no exhaust emission leaks.
P

TURBOCHARGER
TURBOCHARGER
JPBIA7121GB
1. Exhaust gas temperature sensor 2. Oxygen sensor 3. Heat shield

4. Turbocharger air outlet pipe 5. Pipe bracket 6. Clamp
7. Eye bolt 8. Oil feed and return pipe 9. Gasket
10. Turbocharger bracket 11. Gasket 12. Stud bolt
13. Turbocharger 14. Heat shield
A. To DPF
, , : Indicates that the parts is connected at points with same symbols in actual vehicle.
REMOVAL
NOTE:
ing.
1. Remove front wheel and tire (RH) using a power tool. Refer to WT-10, "Removal and Installation".
3. Remover main muffler. Refer to EX-18, "Exploded View".
4. Remove DPF (diesel particulate filter). Refer to EM-319, "Removal and installation"
5. Remove air cleaner assembly. Refer to EM-307, "Exploded View".
6. Remove air duct 1 and air duct 2. Refer to EM-307, "Exploded View".
7. Remove air inlet tube (silencer) and air inlet hose 1. Refer to EM-309, "Exploded View".
8. Disconnect O2 sensor harness connector.

TURBOCHARGER
9. Remove O2 sensor.
10. Remove heat insulator. A
11. Remove water pipe cover. Refer to CO-73, "Exploded View".
12. Remove engine oil level gauge tube.
EM
13. Remove High pressure compressor bypass valve control solenoid valve.
14. Remove turbocharger air outlet pipe.
15. Remove oil return pipe and oil feed pipe. C
CAUTION:
Be careful not to deform water tube and oil-feed-and-return tube.
16. Remove turbocharger bracket.
D
17. Remove turbocharger from exhaust manifold and turbocharger.
CAUTION:
• Be careful not to contact with the vehicle. E
18. Remove gasket.
19. Remove stud bolt from exhaust manifold and turbocharger, if necessary. F
INSTALLATION
G
CAUTION:
• Replace turbocharger stud if loosened.
• Do not reuse gasket.. H
I
Turbocharger
J
E1BIA0653ZZ
O
Check there is no leakage on the different side of the turbocharger (exhaust gas and oil)
P
CAUTION:
When the compressor wheel, turbine wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
Suction side: Between turbocharger and air cleaner

Between turbocharger and charge air cleaner

TURBOCHARGER
Exhaust side: Between turbocharger and diesel particle filter
Between turbocharger and exhaust manifold
Turbocharger Boost Control
• Connect the handy vacuum pump (A) to the actuator, and check
that the rod strokes smoothly in compliance with the following
pressure.
Standard (value of vacuum/value of rod moving):

Refer to EM-414, "Turbocharger".
JPBIA0665ZZ

Start engine and raise engine speed to check no exhaust emission leaks.

OIL PAN (LOWER)
OIL PAN (LOWER)
A
EM
JPBIA7115GB
N
Engine oil level sensor Oil pan (upper) Oil level gauge
Oil level gauge guide O-ring Oil pan drain plug
Drain plug washer Oil pan (lower) Oil filter body O
Oil filter O-ring Engine oil pressure switch
O-ring Cylinder block
P
Comply with the installation proce-
Comply with the removal procedure.
dure when tightening. Refer to IN-
Refer to INSTALLATION.
STALLATION.

OIL PAN (LOWER)
: Sealing point
, : Indicates that the parts is connected at points with same symbols in actual vehicle.
REMOVAL
1. Drain engine oil. Refer to LU-44, "Draining".
CAUTION:
Perform this step when engine is cold.
2. Remove oil pan (lower) with the following procedure:
a. Loosen mounting bolts in the order from 9 to 1 as shown in the
figure.
JSBIA6394ZZ
b. Remove the lower oil pan.

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

CAUTION:
• 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.
AWBIA1249GB
INSTALLATION
1. Install oil pan (lower) with the following procedure:
faces.
CAUTION:
Never scratch or damage the mating surfaces when clean-
JPBIA0025ZZ

OIL PAN (LOWER)
(commercial service tool) as shown in the figure. A
(1) : Oil pan (lower)

(a) : 2.5 - 4.5 mm (0.098 - 0.177 in) EM
: Engine front
Use Genuine Liquid Gasket or equivalent

CAUTION: C
Attaching should be done within 5 minutes after coating.
JSBIA6397ZZ
D
c. Tighten mounting bolts in the order from 1 to 9 as shown in the
figure.
E
Oil pan (lower) bolts : 10 N·m (1.0 kg-m, 7 ft-lb)
G
JSBIA6394ZZ
d. Install oil pan (lower) drain plug.

H
Oil pan (lower) drain plug : 50 N·m (5.1 kg-m, 37 ft-lb)
CAUTION:
Do not reuse drain plug washer. I
NOTE:
Wait 30 minutes after oil pan (lower) has been installed to add engine oil. J
K
Clean oil strainer if any object attached.
INSPECTION AFTER INSTALLATION L
1. Check the engine oil level and adjust engine oil. Refer to LU-43, "Inspection".
2. Start engine, and check there is no leak of engine oil.
M
4. Check the engine oil level again. Refer to LU-43, "Inspection".
N

GLOW PLUG
GLOW PLUG
AWBIA2685ZZ
1. Glow plug Front
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect harness connector from glow plug.
2. Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal.
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Installation of remaining components is in the reverse order of removal..

VACUUM PUMP
VACUUM PUMP
A
EM
G
AWBIA2686ZZ
1. Vacuum hose 2. Gasket 3. Vacuum pump

H
Engine front
I
REMOVAL
1. Remove battery. Refer to PG-150, "Removal and Installation".
J
2. Remove air inlet tube 1. Refer to EM-309, "Exploded View".
3. Disconnect vacuum hoses.
4. Disconnect fuel hose quick connector (1) from fuel pump (Feed K
side).
5. Remove bracket bolt (A).
L
(2) : Vacuum pump
JSBIA5488ZZ
N
6. To remove vacuum pump loosen vacuum pump bolts in reverse
order as shown.
O
AWBIA2687ZZ
INSTALLATION
VACUUM PUMP
CAUTION:
• Tighten mounting bolts in numerical order as shown.
AWBIA2687ZZ

OIL SEPARATOR
OIL SEPARATOR
A
EM
J
AWBIA2684ZZ
1. Injector rail protector 2. Injector rail protector seal 3. Oil separator K

4. Fuel return hose 5. Fuel return hose protector seal 6. Fuel injector rail
7. Fuel injector rail protector seal 8. Injection tube 9. Fuel injector support
10. Fuel inlector spacer 11. Fuel injector A. Refer to INSTALLATION L
B. Refer to INSTALLATION C. To fuel tube Engine front
Removal and Installation INFOID:0000000014267259 M
REMOVAL
NOTE: N
ing.
1. Remove engine cover. Refer to EM-305, "Exploded View". O
2. Remove PCV hose.

OIL SEPARATOR
3. Disconnect harness connector (A) of fuel injector.
: Front
JSBIA5489ZZ
4. Remove A/C pipe bracket bolt (A).
(1) : A/C pipe bracket

: Vehicle front
JPBIA6983ZZ
5. Disconnect harness connectors from injectors.

6. Loosen oil separator bolts in the reverse order as shown.
AWBIA2688ZZ
7. Lift the A/C pipe (2) to the top left side, and remove oil separator
(1).
: Front
8. Remove oil separator gaskets.
JPBIA6984ZZ
INSTALLATION
1. Install oil separator gaskets.
CAUTION:
• Do not drop oil separator gaskets.
• Do not reuse oil separator gaskets.
2. Install oil separator.

OIL SEPARATOR
• Tighten mounting bolts in two steps separately in numerical
order as shown in the figure. A
1st step : 5.0 N·m (0.51 kg-m, 44 in-lb)

EM
2nd step : 10.0 N·m (1.0 kg-m, 89 in-lb)
AWBIA2688ZZ
D

AWBIA2684ZZ
1. Injector rail protector 2. Injector rail protector seal 3. Oil separator

4. Fuel return hose 5. Fuel return hose protector seal 6. Fuel injector rail
7. Fuel injector rail protector seal 8. Injection tube 9. Fuel injector support
10. Fuel inlector spacer 11. Fuel injector A. Refer to INSTALLATION
B. Refer to INSTALLATION C. To fuel tube Engine front
REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-288, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• It is forbidden to open an fuel injector. If you open an fuel injector by mistake, you will have to
change it.
NOTE:
• It is possible to replace a single injection tube.
• When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from
spilling.
1. Remove the battery. Refer to PG-150, "Exploded View".
2. Remove oil separator. Refer to EM-335, "Exploded View".
3. Remove fuel return hose.

• Move without removing the fuel return hose clip using a flat
bade screwdriver. A
(1) : Moving direction

4. Disconnect and remove fuel hose. EM
E1BIA0648ZZ
D
5. Remove fuel collector and injection tube (center).
6. Remove injection tube (No. 1, 2, 3, 4).
E
7. Remove fuel injector. While rotating it to left and right, raise it to remove.
• If fuel injector spacer remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
CAUTION:
• Handle fuel injector carefully without giving an impact. F
• Never disassemble fuel injector.
8. Remove injection rail and injection rail protector seal.
CAUTION: G
In case of fuel rail pressure sensor fitted with a color ring:
• replacing the sensor is forbidden
• the injector rail must be completely replaced if the fuel rail pressure sensor fails.
H
9. Plug all the holes in the injection circuit. Refer to EM-288, "Precaution for Diesel Equipment".
INSTALLATION
1. If an injector is removed or replaced, note the IMA code and the corresponding cylinder number and per- I
form “injector adjustment value registration”. Refer to EC-556, "Work Procedure".
2. Install fuel injector, injection tubes and fuel rail with the following procedure:
a. Install fuel injector spacer to fuel injector, and insert them into cylinder head. J
CAUTION:
Completely remove any foreign material among fuel injector and cylinder head.
b. Install injection rail, injection tube (center). K
• Finger tighten until contact the injection tube nuts.
c. Install fuel injector support.
CAUTION: L
Be sure to fit fuel injector support without looseness.
d. Tighten fuel injector support bolt.
M
Fuel injector support bolt : 7 N·m (0.7 kg-m, 62 in-lb)
NOTE:
In case of cylinder head replacement, pre-tighten the fuel injector support bolt and after loosen the fuel N
injector support bolt.
Pre- tightening fuel injec- : 20 N·m (2.0 kg-m, 15 ft-lb) O

tor support bolt (in case of
cylinder head replace-
ment)
P
e. Turn 180 degrees clockwise (angle tightening).
f. Install injection tube (No. 1, 2, 3, 4) in the original position (temporarily).
• Finger tighten until contact the injection tube nuts.
CAUTION:
Never put injection tubes under stress.
g. Tighten injection rail mounting bolts and all injection tube nuts (specified torque).

3. Install fuel return hose onto fuel injectors with the following procedure.
• NOTE:
Failure to observe the following procedure may lead to an immobilizing default.
• Fit the clip on the fuel return hose.
• Install fuel return hose onto fuel injectors.
• Always carry out a “push-pull” test (1), to check that the fuel
return hose is correctly fitted onto fuel injector.
• Always carry out a “push-pull” test, to check that the fuel return
hose is correctly fitted onto fuel hose.
E1BIA0648ZZ


• When replacing fuel injector, this procedure must be performed. Refer to EC-556, "Work Procedure"
CAUTION:
After any operation, check that there are no diesel leaks. Refer to EM-288, "Precaution for Diesel
Equipment".

FUEL PUMP
FUEL PUMP
A
EM
I
JPBIA7102GB
Fuel hose Fuel hose protector seal Fuel hose protector seal J
Bracket Fuel pump cover stud Fuel pump gear nut
Fuel pump gear O-ring Fuel pump
K
Fuel pump cover Drain hose Fuel collector
Fuel tube
: N·m (kg-m, ft-lb) L
: Always replace after every disassembly. M

, , : , , : Indicates that the parts is connected ato points with same symbols in actual vehecle.
Removal and Installation INFOID:0000000014267264 N
REMOVAL
CAUTION: O
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-288, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit. P
• Never disassemble or adjust the fuel pump body.
NOTE:
ing.
1. Remove the battery. Refer to EM-341, "Exploded View".

FUEL PUMP
3. Remove air inlet tube. Refer to EM-309, "Exploded View".
4. Remove drain hose.
5. Remove fuel collector.
6. Disconnect fuel hoses from fuel pump. Refer to EM-341, "Exploded View".
7. Remove the injection tube (center). Refer to EM-341, "Exploded View".
8. Plug all the holes of the injection circuit. Refer to EM-288, "Precaution for Diesel Equipment".
9. Remove the fuel pump by loosening bolts in the reverse order as shown.
10. In case of replacement of the fuel pump you need to install the old fuel pump sprocket on the new fuel
pump. Refer to EM-343, "Removal and Installation".
INSTALLATION
1. To install fuel pump, tighten bolts in two steps separately in numerical order as shown in the figure.
Fuel pump bolts : 25.0 N·m (2.6 kg-m, 18 ft-lb)

CAUTION:
• Do not reuse O-ring.
• Be sure to check that the fuel pump is in contact with the
cylinder head before tightening the mounting bolts.
E1BIA0609ZZ
2. Install the injection tube (center). Refer to EM-338, "Exploded View".

CAUTION:
Finger tighten until contact the injection tube nuts.
4. Perform “Fuel pump learning value clearing”. Refer to EC-567, "Work Procedure". when replacing fuel
pump.

CAUTION:
After any operation, check that there are no diesel leaks. Refer to EM-288, "Precaution for Diesel
Equipment".

FUEL PUMP SPROCKET
FUEL PUMP SPROCKET
A
EM
I
JPBIA7102GB
Fuel hose Fuel hose protector seal Fuel hose protector seal J
Bracket Fuel pump cover stud Fuel pump gear nut
Fuel pump gear O-ring Fuel pump
K
Fuel pump cover Drain hose Fuel collector
Fuel tube
: N·m (kg-m, ft-lb) L
: Always replace after every disassembly. M

, , : , , : Indicates that the parts is connected ato points with same symbols in actual vehecle.
Removal and Installation INFOID:0000000014267267 N
REMOVAL
NOTE: O
ing.
P

FUEL PUMP SPROCKET
1. Lock the fuel pump on the work-bench in a vice with protective
jaws.
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2. Using the tool [SST (Mot.1906)] (1), lock the fuel pump gear.
E1BIA0607ZZ
3. Remove the nut (2).
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4. Fit suitable tool (1) under the fuel pump gear (2).
E1BIA0220ZZ

FUEL PUMP SPROCKET
5. Install suitable tool (3) on the separator.
A
EM
G
E1BIA0221ZZ
6. Remove the fuel pump gear.

H
INSTALLATION
1. Refit the fuel pump gear to the new fuel pump.
2. Screw in the new fuel pump gear on the work-bench, without tightening it. I
3. Lock the fuel pump on the workbench in a vice with protective jaws.
4. Torque tighten the nut.
J

TIMING CHAIN
TIMING CHAIN
YS23DDT
JSBIA6120GB
Intake camshaft timing sprocket Exhaust camshaft timing sprocket

1. Intake camshaft timing sprocket 2. 3.
spacer (rear)
Exhaust camshaft timing sprocket
4. 5. Timing sprocket spacer 6. Tension guide
(front)
7. Timing chain 8. Slack guide 9. Timing chain tensioner
10. Crankshaft spacer (crankshaft side) 11. Crankshaft sprocket 12. Front cover
13. O-ring 14. Oil filler cap 15. Oil filler
Crankshaft spacer
16. Front oil seal 17. Crankshaft pulley 18.
(crankshaft pulley side)
19. Crankshaft pulley bolt 20. Solenoid valve 21. Vacuum hose
22. Vacuum hose A. Refer to INSTALLATION B. Refer to INSTALLATION
C. Refer to INSTALLATION D. Refer to INSTALLATION E. To turbocharger

TIMING CHAIN
YS23DDTT
A
EM
JPBIA7114GB
K
Intake camshaft timing sprocket Exhaust camshaft timing sprocket

1. Intake camshaft timing sprocket 2. 3.
spacer (rear) L
4. 5. Timing sprocket spacer 6. Tension guide
(front)
7. Timing chain 8. Slack guide 9. Timing chain tensioner
M
10. Crankshaft spacer (crankshaft side) 11. Crankshaft sprocket 12. Front cover
13. O-ring 14. Oil filler cap 15. Oil filler
Crankshaft spacer
16. Front oil seal 17. Crankshaft pulley 18. N
(crankshaft pulley side)
19. Crankshaft pulley bolt 20. Solenoid valve 21. Vacuum hose
22. Solenoid valve 23. Vacuum hose 24. Vacuum hose
O
A. Refer to INSTALLATION B. Refer to INSTALLATION C. Refer to INSTALLATION
D. Refer to INSTALLATION E. To turbocharger F. To vaccum hose
G. To turbocharger
P
REMOVAL
CAUTION:

TIMING CHAIN
2. Disconnect the battery cable from the negative terminal.
• Engine under cover: Refer to EXT-31, "ENGINE UNDER COVER : Removal and Installation".
• Load wheel tire (RH): Refer to WT-10, "Removal and Installation".
• Fender protector (RH): Refer to EXT-29, "Exploded View".
• Drive belt auto-tensioner: Refer to EM-299, "Exploded View".
• Engine coolant bypass control solenoid valve: Refer to EM-314, "Exploded View".
• Fuel filter: Refer to FL-44, "Removal and Installation".
4. Remove crankshaft pulley with the following procedure:
a. Lock the crankshaft pulley using suitable tool (A) and loosen the
crankshaft pulley bolt.
b. Remove crankshaft pulley and spacer.
• Pull crankshaft pulley with both hands to remove it.
CAUTION:
Be careful not to damage front oil seal lip.
JPBIA0730ZZ
5. Remove front oil seal. Refer to EM-364, "FRONT OIL SEAL : Removal and Installation".
6. Remove the through bolt between rear torque rod and rear torque rod bracket, and hold the rear
torque rod bracket with a transmission jack. Refer to EM-366, "Exploded View".
CAUTION:
Never hold the oil pan (lower).
7. Remove the upper torque rod and the engine mounting insulator (RH). Refer to EM-366, "Exploded View".
8. Remove engine mounting bracket (RH).
9. Remove water pump pulley bolts. Refer to CO-71, "Exploded View".
10. Remove front cover with the following procedure:
a. Loosen front cover mounting bolts.
b. Use Tool (A) to cut liquid gasket for removal.
After removing the bolts, separate the mating surface and
remove the old liquid gasket using Tool.
Tool number : KV10111100 (J-37228)

CAUTION:
• Do not damage mating surfaces.
• Do not use a screwdriver or similar tool to remove old liq- AWBIA1249GB
uid gasket material.
• After removing the bolts, separate the mating surface and remove the old liquid gasket using
Tool.
NOTE:
Unstick the front cover by hand, using a jerking motion to ensure it is not damaged.
11. Align the hole (1) on the exhaust camshaft timing sprocket
(front) with the hole (2) on the cylinder head housing.
NOTE:
Turn the crankshaft clockwise using the tool [SST: —
(Mot.1770)].
E1BIA0586ZZ

TIMING CHAIN
12. Remove the TDC pin plug. Refer to EM-354, "Exploded View".
13. In place of plug, manually tighten the tool [SST: — (Mot.1970)]. A
14. Turn the crankshaft clockwise until it makes contact with the pin.
15. Make a mark:
• on the intake camshaft timing sprocket (A) and the rocker EM
cover (B) (vertically).
• on the hole (C) on the exhaust camshaft timing sprocket (front)
and on the rocker cover (D). C
• Check the mark alignment (E) and (F).
H
JPBIA6985ZZ
16. Loosen the exhaust camshaft timing sprocket bolts (front).

I
17. Compress the timing chain tensioner (1) with slack guide (2),
and then insert a stopper pin (A) into hole on timing chain ten-
sioner.
NOTE: J
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin
K
L
JPBIA0727ZZ
18. Remove the timing chain with the following procedure: M

a. the timing chain tensioner,
b. the slack guide,
c. the exhaust camshaft timing sprocket bolts, N
d. the timing sprocket spacer,
e. the crankshaft spacer,
O
f. the “Exhaust camshaft timing sprocket (front) - timing chain - crankshaft sprocket” assembly,
g. the tension guide,
h. the tool [SST: — (Mot.1970)].
P
INSTALLATION
1. Set the engine at TDC.
2. Install the tool [SST: — (Mot.1970)].
3. Install tension guide.
4. Tighten timing chain guide bolts.
5. Install the crankshaft sprocket onto the crankshaft.

TIMING CHAIN
6. Install timing chain.
a. The timing chain on the crankshaft sprocket (align the sprocket
mark with the cooper chain link (1).
E1BIA0593ZZ
b. The timing chain on the exhaust camshaft timing sprocket (front)

(align the sprocket mark with the cooper chain link (1).
E1BIA0592ZZ
7. Install the exhaust camshaft timing sprocket (front) onto the exhaust camshaft.
8. Place the timing sprocket spacer on the exhaust camshaft timing sprocket (front).
9. Finger tighten the exhaust camshaft timing sprocket bolts.
NOTE:
Allow the timing sprocket to rotate freely.
10. Install the crankshaft spacer.
11. Install the slack guide.
12. Tighten the bolt of the slack guide.
13. Install the timing chain tensioner with its locking pin.
NOTE:
Check that the hydraulic tensioner is in contact with the cylinder block before tightening the bolts.
14. Tighten the bolts of the timing chain tensioner.
15. Remove the locking pin.
16. Engage the collet of the tool [SST: — (Mot.1969)] (1) into the
exhaust camshaft groove.
E1BIA0594ZZ
17. Turn the tool to align the shafts on the spacer and the hole of the rocker cover.
18. Detach the collet of the tool from the exhaust camshaft groove.
19. Engage the pins of the tool in the holes in the intake camshaft timing sprocket.
NOTE:
Do not install the collet of the tool into the groove on the exhaust side of the camshaft.
20. Turn the tool to align the shafts on the spacer and the hole of the rocker cover.

TIMING CHAIN
21. Install the collet of the tool into the groove on the exhaust camshaft without forcing it (if necessary, start
the previous operation again). A
22. Install the rocker cover onto the tool [SST: — (Mot.1969)].
23. Tighten the exhaust camshaft timing sprocket bolts.
24. Turn 40 degrees clockwise (angle tightening). EM
25. Remove the tools.
• The bolts from the tool [SST: — (Mot.1969)]
• The tool [SST: — (Mot.1969)] C
• The tool [SST: — (Mot.1970)]
26. Tighten the TDC hole plug.
27. Check the marks (1) (if necessary, start the previous operation D
again).
E1BIA0595ZZ G
E1BIA0596ZZ
28. Install front cover with the following procedure: K

a. Apply liquid gasket to the front cover side, referring to the appli-
cation point shown in the figure.
L
(1) lower side:
10.0 - 13.0 mm (0.3937 - 0.5118 in) in diameter
(2) upper side: M
3.0 - 7.0 mm (0.1181 - 0.2756 in) in diameter

(3) center: N
1.5 - 3.5 mm (0.394 - 0.591 in) long
AWBIA2673ZZ

NOTE: O
Liquid gasket should be applied to the front cover side because the work space is narrow.

TIMING CHAIN
b. Install the front cover.
i. Pre-tighten the front cover bolts.
Front cover bolts : 5.0 N·m (0.51 kg-m, 44 in-lb)

ii. Tighten the front cover bolts.
Front cover bolts : 15 N·m (1.6 kg-m, 12 ft-lb)
E1BIA0652ZZ
29. Install crankshaft pulley with the following procedure:

a. Tighten crankshaft pulley bolt.
Crankshaft pulley bolt : 100 N·m (10 kg-m, 74 ft-lb)

b. Turn 150 degrees clockwise using Tool.
CAUTION:
Check and confirm the tightening angle by using Tool. Avoid judgment by visual inspection with-
out Tool.
Tool Number : KV10112100 (BT-8653-A)


Inspection for Leaks
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.


TIMING CHAIN
A
*: Power steering fluid, brake fluid, etc. EM

TIMING SPROCKET
TIMING SPROCKET
JPBIA6954GB

1. Front cover 2. 3. Guide bolt
bolt
Exhaust camshaft timing sprocket Exhaust camshaft timing sprocket
4. Timing sprocket spacer 5. 6.
(front) (rear)
7. Exhaust camshaft 8. Intake camshaft 9. Intake camshaft timing sprocket
10. Intake camshaft timing sprocket
11. Intake camshaft timing sprocket bolt 12. Crankshaft
spacer
13. Tension guide 14. Crankshaft sprocket 15. Timing chain
16. Slack guide 17. Timing chain tensioner 18. Crankshaft spacer
19. Timing chain cover pin 20. Front oil seal 21. Crankshaft pulley bolt
22. Crankshaft spacer 23. Crankshaft pulley A. Refer to INSTALLATION
B. Refer to INSTALLATION

TIMING SPROCKET
Removal and installation INFOID:0000000014267272
A
REMOVAL
1. Remove the timing chain. Refer to EM-346, "Exploded View".
EM
2. Immobilize the intake camshaft timing sprocket using the tool
[SST: — (Mot.1969)] (1)
3. Loosen the intake camshaft timing sprocket bolt (2).
C
4. Remove the tool [SST: — (Mot.1969)].
E
E1BIA0455ZZ
5. Place a screw driver in the hole (2), compress the spring of the
F
intake camshaft timing sprocket (1) and remove the exhaust
camshaft timing sprocket (rear) (3).
E1BIA0456ZZ
I
6. Remove the intake camshaft timing sprocket with the following procedure:
a. Remove the screwdriver. J
b. Remove the intake camshaft timing sprocket bolt.
c. Remove the intake camshaft timing sprocket spacer.
d. Remove the intake camshaft timing sprocket. K
INSTALLATION
L
1. Install the intake camshaft timing sprocket with the following procedure:
a. Set the intake camshaft timing sprocket (1) on base plate of
positioning tool [SST: — (Mot. 1773)] (A).
M
JPBIA0766ZZ

TIMING SPROCKET
b. Set the lever (B) in the lower gear teeth (A). Pivot the lever
counterclockwise until the two gear teeth are aligned.
(1) : Wear compensation gear
JPBIA0594ZZ
c. Set a stopper pin (A) in the gear hole.
(1) : Wear compensation gear

NOTE:
Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin
JPBIA0595ZZ
d. Install intake camshaft timing sprocket (1) and intake camshaft

timing sprocket spacer (2) to the camshaft.
e. Align matching mark (B) on intake camshaft timing sprocket and
mark (A) of cylinder head housing.
(C) : Stopper pin
f. Temporarily tighten mounting bolt.
JPBIA0616ZZ
2. Install exhaust camshaft timing sprocket (rear) with the following procedure:
a. Check that the exhaust camshaft groove (1) is horizontal (large ring facing upwards).
b. Center the exhaust camshaft timing sprocket (rear) openings on
the camshaft hub mounting holes (2).
c. Set the exhaust camshaft timing sprocket (rear) fully onto the
camshaft (right side) hub.
d. Remove stopper pin.
E1BIA0462ZZ
3. Re-install the tool [SST: — (Mot.1969)] to immobilize the intake camshaft timing sprocket.
4. Tighten the intake camshaft timing sprocket bolt
Intake camshaft timing : 22 N·m (2.2 kg-m, 16 ft-lb)

sprocket bolt:
5. Turn 35 degrees clockwise using Tool.
CAUTION:

TIMING SPROCKET
Check and confirm the tightening angle by using Tool. Avoid judgment by visual inspection with-
out Tool. A
EM

CAMSHAFT
CAMSHAFT
AWBIA2674ZZ
1. Camshaft position sensor 2. Engine cover support bracket locator 3. Bracket

4. Exhaust camshaft 5. Camshaft bracket 6. Camshaft bracket
7. Camshaft bracket pin 8. Camshaft bracket 9. Camshaft bracket
10. Camshaft bracket pin 11. Intake camshaft 12. Fuel pump gear
13. Cylinder head housing 14. O-ring A. Refer to INSTALLATION
B. To exhaust camshaft sprocket C. To intake camshaft sprocket Front
REMOVAL
• Oil separator: Refer to EM-335, "Exploded View".
• Fuel injector: Refer to EM-338, "Removal and Installation".
• Engine slinger (front side): Refer to EM-381, "Exploded View".
• Front cover and timing chain related parts: Refer to EM-346, "Exploded View".
• Fuel pump: Refer to EM-341, "Exploded View".
• Vacuum pump: Refer to EM-333, "Exploded View".
CAUTION:
• Handle camshaft position sensor carefully and avoid impacts.
• Do not disassemble camshaft position sensor.
• Do not place sensor where it is exposed to magnetism.
3. Remove cylinder head housing with the following procedure:

CAMSHAFT
a. Loosen mounting bolts in reverse order as shown in the figure.
A
EM
H
E1BIA0605ZZ
b. Remove the cylinder head housing (1) using suitable tool (A).
(B) : Protective shim (suitable tool) I
CAUTION:
Be careful not to damage the mating surface.
J
JPBIA0606ZZ
L
4. Remove camshafts with the following procedure:
a. Install cylinder head housing (1) to suitable cylinder head stand
(A). M
b. Loosen mounting bolts, and remove camshaft brackets and
camshafts.
• Mark camshafts and camshaft brackets so they are placed in
the same position and direction for installation. N
JPBIA0641ZZ
P
5. Remove camshaft sprocket (for fuel pump) from camshaft (right side), if necessary.
INSTALLATION
1. Install fuel pump gear to exhaust camshaft (if removed).
2. Tighten fuel pump gear bolt to specification.

CAMSHAFT
Step One : 30 N·m (3.1 kg-m, 22 ft-lb)

Step Two : 120° degrees rotation clockwise in order
CAUTION:
Do not reuse fuel pump gear bolt.
3. Install camshaft to cylinder head housing with the following procedure:
a. Clean camshaft journal to remove any foreign material.
b. Install camshafts.
c. Refer to the figure to install camshaft bracket in its original.
(A) : Part marking ADM1

(B) : Part marking ADM2
(C) : Part marking ECH1
(D) : Part marking ECH2
: Engine front
JPBIA0761ZZ
d. Tighten camshaft bracket mounting bolts.

• Finger tighten the camshaft bracket mounting bolts, until they just make contact.
4. Install cylinder head housing with the following procedure:
a. Align the crankshaft groove (A) with the cylinder block hole (B).
NOTE:
This is for the purpose of preventing interferences of valve and
piston head.
JPBIA0610ZZ
b. Remove foreign material completely from cylinder head housing backside and cylinder head installation
face.
c. Apply liquid gasket to cylinder head as shown in the figure.
(B) : 0.5 - 2.5 mm (0.020 - 0.098 in)

: Engine front
JPBIA0609ZZ

CAMSHAFT
d. Install so that camshafts are positioned in the directions shown
in the figure. A
• Parallelize the groove of camshaft (right side) (1) to face the
offset side upward.
• Fit the groove of camshaft (left side) (2) and boss of cylinder
EM
head housing.
JPBIA0729ZZ
D
e. Tighten mounting bolts of cylinder head housing in the following steps.
E1BIA0605ZZ
i. Tighten in order and successively, the cylinder head housing bolts No. 6, 4, 8 and 12 to gradually fit the L
cylinder head housing on the cylinder head.
ii. Tighten the remaining bolts (temporarily).
iii. Loosen bolts No. 6, 4, 8 and 12. M
iv. Tighten the bolts No. 6, 4, 8 and 12 (temporarily).
v. Tighten bolts in numerical order.
N
Cylinder head housing bolts : 5.0 N·m (0.51 kg-m, 44 in-lb)

vi. Tighten bolts in numerical order. O
Cylinder head housing bolts : 15.0 N·m (1.5 kg-m, 11 ft-lb)

CAUTION: P
After tightening mounting bolts of cylinder head housing, be sure to wipe off excessive liquid gas-
ket from the mating surface of cylinder head.
5. Install timing chain and related parts. Refer to EM-346, "Exploded View".
6. Install camshaft position sensor (if removed).
CAUTION:

CAMSHAFT

Camshaft Journal oil clearance
CAMSHAFT JOURNAL
• Measure the camshaft journal with a micrometer (A).
JPBIA0122ZZ
CYLINDER HEAD HOUSING AND CAMSHAFT BRACKET INNER DIAMETER

• Measure the inner diameter (A) of cylinder head housing and cam-
shaft bracket with a bore gauge.
PBIC1645E
CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Bracket inner diameter) – (Camshaft journal diameter)

• If it exceeds the standard, replace camshaft or/and cylinder head housing and cylinder head assembly.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including


CAMSHAFT
A
*: Power steering fluid, brake fluid, etc. EM

OIL SEAL
OIL SEAL
FRONT OIL SEAL
REMOVAL
• Front fender protector (RH): Refer to EXT-29, "Exploded View".
• Crankshaft pulley: Refer to EM-306, "Exploded View".
2. Remove front oil seal using service tool (A).
NOTE:
The service tool is supplied in the new seal parts kit.
JPBIA0765ZZ
INSTALLATION
1. Install front oil seal with the following procedure:
a. Fit the protector (A) to front oil seal .
• Align the front oil seal notches with front cover notches.
NOTE:
The protector is supplied in the new seal parts kit.
JPBIA0778ZZ
b. Tighten to front oil seal using service tool (A).
: 47 N·m (4.8 kg-m, 35 ft-lb)
NOTE:
The service tool is supplied in the new seal parts kit.
JPBIA0591ZZ
c. Remove the protector.

REAR OIL SEAL
REMOVAL

OIL SEAL
1. Remove transaxle assembly. Refer to TM-39, "Exploded View" (M/T models) or TM-318, "Exploded View"
(A/T models). A
2. Remove clutch cover and clutch disk. Refer to CL-40, "Exploded View" (M/T models).
3. Remove flywheel or drive plate. Refer to EM-374, "Exploded View" (flywheel) or EM-376, "Exploded View"
(drive plate). EM
4. Remove rear oil seal retainer.
INSTALLATION
C
1. Install rear oil seal retainer with the following procedure:
a. Set guide bolt (a) and protector (B) to rear oil seal retainer (1).
NOTE: D
The protector is supplied in the new seal parts kit.
b. Move the rear oil seal retainer evenly by hand until it makes con-
tact with the cylinder block.
E
JPBIA0777ZZ
G
c. Remove guide bolts and protector.
d. Tighten rear oil seal retainer bolts in two steps separately in
numerical order as shown in the figure.
H
Step one : 5.0 N·m (0.51 kg-m, 44 in-lb)

Step two : 12.0 N·m (1.2 kg-m, 9 ft-lb) I
2. Installation of remaining components is in the reverse order of
removal.
J
JPBIA0645ZZ

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [YS23DDT/YS23DDTT (M9T)]
UNIT REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
JPBIA7100GB
1. Engine mounting bracket (RH) 2. Heat insulator 3. Engine mounting insulator (RH)
4. Engine mounting bracket (LH) 5. Engine mounting insulator (LH) 6. Transmission cross member
7. Engine mounting insulator (rear) 8. Engine mounting insulator (rear) A. A/T models
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
CAUTION:
• Never start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
• For supporting points for lifting and jacking point at rear axle, refer to GI-29, "Garage Jack and
Safety Stand".
NOTE:
When removing components such as hoses, tubes / lines, etc., cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
Description of work
Remove transmission assembly from vehicle downward. Then hoist the engine from vehicle upward.

ENGINE ASSEMBLY
Preparation
1. Disconnect battery cable from negative terminal. Refer to PG-155, "Exploded View". A
• Front under cover: Refer to EXT-30, "FRONT UNDER COVER : Exploded View". EM
LIGENT KEY SYSTEM). C
• Front grill: Refer to EXT-24, "Exploded View".
• Engine cover: Refer to EM-305, "Exploded View".
• Air duct (inlet), air duct, and air cleaner case: Refer to EM-307, "Exploded View".
• Brake pipe lines, fuel pipe lines brackets. D
• Radiator hose (upper and lower): Refer to CO-66, "Exploded View".
4. Discharge refrigerant from A/C circuit. Refer to HA-124, "Recycle Refrigerant".
E
7. Remove air inlet hose. Refer to EM-309, "Exploded View".
F
Engine Room Front
1. Remove radiator reservoir tank. Refer to CO-66, "Exploded View".
2. Remove the radiator shroud (upper and lower). Refer to CO-66, "Exploded View". G
3. Remove compressor belt and drive belt. Refer to EM-299, "Exploded View".
4. Remove the cooling fan assembly. Refer to CO-75, "Exploded View".
H
5. Remove the water pump pulley. Refer to CO-71, "Exploded View".
6. Separate the cooler pipe (HI) (LOW) from condenser side. Refer to HA-136, "Exploded View".
7. Remove the refrigerant pressure sensor harness connector.
I
8. Separate A/T fluid cooler from the condenser (A/T models).
9. Disconnect A/T fluid cooler hose from the radiator (A/T models). Refer to CO-66, "Exploded View".
10. Remove radiator assembly along with condenser. Refer to CO-66, "Exploded View". J
11. Remove generator. Refer to CHG-53, "YS23DDT/YS23DDTT (M9T) : Removal and Installation".
12. Remove power steering oil pump mounting bolt, move to the position which does not interfere the work of
power steering oil pump. Refer to ST-36, "Exploded View - YS23DDT/YS23DDTT (M9T)". K
Engine Room RH
1. Remove brake booster hose in brake booster side.
L
2. Remove air inlet tube (silencer) and air inlet hose. Refer to EM-309, "Exploded View".
3. Remove compressor. Refer to HA-132, "COMPRESSOR : Removal and Installation".
4. Remove low-pressure flexible hose. Refer to HA-137, "LOW-PRESSURE FLEXIBLE HOSE : Removal M
and Installation".
Engine Room LH
1. Disconnect fuel feed hose and return hose, and plug it to prevent fuel from draining. Refer to EM-338, N
"Exploded View".
2. Disconnect fuel filter harness connector.
3. Remove fuel filter and fuel filter bracket mounting bolt. Refer to FL-44, "Exploded View". O
4. Remove fuel filter and fuel filter bracket. Refer to FL-44, "Exploded View".
5. Disconnect A/C piping from heater unit. Refer to HA-136, "Exploded View".
6. Disconnect heater hose, and install plug it to prevent engine coolant from draining. P
Vehicle Underbody
1. Remove Main muffler. Refer to EX-18, "Exploded View".
2. Remove DPF (diesel particulate filter). Refer to EM-319, "Removal and installation".
3. Remove front propeller shaft. Refer to DLN-137, "Exploded View".
4. Remove rear propeller shaft. Refer to DLN-158, "Exploded View".

ENGINE ASSEMBLY
5. Separate the lower joint from the steering gear assembly. Refer to ST-28, "Exploded View".
6. Remove clutch operating cylinder from transmission, and move it aside (M/T models). Refer to CL-28,
"YS23DDT/YS23DDTT (M9T) : Exploded View".
7. Remove starter motor. Refer to STR-40, "YS23DDT/YS23DDTT (M9T) : Removal and Installation".
8. Remove A/T fluid cooler tube B. (A/T models).
9. Remove front cross member.
10. Remove transmission cross member.
11. Remove transmission assembly. Refer to followings:
• M/T models: TM-35, "4WD : Removal and Installation".
• A/T models: TM-318, "Removal and Installation".
Removal
2. Loosen LH and RH engine mounting insulator mounting nuts.
3. Remove engine.
CAUTION:
body side.
SEM896G
INSTALLATION
CAUTION:
• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-
ing insulator.
• Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
Preparation
Engine mounting bracket (RH)

1. Tighten the bolts No. 1 to 7 as shown in the figure. (specified
torque)
: Front
JSBIA5505ZZ
Engine mounting bracket (LH) for M/T models

ENGINE ASSEMBLY
1. Check that stud bolt (1) shown in the figure is tightened to the
specified torque. A
(2) : Engine mounting bracket (LH)
EM
JPBIA6936ZZ
D
Engine mounting bracket support (LH) for M/T models
1. Tighten the bolts in order of No. 6 and No. 4 as shown in the fig-
ure. (temporarily) E
2. Tighten the bolts No. 1 to 6 as shown in the figure. (specified
torque)
: Front F
K
JPBIA6993ZZ
Engine mounting insulator (LH) for A/T models

L

ENGINE ASSEMBLY
1. Tighten the bolt in order of No. 6 and No. 3 as shown in the fig-
ure. (temporarily)
: Front
2. Tighten the bolts in order of No. 1 to 6 as shown in the figure.

(specified torque)
JPBIA6937ZZ
Engine mounting insulator (RH)

1. Tighten the bolt as shown in the figure. (temporarily)
: Front
JPBIA6933ZZ
Rear torque rod bracket

1. Tighten the bolts in order of No. 1 to 3 as shown in the figure.
(temporarily)
: Front
2. Tighten the bolt as shown in the figure. (specified torque)
JPBIA6934ZZ
Installation
1. Install engine mount (LH).
M/T models
1. Tighten the nuts in order of No. 1 to 2 as shown in the figure.

ENGINE ASSEMBLY
(temporarily)
2. Tighten the nut (A) on engine mounting insulator (LH). A
(specified torque)
3. Tighten the nuts in order of No. 1 to 2 as shown in the figure
after removing the jack.(specified torque)
EM
JPBIA6994ZZ
D
A/T models
1. Tighten the bolt in order of No. 3 and 4 to shown in the fig-
ure (temporarily). E
: Front
2. Tighten the bolt shown in the figure (specified torque). F
JPBIA6938ZZ
H
2. Install the engine mounting insulator bolts (RH) as follows:
a. Tighten the bolts in order of No. 1 to 3 as shown in the figure.
(specified torque) I
: Front
b. Tighten the bolts in order of No. 4 to 6 as shown in the figure J

after removing the jack. (specified torque)
JPBIA6995ZZ
L
3. Install the rear torque bolts as follows:
a. Tighten the bolts as shown in the figure (specified torque).
M
: Front
JPBIA6935ZZ
4. Install the upper torque rod bolt (RH). P

ENGINE ASSEMBLY
• Tighten the bolts in order of No. 2 to 1 as shown in the figure.
(specified torque)
: Front
JSBIA4537ZZ

- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.


< UNIT DISASSEMBLY AND ASSEMBLY > [YS23DDT/YS23DDTT (M9T)]

EM
NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc. C
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-366, "Exploded View".
2. Install engine to engine stand with the following procedure: D
a. Remove flywheel or drive plate. Refer to EM-374, "Exploded View" (M/T models) or EM-376, "Exploded
View" (A/T models).
b. Lift the engine with a hoist to install it onto widely use engine stand. E
CAUTION:
• Use the engine stand that has a load capacity [approximately 225 kg (496 lb) or more] large
enough for supporting the engine weight. F
• Before removing the hanging chains, check the engine stand is stable and there is no risk of
overturning.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand. G
- Intake manifold: Refer to EM-314, "Exploded View".
- Exhaust manifold: Refer to EM-321, "Exploded View".
- Oil separator: Refer to EM-335, "Exploded View". H
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel
I
removed.
PBIC3227J
L
CAUTION:
Be sure to clean drain plug and install with new gasket.
M

FLYWHEEL
FLYWHEEL
AWBIA2675ZZ
1. Flywheel A. Refer to INSTALLATION Engine front
REMOVAL
2. Remove clutch cover and clutch disk. Refer to CL-40, "Exploded View".
3. Remove flywheel.
• Secure crankshaft using a crankshaft pulley locking tool [SST: — (Mot.1770)], and remove mounting
bolts.
CAUTION:
• Never disassemble them.
• Never place them with signal plate facing down.
• When handling signal plate, take care not to damage or scratch them.
INSTALLATION
CAUTION:
Never damage or scratch and contact surface for clutch disc of flywheel.
1. Install flywheel by aligning the mark (1).
NOTE:
The openings of the flywheel bolts must be aligned.
a. Install bolts without tightening them.
b. Fix flywheel using flywheel locking tool [SST: — (Mot.1431)].
E1BIA0773ZZ

FLYWHEEL
c. Tighten bolts in numerical order as shown.
A
EM
JPBIA0812ZZ
D
2. Tighten flywheel bolts to specification.
Step One : 40 N·m (4.1 kg-m, 30 ft-lb) E

Step Two : 45° degrees rotation clockwise in order
CAUTION:
Do not reuse flywheel bolts. F
G

DRIVE PLATE
DRIVE PLATE
JPBIA7133GB
1. Pilot bushing 2. Drive plate A. Refer to INSTALLATION
REMOVAL
2. Remove drive plate.
CAUTION:
Never disassemble them.
a. Fix drive plate using flywheel locking tool [SST: — (Mot.1431)].
b. Loosen bolts in reverse order as shown in the figure with the fol-
lowing procedure:
3. Remove pilot bushing using the pilot bushing puller (commercial
service tool), if necessary.
E1BIA1163GB
INSTALLATION
1. Install pilot bushing.
• Using the drift, force fit the pilot bushing until its front end contacts crankshaft.
2. Install drive plate.
a. Install bolts without tightening them.
b. Fix drive plate using flywheel locking tool [SST: — (Mot.1431)].

DRIVE PLATE
c. Tighten bolts in numerical order as shown in the figure with the
following procedure: A
i. Tighten mounting bolts.
Bolts : 50.0 N·m (5.1 kg-m, 37 ft-lb) EM
E1BIA1163GB
D

OIL PAN (UPPER)
OIL PAN (UPPER)
JPBIA7115GB
Engine oil level sensor Oil pan (upper) Engine oil level gauge
Engine oil level gauge guide O-ring Oil pan drain plug
Drain plug washer Oil pan (lower) Oil filter body
Oil filter O-ring Engine oil pressure switch
O-ring
Refer to INSTALLATION. Refer to INSTALLATION.

OIL PAN (UPPER)
: Sealing point
A
, : Indicates that the parts is connected ato points with same symbols in actual vehecle.

EM
REMOVAL
1. Remove oil pan (lower). Refer to EM-329, "Exploded View". C
2. Remove oil strainer and oil pump. Refer to LU-50, "Exploded View".
3. Remove rear oil seal retainer. Refer to EM-364, "REAR OIL SEAL : Removal and Installation".
4. Remove oil pan (upper) with the following procedure: D
a. Loosen mounting bolts in reverse order as shown.
G
E1BIA0650ZZ
b. Set two stud bolts (A), two washers (B) and two nuts (C) in place H
of the oil pan (upper) mounting bolts.
(1) : Oil pan (upper)

I
NOTE:
Use M8 × 90 mm (3.54 in) long stud bolt. J
c. Detach the oil pan (upper) from the cylinder block by gradually
tightening the nuts. Remove oil pan (upper).
K
N
JPBIA0635ZZ
5. Remove oil pump related parts. Refer to LU-50, "Exploded View". O

INSTALLATION
1. Install oil pump. Refer to LU-50, "Exploded View". P
2. Install oil pan (upper) with the following procedure:

OIL PAN (UPPER)
faces.
CAUTION:
Never scratch or damage the mating surfaces when clean-
• Also remove old liquid gasket from mating surface of cylinder
block.
JPBIA0027ZZ

(commercial service tool) to areas shown in the figure.
(a) : φ3.0 - 7.0 mm (0.118 - 0.276 in)

Use Genuine Liquid Gasket or equivalent
CAUTION:
• At the bolt holes marked, liquid gasket should be applied
inside holes.
• Attaching should be done within 5 minutes after coating.
JPBIA6986ZZ
c. Tighten mounting bolts in two steps separately in numerical

order as shown in the figure.
Step one : 1st step: 10.0 N·m (1.0 kg-m, 89 in-lb)

Step two : 2nd step: 25.0 N·m (2.6 kg-m, 18 ft-lb)
E1BIA0650ZZ
3. Install rear oil seal retainer. Refer to EM-364, "REAR OIL SEAL : Removal and Installation".
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.

CYLINDER HEAD
CYLINDER HEAD
A
EM
I
JPBIA7117GB
1. Bracket 2. Engine slinger 3. Engine slinger bracket J

4. Valve 5. Cylinder head gasket 6. Engine slinger
7. Valve oil seal 8. Valve spring 9. Valve spring retainer
10. Tappet 11. Valve collet 12. Hydraulic tappet K
13. Cylinder head bolt 14. Cylinder head A. Refer to EM-383, "Disas-
sembly and Assembly"
L
REMOVAL
M
1. Remove the following components and related parts.
• Intake manifold: Refer to EM-314, "Exploded View".
• Turbocharger: Refer to EM-326, "Exploded View".
• Exhaust manifold: Refer to EM-321, "Exploded View". N
• Water inlet and water outlet: Refer to CO-73, "Exploded View".
• Front cover, timing chain: Refer to EM-346, "Exploded View".
• Camshaft: Refer to EM-358, "Exploded View" O

CYLINDER HEAD
2. Remove cylinder head.
• Loosen mounting bolts in reverse order as shown.
: Front
E1BIA0661ZZ
3. Remove cylinder head gasket.

INSTALLATION
1. Install cylinder head gasket with the following procedure:
CAUTION:
• Before installing cylinder head, inspect piston protrusion.
• Do not reuse gasket.
a. Apply liquid gasket to position (A) shown in the figure.
: Engine front
JPBIA0612ZZ
b. Install cylinder head gasket (1), and apply liquid gasket to posi-
tion (A) shown in the figure.
: Engine front
JPBIA0611ZZ
2. Install cylinder head, and tighten mounting bolts in numerical

order as shown in figure with the following procedure:
: Front
a. Tighten all cylinder head bolts.
Step one : 5.0 N·m (0.51 kg-m, 44 in-lb)

Step two : 20.0 N·m (2.0 kg-m, 15 ft-lb)
Step three : 30.0 N·m (3.1 kg-m, 22 ft-lb)
AWBIA2682ZZ
b.

CYLINDER HEAD
Turn all bolts 300 degrees clockwise using Tool (A).
A
CAUTION:
Check and confirm the tightening angle by using Tool (A). EM
Do not judge by visual inspection alone.
JPBIA0867ZZ
D
E
DISASSEMBLY
1. Support the cylinder head assembly using suitable cylinder head support tool.
F
2. Remove hydraulic tappet.
CAUTION:
Be sure to immerse the hydraulic tappets in a bath of engine oil to ensure no air enters.
3. Remove valve collet (1). G
• Compress valve spring using suitable tool (A).
J
JPBIA0643ZZ
4. Remove valve spring retainer and valve spring.

5. Check dimension of valve oil seal mounting position before removing valve and valve oil seal with the fol- K
lowing procedure:
a. Install the push rod (A) of valve seal drift on the valve oil seal
using suitable tool. L
NOTE:
The inner diameter of the push rod must be identical to that of
the valve. In addition, the bottom of the push rod must come into M
contact with the metal upper section of the valve oil seal.
JPBIA0783ZZ
O

CYLINDER HEAD
b. Install the guide tube (B) over the push rod (A) until the guide
tube comes into contact with the cylinder head, locking the push
rod with the knurled wheel.
• Remove the guide tube assembly plus push rod, being careful
not to loosen the knurled wheel.
JPBIA0790ZZ
6. Push valve stem to combustion chamber side, and remove valve.

7. Remove valve oil seal (1) with a suitable tool (A).
JPBIA0663ZZ
ASSEMBLY
1. Install valve.
NOTE:
Install larger diameter to intake side.
2. Install valve oil seal with the following procedure:
a. Position the protector (A) of valve seal drift on the valve using a
suitable tool.
JPBIA0714ZZ
b. Position a valve oil seal on the protector. Move the valve oil seal past the protector.
CAUTION:
Never lubricate valve oil seal.
c. Remove the protector.
d. Despress suitable tool (A) by hand until the guide tube (B)
makes contact with the cylinder head.
JPBIA0790ZZ

CYLINDER HEAD
3. Install valve spring.
NOTE: A
The intake and exhaust valve springs are identical.
4. Install valve spring retainer.
5. Install valve collet (1). EM
• Compress valve spring with a suitable tool (A).
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition. C
E
JPBIA0643ZZ
6. Install hydraulic tappet. F

• Check that the tappets are filled with oil before refitting them.
G
INSPECTION AFTER DISASSEMBLY
Cylinder Head Distortion
H
NOTE:
When performing this inspection, cylinder block distortion should be also checked.
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION: I
Never allow gasket debris to enter passages for engine oil or water.
measure the distortion in six directions ((A) - (F)). J
Standard: Refer to EM-414, "Cylinder Head".

• If it exceeds the standard, replace cylinder head and cylinder K
head housing.
NOTE:
Cylinder head cannot be replaced as a single part, because it is L
machined together with cylinder head housing. Replace whole
cylinder head housing and cylinder head assembly.
JPBIA0176ZZ
M
VALVE DIMENSIONS
• Check the dimensions of each valve. For the dimensions, refer to EM-414, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. N
VALVE GUIDE CLEARANCE
Valve Stem Diameter O

• Measure the diameter of valve stem with micrometer (A).

P
• Measure the inner diameter of valve guide with bore gauge.
JPBIA0183ZZ

CYLINDER HEAD
• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter)

• If it exceeds the standard, replace valve and/or cylinder head and cylinder head housing.
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circum-
ference.
(A) : OK
(B) : NG
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace
cylinder head and cylinder head housing.
JPBIA0187ZZ
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

• Check valve spring pressure with valve spring seat installed at the
specified spring height.

• If the pressure height is out of the standard, replace valve spring.
SEM113

CYLINDER BLOCK
CYLINDER BLOCK
A
EM
JPBIA7116GB
P
Cylinder block Compression ring Sealing ring
Scraper ring Piston Piston pin
Snap ring Connecting rod Connecting rod bearing shell
Connecting rod bearing shell Connecting rod bearing cap Rear oil seal retainer
Crankshaft position sensor target Connecting rod bolt Balancer unit
Adjust shim Balancer unit bolt Crankshaft bearing cap bolt

CYLINDER BLOCK
Crankshaft bearing cap Main bearing (lower) Crankshaft
Main bearing (upper) Thrust washer Cover
O-ring Crankshaft position sensor TDC hole plug
Comply with the assembly procedure Comply with the assembly procedure Comply with the assembly procedure
when tightening. Refer to EM-388, "Dis- when tightening. Refer to EM-388, when tightening. Refer to EM-388,
assembly and Assembly" "Disassembly and Assembly" "Disassembly and Assembly"
Comply with the assembly procedure
when tightening. Refer to EM-388, "Dis- View
assembly and Assembly"
: Should be lubricated with oil.
: Sealing point
: Select with proper thickness.
Disassembly
1. Remove cylinder head. Refer to EM-381, "Removal and Installation".
2. Remove crankshaft position sensor.
3. Remove engine oil cooler. Refer to LU-48, "Removal and Installation".
4. Remove rear oil seal retainer. Refer to EM-364, "REAR OIL SEAL : Removal and Installation".
5. Remove oil pan (upper). Refer to EM-378, "Exploded View".
6. Remove oil pump. Refer to LU-50, "Removal and Installation".
7. Remove balancer unit with the following procedure:
a. Set No.1 cylinder at TDC of its compression stroke using TDC
set pin [SST: Mot 1766] (A).
CAUTION:
Check that weigh (B) of balancer unit faces the opposite
side (oil pan side) of crankshaft.
JSBIA6094ZZ
b. Insert fixing pin (A) into the shaft part of balancer unit.
NOTE:
Leave the balancer unit fixed with fixing pin until installed.
JSBIA6095ZZ

CYLINDER BLOCK
c. Loosen mounting bolts in the order of 6 to 1 as shown in the fig-
ure. A
: Engine front
EM
JSBIA6096ZZ
D
d. Remove balancer unit and baffle plate.
e. Remove adjust shims.
f. Remove TDC set pin. E
8. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-401, "Inspection".
F
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.
• Put a paint mark on cap to identify each cylinder. G
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
H
J
PBIC0259E
CAUTION: K
• Be careful not to damage oil jets (A), cylinder wall and
crankshaft pin, resulting from an interference of the con-
necting rod big end.
L
• Never disassemble oil jets.
N
JPBIA1817ZZ
9. Remove connecting rod bearing shells.

O
CAUTION:
When removing them, note the installation position. Keep them in the correct.
10. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-401, "Inspection". P

CYLINDER BLOCK
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
them excessively.
JPBIA0194ZZ
11. Remove the snap rings (1) using a screwdriver (A), and then
release the piston pin.
(B) : Channel
JPBIA0639ZZ
12. Remove main bearing cap mounting bolts with the following procedure:
• Measure crankshaft end play before loosening main bearing cap mounting bolts. Refer to EM-401,
"Inspection".
a. Loosen mounting bolts in the order of 10 to 1 as shown in the
figure.
: Engine front
JSBIA6097ZZ
b. Remove crankshaft bearing caps.

c. Remove crankshaft.
d. Remove crankshaft bearing shells.
NOTE:
Always mark the position of each crankshaft bearing shell using an indelible marker pen, in relation to the
crankshaft bearing number
13. Remove crankshaft position sensor target.
Assembly
1. Fully air-blow engine coolant and engine oil passages in the cylinder block, cylinder bore and crankcase
to remove any foreign matter.
CAUTION:
Use a goggles to protect your eye.
2. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil from the bearing mating surfaces of the cylinder block and main bearing
cap.

CYLINDER BLOCK
b. Center the grooved bearing shell on bearing No.1 of the cylinder
block while aligning the groove of the bearing shell with the hole A
of the bearing (A).
• Secure the flush bearing shell (1) and push from the opposite
side the position of the bearing shell flush with the bearing.
EM
JPBIA0711ZZ
D
c. Measure the distance (X1) between the bearing face (17) and
the edge of the bearing shell at points (A), (B) and (C) using a
depth gauge.
E
d. If necessary, adjust the position of the bearing shell to the value
(X1).
X1 : 182.61 - 182.81 mm (7.19 - 7.20 in) F
G
JMBIA4332ZZ
e. Repeat the previous operations for the bearing shells of the bearings No 2, 4 and 5.
H
P
E1BIA0534GB
f. If necessary, adjust the position of the bearing shells.

• Bearings No. 2 and 4 to the value (X2)
X2 : 90.61 - 90.81 mm (3.5673 - 3.5752 in)

CYLINDER BLOCK
g. Secure the flush bearing shell against the rectified shim (2) and
push from the opposite side to position the bearing shell flush
with the bearing.
Place:
• Dial indicator stand set [SST: KV113B0040 (Mot.251-01)] (1)
against the mating face of the crankshaft thrust washer on
bearing No.3
• the grooved bearing shell against the rectified shim.
E1BIA0535ZZ
h. Measure the distance (X3) between the bearing face of the

thrust washer and the bearing shell edge using a depth gauge.
X3 : 1.9 - 2.1 mm (0.075 - 0.083 in)
E1BIA0536GB
i. Center the grooved bearing shell on the bearing, aligning the

shell with the hole groove.
• Adjust the position of the bearing shell at points (A), (B) and
(C) using the dial indicator stand set [SST: KV113B0040
(Mot.251-01)] (5) and a set of feeler gauges (thickness of the
shim (6).
Thickness of the shim : 1.9 - 2.1 mm (0.075 - 0.083 in)
E1BIA0537ZZ
j. Secure the flush bearing shell with the bearing cap at (1) and
push from the opposite side to bring the bearing shell flush with
the bearing cap.
Place:
• the bearing cap on a bench,
• a non-grooved bearing shell against the bench.
E1BIA0538ZZ
k. Measure the distance (X4) between the edge of the bearing

shell and the wall of the bearing cap at points (A), (B) and (C)
using a depth gauge.
X4 : 1.9 - 2.1 mm (0.075 - 0.083 in)
E1BIA0539GB

CYLINDER BLOCK
l. Adjust the position of the bearing shell at point (A), (B) and (C)
using a set of feeler gauges (thickness of the shim (1)). A
Thickness of the shim : 1.9 - 2.1 mm (0.075 - 0.083 in)

• Repeat the previous operations for the other bearing caps. EM
E1BIA0540ZZ
D
m. Position the crankshaft thrust washers on the cylinder block
(washer plug (1) in the cylinder block notch)
• Use engine oil to lubricate the crankshaft journal bearing
E
shells and thrust washers (only the face making contact with
the crankshaft).
NOTE:
Ensure the bearing shells and the thrust washers do not move F
when refitting the crankshaft and bearing caps.
G
E1BIA0541ZZ
3. Install crankshaft position target.

H
4. Install crankshaft, the bearing caps and the crankshaft bearing bolts.
NOTE:
Check that the bearing caps are in contact with the cylinder block before tightening the bearing cap bolts.
I
5. Align the identification number to the journal position to install as
: Engine front J
L
JPBIA0786ZZ
6. Tighten main bearing cap bolts with the following procedure:

a. Tighten main bearing cap bolts in the order from 1 to 10 as M
shown in the figure
: Engine front N
Bolts : 20.0 N·m (2.0 kg-m, 15 ft-lb)

O
b. Turn main bearing cap bolts 70 degrees clockwise (angle tight-
ening) in the order from 1 to 10 as shown in the figure.
JPBIA1801ZZ
P
CAUTION:

CYLINDER BLOCK
Confirm the tightening angle by using angle wrench [SST:
KV10112100] (A) or protractor. Never judge by visual
inspection without the tool.
JPBIA4433ZZ
7. After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
8. Check crankshaft end play. Refer to EM-401, "Inspection".
• If replacing the crankshaft, always identify the piston height category to refit in each cylinder to guaran-
tee that the piston protrusion in relation to the cylinder block remains within the tolerance, before refitting
the connecting rod - piston assemblies. Refer to EM-401, "Inspection".
9. Install piston to connecting rod with the following procedure:
CAUTION:
When replacing connecting rod or the piston, identify the new piston grade to fit on the engine by
calculating the height of the piston pin to guarantee a piston protrusion in relation to the cylinder
block within the tolerances
a. Install connecting rod bearing (upper) and connecting rod bearing (lower) to connecting rod and connect-
ing rod cap.
i. Place the connecting rod body on the bench.
ii. Secure the flush bearing shell of the connecting rod body mating
face on side (1) and push from the opposite side (2) until the
connecting rod body mating face is flush.
Flush bearing Upper : 19.3 mm (0.76 in)

shell width Lower : 18.3 mm (0.72 in)
E1BIA0506ZZ
b. Measure the distance (X) between the edge of the bearing shell
and the wall of the connecting rod body at points (A), (B) and
(C).
X : 1.9 - 2.1 mm (0.075 - 0.083 in)
E1BIA0507GB
c. Center the bearing shell on the connecting rod body.

• Adjust the position of the bearing shell at points (A), (B) and
(C) using a set of feeler gauges.
Feeler gauges : 1.9 - 2.1 mm (0.075 - 0.083 in)

• Repeat the previous operations on the remaining connecting
rod bodies and caps
E1BIA0508ZZ

CYLINDER BLOCK
d. Install snap ring to the groove of the piston rear side.
• Insert it fully into the groove. A
e. Assemble piston to connecting rod.
• Point the mark engraved (A) on the piston head facing and the
bosses (B) of the big end as shown in the figure. EM
: Engine front
• Piston pin can be pushed in by hand without excessive force. C

From the front to the rear, insert piston pin into piston and con-
necting rod.
D
JPBIA0732ZZ
E
f. Install snap ring to the groove of the piston front side.
• Insert it fully into the groove.
• After installing, check that connecting rod moves smoothly.
F
10. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively. G
• Position each ring with the gap as shown in the figure referring
to the piston front mark.
H
J
JPBIA1058ZZ
11. Lubricate piston pin with engine oil. K

• Position the connecting rod in relation to the piston (piston
marking (1)“V” is opposite the machined bosses (2) on the big
end)
L
NOTE:
Piston marking V engine flywheel or drive plate end, connecting
rod marking (machined bosses) timing end. M
E1BIA0504ZZ N
12. Engage the pin in the piston and in the small end.
NOTE:
O
Check that the piston pin slides and rotates easily in the piston and the small end.

CYLINDER BLOCK
13. Refit the snap ring to the piston pin using a flat screwdriver
(apply pressure in the groove (1)).
NOTE:
Position the opening in the snap ring towards the piston crown.
E1BIA0505ZZ
14. Install piston and connecting rod assembly to crankshaft with the following procedure:
a. Lubricate with engine oil the following parts
• Cylinder block barrels
• Piston rings
• Piston skirts
• Crankshaft crank pins
b. Check that the piston rings are correctly engaged in the piston
grooves
• Put the piston on a plane and clean surface.
• Verify the absence of over lap (1) of the tips of the scraper
ring.
NOTE:
Manipulate the piston exclusively by the skirt or the connecting
rod, without touching the scraper ring.
E1BIA0509ZZ
c. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
d. Place the position in the mounting ring [allow the piston skirt to protrude by approximately 1 cm (0.39 in)].
e. Compress the piston rings by tightening the bolts (16).
f. Check that the pistons correspond to the cylinder block barrels
(No.1 timing end)
g. Place the connecting rod and piston assembly in the cylinder.
h. Position the point of the “V” (17) engaged on the piston towards
the flywheel end or drive plate end.
WARNING:
Failure to observe the following procedure may result in
destruction of the engine.
• Gradually insert the “connecting rod - piston” assembly JMBIA4298ZZ
in the cylinder (avoid any contact between the connecting
rod and the oil jet) using only of the hand.
• Position the big end on the crankshaft crank pin.
• Refit the connecting rod cap, ensuring that the connecting rod caps and bodies correspond.
Refer to EM-401, "Inspection".
CAUTION:
The piston ring compressor tool on the piston has to be made without forcing. If resistance during
the engagement occurs, put off the tool and to re-engage it.
15. Install connecting rod cap bolts wit the following procedure:
a. Tighten new connecting rod cap bolts.
Bolts : 25.0 N·m (2.6 kg-m, 18 ft-lb)

CYLINDER BLOCK
b. Turn bolts 55 degrees clockwise (angle tightening).
CAUTION: A
Confirm the tightening angle by using an angle wrench
[SST: KV10112100 ( — )] (A) or protractor. Never judge by
visual inspection without the tool.
EM
• After tightening connecting rod cap bolt, check that crankshaft
rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-401,
"Inspection". C
• Check the piston protrusion. Refer to EM-401, "Inspection".
JPBIA0846ZZ
D
16. Install balancer unit with the following procedure:
CAUTION:
When any one of the parts listed below is replaced, adjust backlash of the balancer unit. Refer to
E
EM-398, "Backlash Adjustment".
• Crankshaft
• Cylinder block
• Balancer unit F
a. Obtain No.1 cylinder at the TDC of its compression stroke. Refer to EM-401, "Inspection".
b. Screw in the TDC set pin [SST: — (Mot. 1766)] (A).
c. Align the bolt hole of the balancer unit shim with bolt hole (C) on G
the cylinder block side, and place shim (B) of balancer unit as
H
: Engine front
JSBIA6163ZZ
J
d. Install the balancer unit fixed with fixing pin (A) to cylinder block
together with baffle plate (1).
K
: Engine front
CAUTION:
The balancer unit weights must be positioned on the oppo- L
site side to the crankshaft.
M
JSBIA6164ZZ
e. Temporarily tighten balancer unit mounting bolt (A).

N
: Engine front
JSBIA6165ZZ

CYLINDER BLOCK
f. Press shim (1) of balancer unit to the mounting bolt side (in the
direction shown by arrow).
: Engine front
JSBIA6166ZZ
g. Tighten new balancer unit bolts in the order from 1 to 6 as

shown in the figure with the following procedure:
: Engine front
i. Tighten balancer unit bolts.
Bolts : 15.0 N·m (1.5 kg-m, 11 ft-lb)

ii. Turn bolts 85 degrees clockwise (angle tightening).
CAUTION:
Confirm the tightening angle by using an angle wrench JSBIA6096ZZ
[SST: KV10112100 (—)] or protractor. Never judge by visual

inspection without the tool.
h. Remove the TDC set pin [SST: — (Mot. 1766)].

i. Remove fixing pin.
17. Install rear oil seal retainer with the following procedure:
a. Set guide bolt (A) and protector (B) to rear oil seal retainer (1).
NOTE:
The protector is supplied in the new oil seal parts kit.
b. Move the rear oil seal retainer evenly by hand until it makes con-
tact with the cylinder block.
JPBIA0777ZZ
c. Tighten mounting bolts in two steps separately in numerical

order as shown in the figure.
i. Tighten mounting bolts No.1 and 5.
Bolts : 5.0 N·m (0.51 kg-m, 44 in-lb)

ii. Tighten mounting bolts No. 1 to 8 in numerical order as shown.
Bolts : 12.0 N·m (1.2 kg-m, 9 ft-lb)
JPBIA0645ZZ

Backlash Adjustment INFOID:0000000014267294
CAUTION:
When any one of the parts listed below is replaced, adjust backlash as per the following steps.
• Crankshaft
CYLINDER BLOCK
• Cylinder block
• Balancer unit A
1. Measure the backlash between gears of balancer unit and crank shaft, according to the following instruc-
tions.
CAUTION: EM
To measure backlash, use adjust shim [2.80 mm (0.11 in)] for shim of balancer unit.
a. Set dial gauge (A) on the gear of balancer unit.
CAUTION:
C
TDC set pin and balancer unit fixing pin must be removed
beforehand.
JSBIA6167ZZ
F
NOTE:
Set dial gauge in the center of gear
G
JSBIA6174ZZ
J
b. Measure backlash as shown in the figure.
CAUTION:
Never rotate the gear of balancer unit 360 degrees.
K
M
JSBIA6177ZZ
NOTE: N
To measure backlash with a dial gauge, rotate crank shaft in
steps of 90 degrees in the rotation direction of the engine and
measure backlash at 4 points.
O
: Measuring point
JSBIA6179ZZ
2. Select shim of balancer unit according to the instructions below.

a. Calculate the mean value of the backlash measured at 4 points.

CYLINDER BLOCK
b. Plug the calculated mean value into the following formula and calculate the dimensions of the shim of bal-
ancer unit.
2.80 - [0.5 - (mean value of backlash) / 2]
c. Refer to the shim selection table and select shim of balancer unit.
NOTE:
Round off to two decimal places.
Shim selection table

Grade of shim Backlash measure Grade of shim Backlash measure
12 43 758 79R 2.4 12 43 725 59R 2.62
12 43 754 23R 2.42 12 43 788 07R 2.64
12 43 744 53R 2.44 12 43 702 42R 2.66
12 43 709 80R 2.46 12 43 713 60R 2.68
12 43 717 52R 2.48 12 43 715 52R 2.70
12 43 761 79R 2.50 12 43 700 24R 2.72
12 43 751 88R 2.52 12 43 706 11R 2.74
12 43 797 98R 2.54 12 43 757 00R 2.76
12 43 786 07R 2.56 12 43 725 83R 2.80
12 43 774 62R 2.58 12 43 739 19R 2.62
12 43 718 09R 2.60
3. Remove balancer unit. Refer to EM-388, "Disassembly and Assembly".
4. Install balancer unit by using the selected shim. Refer to EM-388, "Disassembly and Assembly".
5. Measure the backlash between gears of balancer unit and crank shaft, according to the following instruc-
tions.
a. Set dial gauge (A) on the gear of balancer unit.
CAUTION:
TDC set pin and balancer unit fixing pin must be removed
beforehand.
JSBIA6167ZZ
NOTE:
Set dial gauge in the center of gear.
JSBIA6174ZZ

CYLINDER BLOCK
b. Measure backlash as shown in the figure.
CAUTION: A
Never rotate the gear of balancer unit 360 degrees.
EM
JSBIA6177ZZ
D
NOTE:
To measure backlash with a dial gauge, rotate crank shaft in
steps of 90 degrees in the rotation direction of the engine and E
measure backlash at 4 points.
: Measuring point
F
JSBIA6179ZZ
H
c. Check that the mean value of the four measured values is within the reference values.
Standard 0.05 ± 0.03 mm (0.002 ± 0.0012 in) I

d. If the mean value is outside the reference value, then select a shim of balancer unit.
J
CRANKSHAFT END PLAY
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial K
indicator (A).
Standard : Refer to EM-416, "Cylinder Block". L

• If it exceeds the standard, replace thrust bearings, and measure
again. If it still exceeds the standard, also replace crankshaft.
M
JPBIA0845ZZ
N
CRANKSHAFT DEFORMATION OF THE BEARING FACE
• Position the feeler of the dial indicator (A) on the flywheel or drive
plate face of the crankshaft avoiding the holes of the flywheel or O
drive plate bolts.
• Rotate the crankshaft once to measure the mounting flange of the
flywheel face.
P
Standard : Refer to EM-416, "Cylinder Block"
JSBIA6098ZZ
CRANKSHAFT CONCENTRICITY OF CRANKSHAFT JOURNAL

CYLINDER BLOCK
• Support the feeler of dial indicator (A) on the centre of the mating
face of the crankshaft journal check.
• Rotate the crankshaft once to check the concentricity of the jour-
nal.
JSBIA6099ZZ

• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).

• If it exceeds the standard, measure the connecting rod bearing oil
clearance. Refer to “CONNECTING ROD BEARING OIL CLEAR-
ANCE”.
JPBIA0228ZZ

• Measure the outer diameter of crankshaft main journals with a micrometer.

• If it exceeds the standard, measure the main bearing oil clearance. Refer to “MAIN BEARING OIL CLEAR-
ANCE”.
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).

• If it exceeds the standard, replace connecting rod, and measure
again. If it still exceeds the standard, also replace crankshaft.
JPBIA0847ZZ

• Install connecting rod cap without connecting rod bearing installed,
and tightening connecting rod cap bolts to the specified torque.
Refer to EM-388, "Disassembly and Assembly".
: Connecting rod
• Measure the inner diameter of connecting rod big end with an

inside micrometer.

• If it exceeds the standard, replace connecting rod assembly. JPBIA0222ZZ


CYLINDER BLOCK
micrometer (A). A

EM
JPBIA0223ZZ
D
Standard : Refer to EM-416, "Cylinder Block" E
G
JPBIA0218ZZ
PISTON PROTRUSION H
Measure the protrusion of piston with the following procedure:
1. Set piston at a point close to the TDC.
2. Set the dial indicator stand set [SST: KV113B0040 (Mot.251-01)] I
(B) and [SST: KV113B0050 (Mot.252-01)] (A) at the location as
3. Set the indicator scale to “0” where the piston protrusion is max- J
imized.
4. Move the dial indicator stand so that the tip of dial indicator can
contact the cylinder block. Read the difference. K
JPBIA1803ZZ
L
5. If measured value is out of the standard, replace piston. Select a piston in “Piston Protrusion Grade”.
M
Piston Protrusion Grade:
Refer to EM-416, "Cylinder Block"
N
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside O
micrometer (A).

P
JPBIA0217ZZ

CYLINDER BLOCK
JPBIA0218ZZ

• Measure the side clearance of piston ring and piston ring groove
with a feeler gauge (C).
: NG
: OK

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

• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston and piston ring , and
then insert piston ring until middle of cylinder with piston, and
measure piston ring end gap with a feeler gauge (B).
: Measuring point
Standard : Refer to EM-387, "Exploded View"

• If it exceeds the standard, replace piston ring, and measure again.
If it still exceeds the standard, replace cylinder block and piston
rings. JPBIA0220ZZ
CYLINDER BLOCK TOP SURFACE DISTORTION

other contamination.
CAUTION:
• Check using a ruler and a dial gauge - support assembly or a
cylinder head rule and a set of feeler gauges the flatness of the
gasket surfaces of the cylinder block:

• If it exceeds the standard, replace cylinder block.
JMBIA3415ZZ

• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the
specified torque. Refer to EM-388, "Disassembly and Assembly".
CYLINDER BLOCK
gauge. A
: Cylinder block
: Main bearing cap EM

C
• If it exceeds the standard, replace cylinder block and main bearing
caps assembly.
NOTE: JPBIA0225ZZ
Main bearing caps cannot be replaced individually, because it is D

machined together with the cylinder block.
E
• Using a bore gauge, measure the cylinder bore for wear, out-of-round and taper at six different points on
each cylinder.
F
Standard:
Cylinder bore inner diameter
G
: Refer to EM-387, "Exploded View"
• If it exceeds the standard, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder
block. H
Piston Skirt Diameter
I
Measure point : Refer to EM-416, "Cylinder Block" J
JPBIA0227ZZ
L
Calculate by piston skirt diameter and cylinder bore inner diameter.
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)
M
• If it exceeds the standard, replace piston and piston pin assembly and/or cylinder block. N
CONNECTING ROD THICKNESS
Measure using a external micrometer the thickness (X13) of the big
end flank. O

P
JMBIA4309ZZ

CYLINDER BLOCK
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-
fied torque. Refer to EM-388, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale on
NOTE:
The procedure when the measured value exceeds the standard is
the same as that described in “Method by Calculation”.
JPBIA0231ZZ
• Install connecting rod bearings to connecting rod and con-
necting rod bearing cap, and tighten connecting rod cap bolts to
the specified torque. Refer to EM-388, "Disassembly and Assem-
bly".
JPBIA0230ZZ

• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in the crankshaft axial direction, avoiding
oil holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to
the specified torque. Refer to EM-388, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale on
NOTE:
The procedure when the measured value exceeds the standard is
the same as that described in “Method by Calculation”.
JPBIA0231ZZ

A
EM
Determined by match of cylinder block
Between cylinder block and Main bearing grade bearing housing grade (inner diameter of
Main bearing C
crankshaft (bearing thickness) housing) and crankshaft journal grade
(outer diameter of journal)
Combining service grades for connecting
Between crankshaft and Connecting rod bearing grade rod big end diameter and crankshaft pin D
Connecting rod bearing
connecting rod (bearing thickness) outer diameter determine connecting rod
bearing selection
Piston and piston pin as- E
sembly
Between cylinder block and
(piston is available to- Piston grade Piston grade = Piston pin height
piston
gether with piston pin as
an assembly.) F
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the G
selective fitting parts, refer to the text. H
PISTON IDENTIFICATION I
• Piston marking
: Date of manufacture J
: Piston pin height class
: Modification in production suffix
K
: Piston fitting direction
(towards the flywheel or drive plate)
: Piston axis of symmetry
L
: Axis of the gudgeon pin hole
NOTE: JMBIA4299ZZ
Piston pin height class which corresponds to the height between M
the piston pin and the piston crown.
• Piston pin height class
NOTE:
There are two types of piston N
- Without piston pin bronze ring
H1 : Piston pin height O
JMBIA4300ZZ

- With piston pin bronze ring
H1 : Piston pin height

: Piston pin bronze ring
NOTE:
The piston pin bronze ring cannot be replaced.
JMBIA4301ZZ
Piston protrusion grade : Refer to EM-416, "Cylinder Block"
CONNECTING ROD BEARING IDENTICATION

1. Apply connecting rod big end diameter grade stamped on con-
necting rod side face.
: Big end diameter value

: Day
: Weighty class
: Year
: Team
: Centre to centre distance
JPBIA7134ZZ
: Class of centre to centre distance
Connecting rod big end diameter : Refer to EM-416, "Cylinder Block"
2. Apply crankshaft pin journal diameter grade stamped on crank-

shaft rear side.
: Line indicating the diameter class of the journals.

: Line indicating the dismeter class of the crankpins.
: Last three numbers of the crankshaft part number.
: Line reserved for the factory.
Crankshaft pin
: Refer to EM-416, "Cylinder Block"
journal diameter JMBIA3402ZZ
3. Apply the symbol obtained to the “Connecting Rod Bearing Selection Table” to select connecting rod bear-
ing.
Upper bearing shell

Big end diameter grade A

A B C D E F G H I J K L M N O P Q R S T
A R N
B R N
EM
C R N
D R N C
E R N
F R N
G B R N D
H B R N
Cra I B R N
nk-
E
J B R N
sha
ft K B R
pin
L B R F
gra
de M B R
N B R
G
O J B R
P J B R
Q J B R H
R J B R
S J B
I
T J B
U J B
• B : Blue J
• R : Red
• J : Yellow
• N : Black
K
Lower bearing shell

Big end diameter grade

A B C D E F G H I J K L M N O P Q R S T U
A R B J
B R B J
C R B J
D R B J
E R B J
F R B J
G R B J
H R B J
Cr
an I R B J
ksh J N R B J
aft
pin K N R B J
gra L N R B J
de
M N R B J
N N R B J
O N R B J
P N R B
Q N R B
R N R B
S N R B
T N R B
• B : Blue
• R : Red
• J : Yellow
• N : Black
MAIN BEARING INDETIFICATION

1. “Cylinder Block Bearing Diameter Table” rows correspond to
main bearing housing grade on rear side of cylinder block.
: Cylinder block bearing diameter category:

• Identification by letter of the crankshaft bearing diameter,
• the order of the marking letters goes from the bearing on the
timing end to the bearing on the flywheel end.
• : cylinder diameter category.
• : marking only for factory use.
Cylinder block : Refer to EM-416, "Cylinder E1BIA0564ZZ

bearing diameter Block"

2. Apply crankshaft journal diameter grade stamped on crankshaft
rear side. A
: Line indicating the diameter class of the journals.

: Line indicating the dismeter class of the crankpins. EM
: Last three numbers of the crankshaft part number.
: Line reserved for the factory.
C
Crankshaft journal : Refer to EM-416, "Cylinder
diameter Block" JMBIA3402ZZ
D
MAIN BEARING SELECTION TABLE
Upper bearing shell E
Cylinder block bearing diameter grade

A B C E H J K L M P S T U Z F
A R N
B R N
C R N G
D R N
E R N H
F R N
G R N
H R N I
Crank I B R N
shaft
J B R N
jour- J
nal di- K B R N
amet
L B R
er
grade M B R K
N B R
O B R
L
P B R
Q J B R
R J B R M
S J B R
T J B
N
U J B
• B : Blue
• R : Red
• J : Yellow O
• N : Black
Lower bearing shell
P
A B C E H J K L M P S T U Z

A R N
B R N
C R N
D R N
E B R N
F B R N
G B R N
H B R
Crank I B R
shaft
J B R
jour-
nal di- K B R
amet
L B R
er
grade M J B R
N J B R
O J B R
P J B
Q J B
R J B
S J B
T J B
U J B
• B : Blue
• R : Red
• J : Yellow
• N : Black

< SERVICE DATA AND SPECIFICATIONS (SDS) [YS23DDT/YS23DDTT (M9T)]
SERVICE DATA AND SPECIFICATIONS (SDS) A

EM
GENERAL SPECIFICATIONS
C
Engine type YS23DDT/YS23DDTT (M9T)
Displacement cm3 (cu in) 2,298 (140.22) D
Bore and stroke mm (in) 85.0 x 101.0 (3.346 x 3.976)
E
Compression 2
Oil 1 F
Compression ratio 15.5
H
Valve timing
EM120
J
Unit: degree
a b c d e f
K
198 187 - 11 18 - 17 35
Drive Belts INFOID:0000000014267301

L
DRIVE BELT
Tension of drive belt Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner. M
Intake Manifold INFOID:0000000014267302
N
INTAKE MANIFOLD
Unit: mm (in)
Items Standard O
Surface distortion 0.05 (0.0020)
Exhaust Manifold INFOID:0000000014267303 P
EXHAUST MANIFOLD
Unit: mm (in)
Items Standard
Surface distortion 0.7 (0.028)

Turbocharger INFOID:0000000014267304
Valve rod moving length

25 kPa (250 mbar, 187.525 mmHg, 7.3825 inHg) 2.95 - 5.95 mm (0.1161 - 0.2343 in)
Value of vacuum
More than 60 kPa (600 mbar, 450.06 mmHg, 17.718 inHg) The rod should not move
CAMSHAFT
Unit: mm (in)

Camshaft runout [TIR*] 0.05 (0.002) —
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
Camshaft end play 0.08 - 0.18 (0.0031 - 0.0071) —
Camshaft journal diameter 24.98 - 25.0 (0.9835 - 0.9846)
Crankshaft radial play 0.04 - 0.08 (0.0016 - 0.0031) —
SEM671
Cam height “A” Intake / Exhaust 39.03 - 39.13 (1.5366 - 1.5405)

CYLINDER HEAD
Unit: mm (in)
Items Standard
Head surface distortion 0.05 (0.0020)
JPBIA0792ZZ
Normal cylinder head height “ ” 132.5 (5.22)
VALVE DIMENSIONS

Unit: mm (in)
A
EM
D
JSBIA6126ZZ
Item Standard
Intake 27.58 - 27.82 (1.0858 - 1.0953) E
Valve head diameter “D”
Exhaust 25.88 - 26.12 (1.0189 - 1.0283)
Intake 103.89 (4.090)
Valve length “L” F
Exhaust 103.78 (4.086)
Intake 5.970 - 5.990 (0.2350 - 0.2358)
Exhaust 5.960 - 5.980 (0.2346 - 0.2354) G
Measuring point “X1” 35.0 (1.378)
Valve seat angle “α” 45°- 45°15′
H
Intake 1.1(0.043)
Exhaust 0.94 (0.037)
Valve lift amount 8.0 (0.315) I
VALVE GUIDE
Unit: mm (in)
J
JSBIA6127ZZ
Items Standard N
Valve guide Inner diameter (X3) 6.00 - 6.02 (0.2362 - 0.2370)
Cylinder head valve guide hole diameter 10.987 - 11.013 (0.4326 - 0.4336)
Interference fit of valve guide 0.020 - 0.057 (0.0008 - 0.0022) O
Intake 0.02 - 0.06 (0.0008 - 0.0024)
Exhaust 0.03 - 0.07 (0.0012 - 0.0028)
P
Valve guide angle “ ” 90°
VALVE SEAT

Unit: mm (in)
JPBIA0787ZZ
Items Standard
Intake 28.163 - 28.191 (1.1088 - 1.1099)
Cylinder head seat recess diameter “D”
Exhaust 26.986 - 27.014 (1.0624 - 1.0635)
Intake 28.276 - 28.292 (1.1132 - 1.1139)
Valve seat outer diameter “d”
Exhaust 27.076 - 27.092 (1.0660 - 1.0666)
Intake 0.085 - 0.129 (0.0033 - 0.0051)
Exhaust 0.062 - 0.106 (0.0024 - 0.0042)
Angle “α” 89°30′
Intake 1.40 (0.0551)
Contacting width “W”*1
Exhaust 1.544 (0.0608)
Intake 4.56 - 4.64 (0.1795 -0.1827)
Height “h”
Exhaust 4.905 - 4.985 (0.1931 - 0.1963)
Intake 6.95 (0.2736)
Depth “H”
Exhaust 7.25 (0.2854)
*1: Machining data
VALVE SPRING
Unit: mm (in)
Free height 46.70 (1.8390)
200 - 220 N (20.4 - 22.4 kg, 45 - 49 lb) 34.90 (1.3740)
Pressure height
353 - 387 N (36.0 - 39.5 kg, 79 - 87 lb) 26.90 (1.0591)
Full pressed height 24.40 (0.9606)
Diameter of the wire 2.78 - 2.82 (0.1094 - 0.1110)
Inner diameter 13.90 - 14.30 (0.5472 - 0.5630)
Outer diameter 19.50 - 19.90 (0.7677 - 0.7835)
Valve spring squareness 1.2 (0.047)
CRANKSHAFT

Unit: mm (in)
Item Standard A
EM
E1BIA0067ZZ
PBIC3459J
E
GRADE mark A 55.985 (2.2041)
GRADE mark B 55.986 (2.2042)
GRADE mark C 55.987 (2.2042)
F
GRADE mark D 55.988 (2.2042)
GRADE mark E 55.989 (2.2043)
GRADE mark F 55.990 (2.2043) G
GRADE mark G 55.991 (2.2044)
GRADE mark H 55.992 (2.2044)
H
GRADE mark I 55.993 (2.2044)
GRADE mark J 55.994 (2.2045)
Crankshaft main journal diameter “Dm” GRADE mark K 55.995 (2.2045) I
GRADE mark L 55.996 (2.2046)
GRADE mark M 55.997 (2.2046)
J
GRADE mark N 55.998 (2.2046)
GRADE mark O 55.999 (2.2047)
GRADE mark P 56.000 (2.2047) K
GRADE mark Q 56.001 (2.2048)
GRADE mark R 56.002 (2.2048)
L
GRADE mark S 56.003 (2.2048)
GRADE mark T 56.004 (2.2049)
GRADE mark U 56.005 (2.2049) M
Crankshaft pin journal diameter “Dp” 52.000 - 52.020 (2.0472 - 2.0480)
Crankshaft end play 0.05 - 0.70 (0.002 - 0.028)
Crankshaft for deformation Less than 0.03 (0.0012) N
Concentricity of the crankshaft journal Less than 0.02 (0.0008)
CONNECTING ROD O
Unit: mm (in)
Item Standard
Center distance (big end and small end) 157.23 - 157.27 (6.1901 - 6.1917) P

Item Standard
GRADE mark A 55.581 (2.1882)
GRADE mark B 55.582 (2.1883)
GRADE mark C 55.583 (2.1883)
GRADE mark D 55.584 (2.1883)
GRADE mark E 55.585 (2.1884)
GRADE mark F 55.586 (2.1884)
GRADE mark G 55.587 (2.1885)
GRADE mark H 55.588 (2.1885)
GRADE mark I 55.589 (2.1885)
GRADE mark J 55.590 (2.1886)
Connecting rod big end diameter
GRADE mark K 55.591 (2.1886)
GRADE mark L 55.592 (2.1887)
GRADE mark M 55.593 (2.1887)
GRADE mark N 55.594 (2.1887)
GRADE mark O 55.595 (2.1888)
GRADE mark P 55.596 (2.1888)
GRADE mark Q 55.597 (2.1889)
GRADE mark R 55.598 (2.1889)
GRADE mark S 55.599 (2.1889)
GRADE mark T 55.600 (2.1890)
Connecting rod bushing end diameter 32.02 - 32.04 (1.1819 - 1.1827)
Connecting rod bushing end oil clearance 0.020 - 0.038 (0.0008 - 0.0015)
Connecting rod side clearance 0.021 - 0.48 (0.0083 - 0.0189)
PISTON PROTRUSION GRADE

Unit: mm (in)
Item Standard
JPBIA0767ZZ
Grade A 47.86 - 47.90 (1.8842 - 1.8858)

Grade B 47.90 - 47.94 (1.8858 - 1.8874)
Piston height “ ” Grade C 47.94 - 47.98 (1.8874 - 1.8890)
Grade D 47.99 - 48.03 (1.8894 - 1.8909)
Grade E 48.03 - 48.07 (1.8909 - 1.8952)
Piston pin hole diameter “ ” 31.99 - 32.01 (1.2594 - 1.2604)

Piston to cylinder bore clearance 0.192 - 0.236 (0.0076 - 0.0093)
AVAILABLE PISTON

Unit: mm (in)
Item Standard A
EM
JPBIA0784ZZ
E
Piston skirt diameter “ ” 84.79 - 84.80 (3.3382 - 3.3386)
Measure point “ ” 44.0 (1.73)

F
I
JPBIA0640ZZ
Piston protrusion " " 0.36 - 0.52 mm (0.0142 - 0.0205 in)

J
JPBIA0633ZZ
N
Capacity of combustion chamber“ ” 24.65 - 25.35 cm3 (1.5041 - 1.546 cu in)
PISTON RING
Unit: mm (in) O
Items Standard
Top 0.09 - 0.13 (0.0035 - 0.0051)
P
Piston ring side clearance 2nd 0.08 - 0.12 (0.0031 - 0.0047)
Oil ring 0.05 (0.002)
Top 0.23 - 0.38 (0.0091 - 0.0150)
Piston ring end gap 2nd 0.60 - 0.80 (0.0236 - 0.0315)
Oil ring 0.25 - 0.50 (0.0098 - 0.020)
PISTON PIN
Unit: mm (in)
Items Standard
JPBIA0768ZZ
Length “ ” 65.7 - 24.15 (0.9390 - 0.9508)
Diameter of chamfer “ ” 23.85 - 24.15 (0.9390 - 0.9508)
Length of the chamfer “ ” 8.7 (0.343)
Piston pin inner diameter “ ” 13.8 - 14.1 (0.543 - 0.555)
Piston pin outer diameter ’“ ” 31.99 - 32.01 (1.2594 -1.2602)

Piston to piston pin oil clearance 0.012 - 0.023 (0.0005 - 0.0009)
CYLINDER BLOCK
Unit: mm (in)
Item Standard
Cylinder block top surface distortion 0.05 (0.0020)
Cylinder bore inner diameter 59.998 - 60.012 (2.3621 - 2.3627)
Grade mark A 59.9975 - 59.9985 (2.36210 - 2.36214)
Grade mark B 59.9985 - 59.9995 (2.36214 - 2.36218)
Grade mark C 59.9995 - 60.0005 (2.36218 - 2.36221)
Grade mark E 60.0005 - 60.0015 (2.36221 - 2.36226)
Grade mark H 60.0015 - 60.0025 (2.36226 - 2.36230)
Grade mark J 60.0025 - 60.0035 (2.36230 - 2.36233)
Cylinder block main bearing Grade mark K 60.0035 - 60.0045 (2.36233 - 2.36238)
housing inner diameter Grade mark L 60.0045 - 60.0055 (2.36238 - 2.36242)
Grade mark M 60.0055 - 60.0065 (2.36242 - 2.36246)
Grade mark P 60.0065 - 60.0075 (2.36426 - 2.36250)
Grade mark S 60.0075 - 60.0085 (2.36250 - 2.36253)
Grade mark T 60.0085 - 60.0095 (2.36253 - 2.36257)
Grade mark U 60.0095 - 60.0105 (2.36257 - 2.36261)
Grade mark Z 60.0105 - 60.0115 (2.36261 - 2.36265)
MAIN BEARING GRADE TABLE

Unit: mm (in)
Marking Thickness Identification color

7943R 1.989 (0.0783) Black
A
Lower shell 6716R 1.984 (0.0781) Red
bearing 6129R 1.980 (0.0780) Blue
1323R 1.976 (0.0778) Yellow EM
8933R 1.987 (0.0782) Black
Upper shell 5724R 1.983 (0.0781) Red

bearing 5296R 1.979 (0.0779) Blue C
2773R 1.975 (0.0778) Yellow
MAIN BEARING OIL CLEARANCE D

Unit: mm (in)
Main bearing oil clearance Standard 0.035 - 0.065 (0.0014 - 0.0026)
E
CONNECTING ROD BEARING OIL CLEARANCE F

Unit: mm (in)
Connecting rod bearing oil clearance Standard 0.053 - 0.093 (0.0021 - 0.0037)
G

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ENGINE

Revision: November 2016 EM-1 2017 D23

FRONT OIL SEAL ..................................................... 83 PREPARATION ................................................ 135

UNIT DISASSEMBLY AND ASSEMBLY ... 89 SYMPTOM DIAGNOSIS ........................... 147

ENGINE STAND SETTING ................................ 89 NOISE, VIBRATION AND HARSHNESS

Revision: November 2016 EM-2 2017 D23

Revision: November 2016 EM-3 2017 D23

CHARGE AIR COOLER ................................... 309

Revision: November 2016 EM-4 2017 D23

Revision: November 2016 EM-5 2017 D23

Revision: November 2016 EM-6 2017 D23

Precautions For Engine Service INFOID:0000000014267031

DRAINING ENGINE COOLANT G

ASSEMBLY AND INSTALLATION M

Revision: November 2016 EM-7 2017 D23

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

Identification mark of sodium-filled exhaust valve (A) :4JM

DEALER DISPOSAL INSTRUCTIONS

(A) : Black color

3. Use hacksaw to cut through approximately half the diameter of

(a) : 40 mm (1.57 in)

Revision: November 2016 EM-8 2017 D23

Tool number : KV10112100 (BT-8653-A)

Tool number (A) : KV10111100 (J-37228) O

LIQUID GASKET APPLICATION PROCEDURE

Revision: November 2016 EM-9 2017 D23

3. Attach liquid gasket tube to the suitable tool.

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

Revision: November 2016 EM-10 2017 D23

— Removing and installing spark plug

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

KV10114400 Loosening or tightening rear heated oxygen P

Revision: November 2016 EM-11 2017 D23

— Installing rear main seal

KV10112100 Tightening bolts for bearing cap, cylinder

Commercial Service Tool INFOID:0000000014267036

Tool number Description

KV10116200 Disassembling valve mechanism

— Removing and installing engine

Revision: November 2016 EM-12 2017 D23

— Pressing the tube of liquid gasket D

— Removing and installing crankshaft pulley

— Finishing valve seat dimensions

— Removing and installing piston ring P

Revision: November 2016 EM-13 2017 D23

— Removing and installing valve guide

— 1: Reaming valve guide inner hole

— Lubricating oxygen sensor thread cleaning

KV10115600 Installing valve oil seal

— Loosening nuts, screws, and bolts

KV10107902 Removing valve oil seal

Revision: November 2016 EM-14 2017 D23

KV10115300 Disassembling and assembling

Revision: November 2016 EM-15 2017 D23

b. Use a feeler gauge, measure the clearance between valve lifter

Valve clearance : Refer to EM-118, "Camshaft".

Revision: November 2016 EM-16 2017 D23

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

(A) : No. 4 cylinder at compression TDC

Revision: November 2016 EM-17 2017 D23