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ENGINE MECHANICAL SECTION

GI MA

EM

LC EC

CONTENTS
PRECAUTIONS ...............................................................3 Parts Requiring Angular Tightening.............................3 Liquid Gasket Application Procedure ..........................3 PREPARATION ...............................................................4 Special Service Tools ..................................................4 Commercial Service Tools ...........................................6 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .....................................................7 NVH Troubleshooting - Engine Noise .........................8 OUTER COMPONENT PARTS .......................................9 Removal and Installation .............................................9 TIGHTENING PROCEDURES ...................................11 MEASUREMENT OF COMPRESSION PRESSURE ....13 OIL PAN.........................................................................14 Components...............................................................14 Removal.....................................................................14 Installation..................................................................17 FRONT TIMING CHAIN CASE......................................21 Removal.....................................................................21 Installation..................................................................24 TIMING CHAIN ..............................................................29 Components...............................................................29 POSITION FOR APPLYING LIQUID GASKET ............31 Removal.....................................................................32 Inspection...................................................................39 Installation..................................................................39 OIL SEAL.......................................................................47 Replacement..............................................................47 VALVE OIL SEAL .....................................................47 FRONT OIL SEAL ....................................................48 REAR OIL SEAL ......................................................48 CYLINDER HEAD..........................................................50 Components...............................................................50 Removal.....................................................................51 Disassembly...............................................................54 Inspection...................................................................55 CYLINDER HEAD DISTORTION ...............................55 CAMSHAFT VISUAL CHECK ....................................55 CAMSHAFT RUNOUT ..............................................55
CAMSHAFT CAM HEIGHT .......................................55 CAMSHAFT JOURNAL CLEARANCE ........................56 CAMSHAFT END PLAY............................................56 CAMSHAFT SPROCKET RUNOUT ...........................57 VALVE GUIDE CLEARANCE ....................................57 VALVE GUIDE REPLACEMENT ................................57 VALVE SEATS .........................................................58 REPLACING VALVE SEAT FOR SERVICE PARTS ....58 VALVE DIMENSIONS ...............................................59 VALVE SPRING .......................................................59 VALVE LIFTER ........................................................60

FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

Assembly ...................................................................60 Installation..................................................................61 Valve Clearance.........................................................66 CHECKING .............................................................66 ADJUSTING ............................................................68 ENGINE ASSEMBLY.....................................................69 Removal and Installation ...........................................69 REMOVAL ...............................................................70 INSTALLATION........................................................72 CYLINDER BLOCK .......................................................73 Components...............................................................73 Removal and Installation ...........................................74 Disassembly...............................................................74 PISTON, CRANKSHAFT AND OIL JET ......................74 Inspection...................................................................75 PISTON AND PISTON PIN CLEARANCE ..................75 PISTON RING SIDE CLEARANCE ............................75 PISTON RING END GAP..........................................75 CONNECTING ROD BEND AND TORSION ...............76 CYLINDER BLOCK DISTORTION AND WEAR ...........76 PISTON-TO-BORE CLEARANCE ..............................77 CRANKSHAFT.........................................................78 BEARING CLEARANCE ...........................................78
CONNECTING ROD BUSHING CLEARANCE (SMALL END) ..........................................................81 REPLACEMENT OF CONNECTING ROD BUSHING (SMALL END) ..........................................81 FLYWHEEL/DRIVE PLATE RUNOUT ........................82 MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS) ................................................................82

CONTENTS
Assembly ...................................................................83 PISTON ..................................................................83 OIL JET ..................................................................83 CRANKSHAFT.........................................................84 KNOCK SENSOR ....................................................86
REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T)........................................87 FLYWHEEL .............................................................87 DRIVE PLATE .........................................................87

(Cont’d)

SERVICE DATA AND SPECIFICATIONS (SDS) .........88 General Specifications...............................................88 Compression Pressure ..............................................88 Cylinder Head ............................................................88 Valve ..........................................................................89 VALVE ....................................................................89 VALVE CLEARANCE................................................89 VALVE SPRING .......................................................89 VALVE LIFTER ........................................................89

VALVE GUIDE .........................................................91 Valve Seat..................................................................92 Camshaft and Camshaft Bearing ..............................93 Cylinder Block............................................................94 Piston, Piston Ring and Piston Pin ...........................95 AVAILABLE PISTON ................................................95 PISTON RING .........................................................96 PISTON PIN ............................................................96 Connecting Rod .........................................................96 Crankshaft..................................................................97 Available Main Bearing..............................................98 UNDERSIZE ............................................................98 Available Connecting Rod Bearing............................99 CONNECTING ROD BEARING .................................99 UNDERSIZE ............................................................99 Miscellaneous Components.......................................99 BEARING CLEARANCE ...........................................99

EM-2

PRECAUTIONS
Parts Requiring Angular Tightening

Parts Requiring Angular Tightening
¼ a) b) c) d) ¼ ¼ ¼

NFEM0001

Use an angle wrench for the final tightening of the following engine parts: Cylinder head bolts Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolt Do not use a torque value for final tightening. The torque values for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil.

GI MA

LC EC FE CL MT

Liquid Gasket Application Procedure
1.

NFEM0002

2. ¼

Use a scraper to remove all traces of old liquid gasket from mating surfaces and grooves. Also, completely clean any oil from these areas. Apply a continuous bead of liquid gasket to mating surfaces. (Use Genuine RTV silicone sealant or equivalent. Refer to GI-51.) Be sure liquid gasket diameter is as specified in this manual.

AT AX SU BR

SEM164F

3. 4. 5.

Apply liquid gasket around the inner side of bolt holes (unless otherwise specified). Assembly should be done within 5 minutes after coating. Wait at least 30 minutes before refilling engine oil and engine coolant.

ST RS BT HA

AEM080

SC EL IDX

EM-3

51) dia.) Tool name ST0501S000 ( — ) Engine stand assembly 1 ST05011000 ( — ) Engine stand 2 ST05012000 ( — ) Base NT042 NFEM0003 Description Disassembling and assembling KV10106500 ( — ) Engine stand shaft NT028 KV10117000 (J41262) Engine sub-attachment KV10117000 has been replaced with KV10117001 (KV10117000 is no longer in production. but it is usable). b: 12 (0.39) Unit: mm (in) NT583 KV10116200 (J26336-A) Valve spring compressor 1 KV10115900 (J26336-20) Attachment NT022 Disassembling valve mechanism EM-4 . NT373 KV10117001 ( — ) Engine sub-attachment Installing on the cylinder block NT372 ST10120000 (J24239-01) Cylinder head bolt wrench Loosening and tightening cylinder head bolt a: 13 (0. Tool number (Kent-Moore No.PREPARATION Special Service Tools Special Service Tools The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.47) c: 10 (0.

87 in) hexagon nut KV10117100 (J3647-A) Heated oxygen sensor wrench HA SC NT379 EL IDX EM-5 . etc.PREPARATION Special Service Tools (Cont’d) Tool number (Kent-Moore No. cylinder head. KV10112100 (BT8653-A) Angle wrench ST RS NT014 BT Loosening or tightening heated oxygen sensor For 22 mm (0.) Tool name (J39386) Valve oil seal drift Description Installing valve oil seal GI MA NT024 EM03470000 (J8037) Piston ring compressor Installing piston assembly into cylinder bore LC EC NT044 ST16610001 (J23907) Pilot bushing puller Removing crankshaft pilot bushing FE CL NT045 KV10111100 (J37228) Seal cutter Removing steel oil pan and rear timing chain case MT AT NT046 AX Pressing the tube of liquid gasket WS39930000 ( — Tube presser ) SU NT052 BR Tightening bolts for bearing cap.

NT016 (J-43897-18) (J-43897-12) Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.0 mm (0.) Tool name Spark plug wrench Description Removing and installing spark plug NFEM0004 NT047 Valve seat cutter set Finishing valve seat dimensions NT048 Piston ring expander Removing and installing piston ring NT030 Valve guide drift Removing and installing valve guide Intake & Exhaust: a = 9.217 in) dia.402 in) dia.5 mm (0.) for titania heated oxygen sensor AEM488 Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A907) Lubricating heated oxygen sensor thread cleaning tool when reconditioning exhaust system threads AEM489 EM-6 . d2 = 10.5 mm (0. b = 5.2 mm (0.374 in) dia.236 in) dia.) a = J-43897-18 (18 mm dia. NT015 Valve guide reamer Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1 = 6.) for zirconia heated oxygen sensor b = J-43897-12 (12 mm dia.PREPARATION Commercial Service Tools Commercial Service Tools Tool number (Kent-Moore No.

NFEM0005 NOISE. VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING GI MA LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX SEM706G EM-7 .

2. 4. EM-75. 3. Check specified noise source. EM-76 A B C B B B Connecting rod bushing clearance (Small EM-81. “ENGINE MAINTENANCE”) LC section (“Water Pump Inspection”.NOISE. Confirm the type of noise. EM-75. “ENGINE COOLING SYSTEM”) Squall Creak A B — B A B Water pump noise Water pump operation A: Closely related B: Related C: Sometimes related —: Not related EM-8 . EM-29 Squeaking or fizzing A B — B — C Drive belts (Sticking Drive belts deflection or slipping) Drive belts Idler pulley bearing (Slipping) operation Creaking Front of engine A B A B A B MA section (“Checking Drive Belts”. end) EM-80 Connecting rod bearing clearance (Big end) EM-78. Specify the operating condition of engine. Locate the area where noise occurs. repair or replace these parts. If necessary. Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head Type of noise Ticking or clicking Before After When warm-up warm-up starting C A — When idling A When While revving driving B — Source of noise Tappet noise Camshaft bearing noise Piston pin noise Check item Reference page Valve clearance EM-66 Rattle C A — A B C Camshaft journal clearEM-56. ance EM-55 Camshaft runout Piston and piston pin clearance Connecting rod bushing clearance EM-75. 1. VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting — Engine Noise NVH Troubleshooting — Engine Noise NFEM0005S01 Use the chart below to help you find the cause of the symptom. EM-81 Slap or knock — A — B B — Crankshaft Slap or pulley rap Cylinder block (Side of engine) Oil pan Knock A — — B B A Piston-to-bore clearance Piston ring side clearPiston slap ance noise Piston ring end gap Connecting rod bend and torsion Connecting rod bearing noise EM-77. EM-78 Knock Front of engine Timing chain cover A B — A B C Main bearing oil clearMain bearance ing noise Crankshaft runout Timing chain and chain tensioner noise Timing chain cracks and wear Timing chain tensioner operation Tapping or ticking A A — B B B EM-39.

Power valve VIAS control solenoid valve Fuel tube Fuel damper 9. 12. 10. 3. 8. 11. 6. 7. 2.OUTER COMPONENT PARTS Removal and Installation Removal and Installation NFEM0006 GI MA LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL SEM707GA 1. Electronic control throttle actuator Intake manifold upper collector EVAP canister purge volume control solenoid valve Intake manifold lower collector 5. 4. Fuel damper Vacuum tank Intake manifold Service port IDX EM-9 .

6. Heated oxygen sensor 1 (bank 1) Exhaust manifold TWC (manifold) 4. 2. 9. Thermostat with water inlet Exhaust manifold Heated oxygen sensor 1 (bank 2) 7.OUTER COMPONENT PARTS Removal and Installation (Cont’d) SEM708GA 1. 8. 5. TWC (manifold) Heated oxygen sensor 2 (bank 2) Water outlet EM-10 . 3.

6. Tighten all bolts and nuts to 4. Refer to “BASIC SERVICE PROCEDURE” in EC section. 64 to 84 inlb). ¼ Tighten screws evenly several times to have the fuel damper tightened to the specified torque.3 to 10.39 kg-m. 26.5 N·m (2.0 to 33.9 ft-lb). ¼ Always replace O-ring with new ones. Tighten in numerical order shown in the figure.9 in-lb). AT AX SU BR SEM952F Electronic Control Throttle Actuator SEM711G ¼ Tighten in numerical order shown in the figure. Tighten all bolts and nuts to the final torque. 2. Tighten all bolts to 7.95 to 1. 2.4 N·m (2. 4 to 7 ft-lb).6 to 26. 20 to 23 ft-lb).97 kg-m.74 to 0.8 N·m (0.9 to 3. NFEM0006S0105 ST RS BT HA SC EL IDX EM-11 .9 to 9.99 kg-m. ¼ Perform “Idle Air Volume Learning” when electronic throttle control actuator is replaced.1 kg-m.8 N·m (0. NFEM0006S0102 GI MA LC EC FE CL Fuel Tube ¼ 1. CAUTION: ¼ Perform “Throttle Valve Closed Position Learning” when harness connector of electronic throttle control actuator is disconnected.9 to 7.2 kg-m.7 kg-m.6 N·m (0.2 to 9. evenly dividing the tightening into at least three steps. ¼ Lubricate O-ring with new engine oil.50 to 0. 16 to 19 ft-lb).1 to 2.OUTER COMPONENT PARTS Removal and Installation (Cont’d) TIGHTENING PROCEDURES Intake Manifold ¼ ¼ 1.8 N·m (0.7 to 3. Then tighten all bolts to 20. ¼ SEM709G NFEM0006S01 NFEM0006S0101 Loosen in reverse order shown in the figure. Tighten in numerical order shown in the figure.3 to 0. Refer to “BASIC SERVICE PROCEDURE” in EC section. SEM710G MT Fuel Damper NFEM0006S0103 Tighten fuel damper to 2. Finally tighten all bolts and nuts to 26.5 to 31. Tighten all bolts to 9.

OUTER COMPONENT PARTS
Removal and Installation (Cont’d)

Intake Manifold Upper Collector
¼ ¼

NFEM0006S0108

Loosen in reverse order shown in the figure. Tighten in numerical order shown in the figure. Tighten all bolts to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb).

SEM712G

Intake Manifold Lower Collector
¼ ¼

NFEM0006S0107

Loosen in reverse order shown in the figure. Tighten in numerical order shown in the figure. Tighten bolts and nuts to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb).

SEM713G

Power Valve
¼

NFEM0006S0109

Tighten in numerical order shown in the figure. Tighten all bolts to 17.6 to 21.6 N·m (1.8 to 2.2 kg-m, 13 to 15 ft-lb).

SEM714G

Exhaust Manifold
¼ ¼

NFEM0006S0110

Loosen in reverse order shown in the figure. Tighten in numerical order shown in the figure. Tighten nuts to 28.4 to 33.3 N·m (2.9 to 3.3 kg-m, 21 to 24 ftlb).

JEM802G

JEM803G

EM-12

NFEM0007

MEASUREMENT OF COMPRESSION PRESSURE
1. 2. 3. ¼ 4. 5. 6.
SEM087G

Warm up engine. Turn ignition switch OFF. Release fuel pressure. Refer to EC-56, procedure without CONSULT-II of “Fuel Pressure Release”. Remove fuel pump fuse until the end of step 11. Disconnect ignition coil with power transistor harness connectors, then remove ignition coils. Remove all spark plugs. Remove fuse for fuel injector.

GI MA

LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX

7. 8.

Attach a compression tester to No. 1 cylinder. Depress accelerator pedal fully to keep throttle valve wide open. 9. Crank engine and record highest gauge indication. 10. Repeat the measurement on each cylinder as shown in the figure. ¼ Always use a fully-charged battery to obtain specified engine speed.
Unit: kPa (kg/cm2, psi)/rpm
SEM909E

Standard 1,275 (13.0, 185)/300

Minimum 981 (10.0, 142)/300

Difference limit between cylinders 98 (1.0, 14)/300

SEM387CA

11. If compression in one or more cylinders is low: a. Pour a small amount of engine oil into cylinders through spark plug holes. b. Retest compression. ¼ If adding oil helps compression, piston rings may be worn or damaged. If so, replace piston rings after checking piston. ¼ If pressure stays low, a valve may be sticking or seating improperly. Inspect and repair valve and valve seat. (Refer to SDS, EM-89 and EM-92.) If valve or valve seat is damaged excessively, replace them. ¼ If compression stays low in two cylinders that are next to each other: a) The cylinder head gasket may be leaking, or b) Both cylinders may have valve component damage. Inspect and repair as necessary. 12. Install removed parts in reverse order of removal.

EM-13

OIL PAN
Components

Components

NFEM0008

SEM830GA

Removal

NFEM0009

CAUTION: When removing the aluminum oil pan from engine, first remove the crankshaft position sensor (POS) from the assembly. Be careful not to damage sensor edges and signal plate teeth. 1. Remove engine undercover. 2. Drain engine oil. ¼ To avoid the danger of being scalded, never drain the engine oil when the engine is hot. 3. Loosen steel oil pan bolts in reverse order shown in the figure.

SEM956F

EM-14

ST RS BT HA SEM716G SC EL IDX EM-15 . Be careful not to damage aluminum mating surface.OIL PAN Removal (Cont’d) 4. Refer to FE-9. Do not insert screwdriver. Remove oil strainer. EC FE CL SEM960F MT 5. Slide seal cutter by tapping on the side of it with a hammer. a. Insert seal cutter between aluminum oil pan and steel oil pan. or oil pan flange will be deformed. GI MA SEM957F LC b. AT AX SU BR SEM575GA 6. “Removal and Installation”. Remove steel oil pan. c. ¼ ¼ Remove steel oil pan. Remove front exhaust tube and its support.

SEM811E 11. Remove oil filter. 10. Refer to HA-144 or HA-231. Remove oil cooler. Remove oil filter. c. 8. SEM154F EM-16 . a. “REMOVAL AND INSTALLATION”. Remove center member. Remove rear cover plate. Remove air conditioner compressor and bracket. “Checking Drive Belts”. Disconnect water hoses from oil cooler. Loosen front and rear engine mounting nuts and bolts. Remove drive belts.OIL PAN Removal (Cont’d) 7. SEM717G 14. Set a suitable transmission jack under transaxle and hoist engine with engine slinger. oil cooler fixing bolt and water hoses or pipes as follows. b. Refer to MA-13. while pinching hose to prevent coolant from spilling. 13. Remove crankshaft position sensor (POS) from oil pan. 9. 12.

¼ Be careful not to damage aluminum mating surface. a. AT AX SU BR SEM155F 18. or oil pan flange will be deformed. Loosen aluminum oil pan bolts in numerical order as shown in the figure. ST RS BT HA SEM819E Installation 1. Remove aluminum oil pan. b. Remove old liquid gasket from the bolt hole and thread. Pry off aluminum oil pan by moving the tool up and down. ¼ Do not insert screwdriver. Loosen aluminum oil pan. MEM108A EM-17 . Loosen four engine-to-transaxle bolts. Also remove old liquid gasket from mating surface of cylinder block. ¼ ¼ NFEM0010 SC EL IDX Install aluminum oil pan. c.OIL PAN Removal (Cont’d) 15. front cover and steel oil pan. Remove O-rings from cylinder block and oil pump body. EC FE CL SEM949G MT 17. Use a scraper to remove old liquid gasket from mating surfaces. Insert an appropriate size tool into the notch of aluminum oil pan as shown in the figure. GI MA SEM184F LC 16. a.

0 mm (0. Apply sealant to front cover gasket and rear oil seal retainer gasket. ¼ Tighten aluminum oil pan fixing bolts. Apply a bead of 4.0 to 5. ¼ ¼ ¼ ¼ SEM034H Apply liquid gasket to inner sealing surface as shown in figure. ¼ Apply a continuous bead of liquid gasket to mating surface of aluminum oil pan. Install O-rings.217 in) in diameter to area “A”. Assembly should be done within 5 minutes after coating. e. ¼ ¼ g. water hose and pipes.177 to 0. Install oil cooler. SEM819E f.OIL PAN Installation (Cont’d) b. Wait at least 30 minutes before refilling engine oil. refer to LC-9. Be sure liquid gasket is 4. Tighten bolts in numerical order.5 to 5. Use Genuine RTV silicone sealant or equivalent. cylinder block and oil pump body.177 to 0.5 mm (0.197 in) or 4. “Oil Cooler”. apply liquid gasket outside of the holes. SEM964E c. For tightening torque of the oil cooler fixing bolt. For bolt holes with 5 marks (5 locations).157 to 0.5 to 5.5 mm (0. SEM186F EM-18 . d. Refer to GI-51.217 in) wide as shown in the figure.

and heated oxygen sensor 1 (bank 2) harness clamp. For tightening torque. EC FE CL SEM717G MT 4. Install steel oil pan. ¼ Make sure that crankshaft position sensor (POS) and heated oxygen sensor 1 (bank 2) harness clamp are installed correctly as shown in figure. 10. Install drive belts. Install rear cover plate. “Installation”. refer to AT-286 or MT-15. GI MA SEM949G LC 3. ¼ Also remove old liquid gasket from mating surface of aluminum oil pan. Refer to HA-144. AT AX SU BR 8. 7. Tighten front and rear engine mounting insulator nuts and bolts. “REMOVAL AND INSTALLATION”. ST RS BT HA SEM222FD 11. Install oil strainer. Use a scraper to remove old liquid gasket from mating surfaces. Install front exhaust tube and its support. Install crankshaft position sensor (POS) with new rubber seal. Install air conditioner compressor and bracket. SC EL IDX SEM958F EM-19 . Install the four engine-to-transaxle bolts.OIL PAN Installation (Cont’d) 2. 5. 6. a. 9. Install center member.

¼ Warm up engine and check for oil leakage. SEM956F 12. SEM959F c. EM-20 . Wait at least 30 minutes before refilling engine oil. Refer to GI-51. Assembly should be done within 5 minutes after coating.OIL PAN Installation (Cont’d) b. Tighten in numerical order shown in the figure.5 mm (0. Install in the reverse order for remaining steps. ¼ Apply a continuous bead of liquid gasket to mating surface of steel oil pan. SEM159F ¼ ¼ Be sure liquid gasket is 4.217 in) wide.5 to 5. ¼ Check oil level after refilling engine oil. Use Genuine RTV silicone sealant or equivalent.177 to 0. ¼ ¼ Install steel oil pan.

2. ¼ Water hoses ¼ EVAP canister purge hose GI MA LC EC FE CL MT AT AX SU BR 6. Drain engine oil. Remove intake manifold lower collectors loosening bolts in reverse order shown in the figure. 1. ¼ To avoid the danger of being scalded. Refer to EM-29. “TIMING CHAIN”. and install in reverse order of removal. 4. and rear timing chain case in this order. ¼ When secondary timing chain is not removed/installed. collector. “Changing Engine Coolant”. vacuum hoses. ¼ When oil pan (upper) needs to be removed or installed. Remove air duct to intake manifold. Drain coolant by removing cylinder block drain plugs. Refer to MA-14. Remove ornament cover. timing chain related parts. connectors and so on. or when rear timing chain case is removed or installed.FRONT TIMING CHAIN CASE Removal Removal NFEM0071 NOTE: ¼ This section describes removal/installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on vehicle. never drain the engine oil when the engine is hot. ST RS BT HA SEM712G 7. Remove intake manifold upper collectors loosening bolts and nuts in reverse order shown in the figure. “TIMING CHAIN” for component parts location. PCV hose. remove oil pans (upper and lower) first. the steps from 2 to 10 are not required. harness. SC EL IDX SEM713G EM-21 . 5. 3. Remove the following. ¼ Refer to EM-29. fuel hoses. Then remove front timing chain case.

Refer to MA-13. Set No. Remove RH and LH intake valve timing control solenoid valves. Remove drive belts and idler pulley bracket. “Components”. ¼ Loosen bolts in numerical order shown in the figure. SEM722G 9. “Components”. SEM831G 11. SEM918G EM-22 . Remove RH and LH rocker covers from cylinder head. SEM725G 10. 15. Remove power steering oil pump assembly. 13. 16. Remove RH and LH ignition coils. “Checking Drive Belts” and EM-29. Refer to ST-24. Remove engine undercover. Remove front RH wheel and engine side cover. Refer to SC-31. 1 piston at TDC on the compression stroke by rotating crankshaft. “ REMOVAL”. Remove alternator.FRONT TIMING CHAIN CASE Removal (Cont’d) 8. 14. 12. ¼ Disregard this step when timing chain removal is not necessary.

EC FE CL MT AT AX SU BR SEM965F 18. (At this time remove oil pan rear cover plate and set a suitable tool to ring gear so that crankshaft cannot rotate.FRONT TIMING CHAIN CASE Removal (Cont’d) ¼ Check that intake and exhaust cam noses on No. 1 cylinder is at its compression TDC. Support steel oil pan bottom with a transmission jack. Loosen crankshaft pulley bolt. and remove installation bolts at the front of aluminum oil pan. 21. GI MA SEM418G LC 17. SC EL IDX SEM921G EM-23 . “Removal”. Then check mating marks on camshaft sprockets. Install steel oil pan temporarily. 19. remove front timing chain case first. 1 cylinder are located as shown. If not.) ¼ Be careful not to damage the signal plate teeth. Refer to EM-39. turn the crankshaft one revolution (360°) and align as shown in the figure. ST RS BT HA SEM915E 20. Refer to EM-14. “Installation”. Loosen bolts in reverse order shown in figure. Remove steel oil pan. To confirm that No. Remove crankshaft pulley with a suitable puller. rocker cover does not need to be removed. ¼ Perform following operations with engine front-side supported with jack. 22. When only primary timing chain is removed.

CAUTION: ¼ Do not use screwdrivers or something similar. Refer to EM-48. or warp under a load. 31. handle it carefully so it does not tilt. Remove intake valve timing control covers. CAUTION: Be careful not to allow gasket fragments to enter oil pan. Refer to EM-39. NFEM0072 Install timing chain and related parts.FRONT TIMING CHAIN CASE Removal (Cont’d) 23. ¼ ¼ Remove center member assembly. 24. In the cover. 26. (This secures workspace to remove front timing chain case. Raise engine front-side with jack. the shaft is engaged with the center hole of the intake camshaft sprocket. mounting bracket and nuts. Remove right side engine mounting. EM-24 . “Removal”. Insert the appropriate size tool into the notch at the top of the front timing chain case as shown (1). “FRONT OIL SEAL”. “Installation”. Pry off the case by moving the tool as shown (2). a. 30. Installation 1. Remove front timing chain case. Remove front oil seal from front timing chain case. Remove it straight out until the engagement comes off. Loosen bolts in reverse order shown in the figure. “Removal and Installation”. 2.) SEM728G 27. Refer to EM-32. ¼ After removal. ¼ Use seal cutter (special service tool) or an equivalent tool to cut liquid gasket for removal. 25. Loosen front timing chain case bolts in reverse order shown in the figure. Remove water pump cover and timing chain tensioner cover from front timing chain case. Refer to EM-69. Remove residual gasket from front timing chain case and liquid gasket mating surface. SEM730G 28. Remove timing chain and related parts. ¼ Use seal cutter (special service tool) or an equivalent tool to cut liquid gasket for removal. cant. b. SEM156F 29.

“Installation”. Refer to GI-51. Apply new engine oil to the oil seal edges. ¼ Install the front oil seal on the front timing chain case. GI MA PBIC1101E LC 4. Install it so that each seal lip is oriented as shown in figure.FRONT TIMING CHAIN CASE Installation (Cont’d) 3. ¼ Install the water pump cover and the chain tensioner cover to front timing chain case cover. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length. “RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS” and LC-16. EC FE CL SEM715A MT ¼ ¼ Using a suitable drift. Make sure the garter spring is in position and seal lip is not inverted. AT AX SU BR PBIC0790E 5. Apply RTV Silicone Sealant or equivalent. ST RS BT HA SEM744GA SC EL IDX EM-25 . press-fit oil seal until it becomes flush with front timing chain case end face.

Install front timing chain case as follows: Apply liquid gasket to front timing chain case back side as shown. refer to the step 9. “RECOMMENDED CHEMICALPRODUCTSAND SEALANTS”. Hammer dowel pin until the outer end becomes flush with surface. Refer to GI-51. a. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). Install dowel pin on the rear timing chain case into dowel pin hole on front timing chain case. assemble front timing chain case. install bolts and temporarily tighten them.FRONT TIMING CHAIN CASE Installation (Cont’d) 6. While pressing front timing chain case from its front and top as shown in figure. b. ¼ Apply liquid gasket to top surface of oil pan (upper) as shown in figure. a. For bolt length and positions. make entire front timing chain case contact rear timing chain case completely. c. Use Genuine RTV Silicone Sealant or equivalent. PBIC1115E EM-26 . PBIC1100E b. CAUTION: Be careful that oil pan gasket is in place. PBIC1099E 8. As shown in the figure. PBIC0913E 7. From the fitting point.

bolts: 1.6 N·m (1. Use Genuine RTV Silicone Sealant or equivalent. 8 mm (0. Being careful not to move the seal ring from the installation groove.1. AT AX SU BR KBIA1314E c.6 . Tighten two mounting bolts in front of oil pan (upper) in numerical order shown in figure.7 . ¼ Tighten bolts to the specified torque in order shown in the figure. GI MA SEM730G LC 10. bolts: Except the above After tightening. SC EL IDX SEM728G EM-27 .31 in) dia.13 ft-lb) EC FE CL SEM921G MT 11. Refer to GI-51. e. Apply liquid gasket to the intake valve timing control covers.FRONT TIMING CHAIN CASE Installation (Cont’d) 9. a. Install collared O-ring in front timing chain case oil hole (LH and RH sides).24 in) dia. Tighten bolts in the numerical order as shown. ¼ Install RH and LH intake valve timing control covers as follows: Install seal rings in shaft grooves. 12 . “RECOMMENDED CHEMICALPRODUCTSAND SEALANTS”.9 kg-m. ST RS BT HA SEM948G d.18. 2 6 mm (0. align the dowel pins on the chain case with the holes to install the intake valve timing control covers. retighten them to specified torque in numerical order shown in the figure. b. : 15.

FRONT TIMING CHAIN CASE
Installation (Cont’d)

12. Install crankshaft pulley as follows: a. Fix crankshaft using a suitable tool. b. Install crankshaft pulley, taking care not to damage front oil seal. ¼ When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). c. Tighten bolt to 39.2 to 49.0 N·m (4.0 to 5.0 kg-m, 29 to 36 ftlb).

d.

Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by 60 to 66 degrees [Target: 60 degrees (equivalent to one graduation)].

SEM751G

13. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly. 14. For the following operations, perform steps in the reverse order of removal. ¼ If hydraulic pressure inside chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.

EM-28

TIMING CHAIN
Components

Components

NFEM0073

GI MA

LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX
SEM964G

EM-29

TIMING CHAIN
Components (Cont’d)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Timing chain tensioner Internal chain guide Timing chain tensioner Camshaft sprocket (EXH) Timing chain (Secondary) Timing chain (Primary) Camshaft sprocket (INT) Camshaft sprocket (EXH) Timing chain (Secondary) Camshaft sprocket (INT) 11. 12. 13. 14. 15. 16. 17. 18. 19. Slack guide Crankshaft sprocket Timing chain tensioner Intake valve timing control cover Chain tensioner cover Mounting bracket Water hose clamp Water pump cover Intake valve timing control cover 20. 21. 22. 23. 24. 25. 26. 27. 28. Front oil seal Crankshaft pulley Idler pulley Idler pulley bracket Front timing chain case Rear timing chain case Water drain plug Tension guide O-ring

EM-30

in GI MA LC EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX SEM720GA CAUTION: ¼ After removing timing chain. wipe off the protruding sealant. do not turn crankshaft and EM-31 .TIMING CHAIN Components (Cont’d) POSITION FOR APPLYING LIQUID GASKET =NFEM0073S01 Refer to “Liquid Gasket Application Procedure” “PRECAUTIONS”. EM-3. ¼ Before installation.

SEM712G EM-32 . wires. etc. Before disconnecting fuel hose. Removal NFEM0074 NOTE: ¼ This section describes removal and installation procedure for front timing chain. Do not spill engine coolant on drive belts. oil seals. 1. timing chain and its related parts without removing oil pan (upper). Be careful not to damage sensor edges. release fuel pressure. harness.TIMING CHAIN Components (Cont’d) ¼ ¼ ¼ ¼ ¼ camshaft separately. Drain coolant by removing cylinder block drain plugs. 3. ¼ To avoid the danger of being scalded. 5. or valves will strike piston heads. PCV hose. “Changing Engine Coolant”. Remove ornament cover. first remove the crankshaft position sensor (POS) from the assembly. timing chain related parts. 2. When removing the oil pans. connectors and so on. When installing camshafts. Remove the following. 4. crankshaft pulley and camshaft brackets. oil pump assembly and timing chain from engine. and rear timing chain case when oil pan (upper) needs to be removed/installed for engine overhaul. Remove intake manifold upper collectors loosening bolts and nuts in reverse order shown in the figure. fuel hoses. ¼ Water hoses ¼ EVAP canister purge hose 6. or other sliding parts. camshaft sprockets. “FRONT TIMING CHAIN CASE” to remove and install front timing chain case. Refer to EC-56. Apply new engine oil to bolt threads and seat surfaces when installing cylinder head. ¼ Refer to EM-21. chain tensioners. vacuum hoses. Remove air duct to intake manifold. lubricate contacting surfaces with new engine oil. never drain the engine oil when the engine is hot. Refer to MA-14. “Fuel Pressure Release”. collector. Drain engine oil.

Remove engine undercover. Remove RH and LH intake valve timing control solenoid valves. EC FE CL SEM722G MT 9. Remove front RH wheel and engine side cover. Remove RH and LH rocker covers from cylinder head.TIMING CHAIN Removal (Cont’d) 7. 15. Remove drive belts and idler pulley bracket. Remove power steering oil pump assembly. AT AX SU BR SEM725G 10. “Checking Drive Belts” and EM-29. Refer to ST-24. 13. 12. “Components”. Remove intake manifold lower collectors loosening bolts in reverse order shown in the figure. ¼ Loosen bolts in numerical order shown in the figure. “Components”. SC EL IDX EM-33 . 14. Remove RH and LH ignition coils. ST RS BT HA SEM831G 11. Remove alternator. GI MA SEM713G LC 8. “REMOVAL”. Refer to MA-13. Refer to SC-31.

1 cylinder are installed as shown. SEM418G 18. 1 piston at TDC on the compression stroke by rotating crankshaft. turn the crankshaft one revolution (360°) and align as shown. Set No. SEM918G ¼ Check that intake and exhaust cam noses on No. Remove crankshaft position sensor (POS).TIMING CHAIN Removal (Cont’d) 16. If not. SEM750G 17. SEM965F EM-34 . Loosen crankshaft pulley bolt. (At this time remove oil pan rear cover plate and set a suitable tool to ring gear so that crankshaft cannot rotate.) ¼ Be careful not to damage the signal plate teeth.

Refer to FE-9. Remove right side engine mounting. Hang engine at right and left side engine slingers with a suitable hoist. the shaft is engaged with the center hole of the intake camshaft sprocket. Remove intake valve timing control covers. 24. Pry off the case by moving the tool as shown (2). Insert the appropriate size tool into the notch at the top of the front timing chain case as shown (1). ¼ In the cover. Remove it straight out until the engagement comes off. ¼ After removal. “REMOVAL AND INSTALLATION”. “Removal and Installation”. Remove upper and lower oil pans. Remove center member assembly. ¼ Loosen bolts in reverse order shown in the figure. 26. CAUTION: ¼ Do not use screwdrivers or something similar. a. AT AX SU BR ST RS BT HA SEM730G 28. b. handle it carefully so it does not tilt. “Removal and Installation”. GI MA SEM915E LC 20. Refer to EM-69. ¼ Use seal cutter (special service tool) or an equivalent tool to cut liquid gasket for removal. Remove front exhaust tube and its support. “EXHAUST SYSTEM”. 22. 23. Remove crankshaft pulley with a suitable puller. “Removal”.TIMING CHAIN Removal (Cont’d) 19. Refer to EM-69. cant. 27. Loosen front timing chain case bolts in reverse order shown in the figure. Refer to EM-14. or warp under a load. 25. Remove air conditioner compressor. Refer to HA-144. SEM156F SC EL IDX EM-35 . EC FE CL SEM728G MT 21. mounting bracket and nuts. Remove front timing chain case.

Remove internal chain guide.5 mm (0. Remove water pump cover and timing chain tensioner cover from front timing chain case. 32. b) Insert stopper pin into tensioner body hole to fix lever. 30. and keep the tab released. Refer to EM-48. d) Keep slack guide pressed. 33. c) Insert plunger into tensioner body by pressing slack guide.098 in)] is used for stopper pin as an example. Allen wrench [2. SEM733G EM-36 . Pull lever down. ¼ In figure. SEM731G ¼ a) ¼ SEM732G Remove chain tensioner as follows. e) Loosen mounting bolts. Remove primary timing chain and crankshaft sprocket. and fix it by pushing stopper pin through lever hole and body hole. Plunger stopper tab can be pushed up to release (coaxial structure with lever). Remove front oil seal from front timing chain case. “FRONT OIL SEAL”.TIMING CHAIN Removal (Cont’d) 29. and release plunger stopper tab. and remove chain tensioner. 31. Remove timing chain tensioner and slack side chain guide.

Loosen intake and exhaust camshaft sprocket bolts. Disconnect liquid gasket applied portion using seal cutter (special service tool: KV10111100) or an equivalent tool. Remove rear timing chain case as follows. a. Attach a suitable stopper pin to RH and LH camshaft chain tensioners. Use caution during removal. Remove secondary timing chains with camshaft sprockets. ¼ Do not disassemble (Never loosen bolts A and B). Remove cam sprocket and secondary timing chain with timing chain floated from guide groove.5 mm (0. Loosen mounting bolts in reverse order shown in figure.020 in)] into guide between timing chain and chain tensioner plunger. and slacken timing chain of timing chain tensioner-side. (For secondary timing chains) GI MA SEM923G LC 35. ¼ Handle intake camshaft sprocket. EC FE CL KBIA1698J MT 36. AT AX SU BR ST RS BT HA SEM922G SEM734G 37. Rotate camshaft lightly. CAUTION: ¼ Avoid impact. a. ¼ Intake camshaft sprocket is two-for-one structure of primary and secondary sprockets. and remove them. ¼ Secure the hexagonal portion of the camshaft using a spanner to loosen mounting bolts. CAUTION: Chain tensioner plunger may move while fixed stopper pin and plunger both come off during timing chain removal. b. SC EL IDX SEM735G EM-37 . Insert metal or resin plate [thickness: 0. 38. b. taking care of the following. Remove chain tension guide. Then remove rear timing chain case.TIMING CHAIN Removal (Cont’d) 34.

KBIA1307E 39. PBIC0788E 41. if necessary. do not apply any load which affects flatness. chain tensioner cover and intake valve timing control covers. Remove No.TIMING CHAIN Removal (Cont’d) CAUTION: ¼ Do not remove plate metal cover of oil passage. SEM161F 42. b. Remove RH and LH camshaft chain tensioners from cylinder head as follows. Remove chain tensioners with stopper pin attached. Remove O-rings from cylinder block. Refer to EM-51. 40. SEM737G ¼ Remove old liquid gasket from the bolt hole and thread. a. Use a scraper to remove all traces of liquid gasket from water pump cover. SEM926E EM-38 . ¼ After removing chain case. and opposite mating surfaces. “Removal”. Use a scraper to remove all traces of liquid gasket from front and rear timing chain cases. 1 camshaft brackets.

referring to the following instructions and figure. ¼ a. ST RS BT HA SEM945G 5. Install No. “POSITION FOR APPLYING LIQUID GASKET”. b. 9. 9 . Replace chain if necessary.2 . if removed. AT AX SU BR PBIC0788E 3. Install O-rings to cylinder head. 2. Tighten mounting bolts in order as shown in the figure. 7. 3.13 N·m (1. 1 camshaft brackets. 4. 8. Install O-rings onto cylinder block.1.TIMING CHAIN Inspection Inspection NFEM0075 Check for cracks and excessive wear at roller links.10 ft-lb) SC EL IDX EM-39 . Then install it.63 in) (other than the above) : 12 . and 10 in the figure) 16 mm (0. 6. Do not allow O-ring to drop. GI MA PBIC0282E LC Installation 1. Refer to EM-31. EC FE CL SEM947G MT 2. Install chain tensioners with stopper pin attached and new O-ring.4 kg-m.79 in) (1. Bolt length: 20 mm (0. Install two types of mounting bolts. NFEM0076 Install RH and LH camshaft chain tensioners to cylinder head as follows. ¼ SEM735G Align rear timing chain case and water pump assembly with dowel pins (RH and LH) on cylinder block. Apply liquid gasket to rear timing chain case. a. if removed.

Standard Rear timing chain case to cylinder block: −0. dowel pin and crankshaft key are located as shown in the figure. Camshaft dowel pin hole (intake-side): At cylinder head upper face side in each bank Camshaft dowel pin (exhaust-side): At cylinder head upper face side in each bank Crankshaft key: At cylinder head side of RH bank CAUTION: Hole on small diameter side must be used for intake camshaft sprocket dowel pin.24 to 0.0055 in) If not within standard. Do not misidentify (Ignore big diameter side). 8. 6. Install chain tension guide.TIMING CHAIN Installation (Cont’d) b. After installing rear timing chain case. repeat above installation procedure. ¼ 7. check surface height difference between following parts on oil pan mounting surface. After all bolts are temporarily tightened.14 mm (−0. retighten them to specified torque in order shown in the figure. EM-40 . 1 cylinder.0094 to 0. ¼ Make sure that dowel pin hole. KBIA1073E Make sure that camshaft and crankshaft are at TDC position of No.

After confirming the mating marks are aligned. They should be used for RH/LH banks respectively. Tightening them by hand is enough to prevent dislocation of dowel pins. ST RS BT HA PBIC0891E 10. ¼ Matching marks of intake sprocket are on back side of secondary sprocket. ¼ On exhaust side. make a mating mark on the top of sprocket teeth and its extended line in advance with paint. Then install them. tighten the camshaft sprocket mounting bolts. RH bank: Use round type.TIMING CHAIN Installation (Cont’d) SEM430G 9. Align matching marks on secondary timing chain (gold link) with the ones on intake and exhaust sprockets (stamped). Align dowel pin and pin hole on camshaft with groove and dowel pin on sprocket. and keep it pressed with stopper pin. align dowel pin on camshaft front end with pin groove on camshaft sprocket. a. LH bank: Use oval type. ¼ There are two types of matching marks: round and oval types. align pin hole on small diameter side of camshaft front end with dowel pin on back side of camshaft sprocket. intake and exhaust camshaft sprockets slip easily. SC EL IDX KBIA1698J EM-41 . b. Install secondary timing chain and camshaft sprocket. Confirm all matching mark positions repeatedly during the installation process. CAUTION: Matching marks between timing chain. Then install them. ¼ On intake side. ¼ Mounting bolts for camshaft sprockets must be tightened in step 10. GI MA LC EC FE CL MT AT AX SU BR PBIC0886E ¼ It may be difficult to visually check the dislocation of mating marks during and after installation. Then install them. ¼ Push sleeve of secondary chain tensioner. ¼ Secure the camshaft hexagonal portion using a spanner to tighten mounting bolts. To make the matching easier. Then install them.

respectively. with matching mark to timing chain facing front of engine. Pull out the stopper pin from the secondary timing chain tensioner. Install primary timing chain. ¼ Install crankshaft sprocket. When it is difficult to align mating marks of the primary timing chain with each sprocket.TIMING CHAIN Installation (Cont’d) 11. SEM929E ¼ ¼ Install primary timing chain so that mating mark (punched) on camshaft sprocket is aligned with that (yellow link) on the timing chain. SEM923G 12. and mating mark (notched) on crankshaft sprocket is aligned with that orange link on the timing chain. PBIC0917E EM-42 . gradually turn the camshaft hexagonal portion using a spanner so it is aligned with the mating mark.

“FRONT OIL SEAL”. SC EL IDX SEM743G EM-43 . ¼ When installing chain tensioner. 16. ¼ After installing. ¼ Remove dirt and foreign materials completely from back and mounting surfaces of chain tensioner. Confirm again that matching marks on sprockets and timing chain have not slipped. Install internal chain guide. Refer to EM-48. Install chain tensioner for slack guide. ST RS BT HA SEM733G 17. push in sleeve and keep it pressed with stopper pin. GI MA LC EC FE CL SEM740G MT ¼ Take care not to overtighten mounting bolts for slack guide. Install front oil seal to front timing chain case. It is normal for a gap to exist under bolt seats when mounting bolts are tightened to specified torque. pull out stopper pin by pressing slack guide. Install slack guide.TIMING CHAIN Installation (Cont’d) 13. AT AX SU BR SEM741G 15. 14.

Standard Front timing chain case to rear timing chain case: −0. repeat above installation procedure.14 mm (−0. 19. SEM943G EM-44 . wipe off the protruding sealant. SEM828G 24. Apply liquid gasket to front timing chain case.0055 in) ¼ If not within standard. 23. Tighten bolts to the specified torque in order shown in the figure. ¼ Before installation.14 to 0. SEM744GA 20. SEM946G 22. wipe off the protruding sealant. 21.TIMING CHAIN Installation (Cont’d) 18. “Installation”. “RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS”. ¼ Refer to “POSITION FOR APPLYING LIQUID GASKET”. After installing front timing chain case. Refer to LC-16. Refer to GI-51. EM-31. ¼ Before installation. ¼ Use Genuine RTV Silicone Sealant or equivalent. Install water pump cover and chain tensioner cover. Install front timing chain case. Install O-rings on rear timing chain case.0055 to 0. Apply liquid gasket to water pump cover and chain tensioner cover. check surface height difference between following parts on oil pan mounting surface. ¼ Align dowel pin on rear timing chain case with hole on front timing chain case.

Replace rocker cover if necessary. ¼ Use genuine RTV silicone sealant or equivalent. ¼ Use Genuine RTV Silicone Sealant or equivalent. Refer to EM-31. ST RS BT HA SC EL IDX SEM749G EM-45 . a. Apply liquid gasket to intake valve timing control covers. a. b. “POSITION FOR APPLYING LIQUID GASKET”.TIMING CHAIN Installation (Cont’d) 25. Install collared O-ring in front timing chain case oil hole (LH and RH sides). “RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS”. GI MA PBIC1123E LC c. ¼ Apply liquid gasket to RH and LH rocker covers.33 to 9.96 to 2. SEM728G SEM748G 26.10 to 0.33 N·m (0. Install RH and LH rocker covers. AT AX SU BR e. Refer to GI-51. ¼ Check spark plug hole oil seal for cracks and damage on sealing portion. Tighten in numerical order as shown in the figure. b. Install LH and RH intake valve timing control covers. Refer to GI-51. Rocker cover tightening procedure: ¼ Tighten in numerical order as shown in the figure.96 N·m (0. align the dowel pins on the chain case with the holes to install the intake valve timing control cover.30 kg-m. Tighten bolts 1 to 10 in that order to 0.75 to 0. Being careful not to move the seal ring from the installation groove.95 kg-m. EC FE CL SEM948G MT d. 65 to 82 in-lb). Then tighten bolts 1 to 10 as indicated in figure to 7. 9 to 26 in-lb). Install new seal ring at intake valve timing control cover with new engine oil applied on it.

a. keep idling for three minutes. Again tighten by turning 60° to 66° [Target: 60 degrees (equivalent to one graduation)]. 28. Tighten to 39.0 kg-m.000 rpm under no load to purge air from the high-pressure chamber of the chain tensioners. 29 to 36 ft-lb). ¼ When installing fuel tube assembly. b. 29. SEM751G SEM222FF 32. ¼ Check oil level after refilling engine oil. Refer to EC-57. SEM968F c. Install RH and LH ignition coils. ¼ After starting engine.0 to 5. The engine may produce a rattling noise. Then rev engine up to 3. Refer to “TIGHTENING PROCEDURES”.0 N·m (4. Install RH and LH intake valve timing control solenoid valves. EM-11. EM-46 . Install intake manifold upper and lower collectors. Put a paint mark on the crankshaft pulley. Install crankshaft pulley to crankshaft. This indicates that air still remains in the chamber and is not a matter of concern.2 to 49. SEM725G 31.TIMING CHAIN Installation (Cont’d) 27. Reinstall removed parts in reverse order of removal. Install intake manifold collector gasket. ¼ Make sure that crankshaft position sensor (POS) and heated oxygen sensor 1 (bank 2) harness clamp are installed correctly as shown in figure. “Removal and Installation”. 30.

oil pump assembly and timing chain from engine. Remove ornament cover. Remove intake manifold upper collector and intake manifold lower collector. first remove the crankshaft position sensor (POS) from the assembly. Refer to EM-32. Apply a pressure of 490 kPa (5 kg/cm2. 71 psi). “Removal”. “Removal”. GI MA VALVE OIL SEAL 1. then install air hose adapter into spark plug hole and apply air pressure to hold valves in place. Refer to EM-51. fix valve as follows. “Removal. Remove camshaft brackets and camshaft. Remove valve lifters. 4. Refer to EM-14. SC EL IDX SEM827E EM-47 . Remove valve oil seal. Refer to EM-14. Refer to EM-32. “Components”. 9. Refer to EM-11. Piston concerned should be set at TDC to prevent valve from falling.OIL SEAL Replacement Replacement NFEM0015 CAUTION: When removing the oil pans. 5. 7. LC EC FE CL MT AT AX SU BR 10. ST RS BT HA SEM826E 11. Remove RH and LH ignition coils. Remove oil pan. 8. “Removal”. Remove crankshaft position sensor (POS). 6. “TIGHTENING PROCEDURES”. Before removing valve spring. Be careful not to damage sensor edges. PBIC1147E Remove spark plug. Remove RH and LH rocker covers from cylinder head. Remove timing chain. NFEM0015S01 3. Remove valve spring with Tool. 2.

Remove flywheel or drive plate. ¼ NFEM0015S04 Remove transaxle. Be careful not to damage sensor edges. SEM829E ¼ Install new oil seal in the direction shown in the figure. Crankshaft pulley. Use seal cutter (SST) or an equivalent tool to cut liquid gasket for removal. Apply engine oil to new valve oil seal and install it with Tool. SEM828E FRONT OIL SEAL 1. “Checking Drive Belts”. “Components”. SEM830E EM-48 . Refer to AT-286 or MT-14. Remove front oil seal using a suitable tool. 2. 3. Refer to EM-73. Apply engine oil to new oil seal and install it using a suitable tool. ¼ ¼ ¼ ¼ Remove the following parts: Engine undercover Front RH wheel and engine side cover Drive belts. Remove oil pan. Remove rear oil seal retainer. Reinstall any parts removed in reverse order of removal. Refer to EM-14. Refer to EM-21.OIL SEAL Replacement (Cont’d) 12. 3. 4. Be careful not to scratch front cover. SEM715A REAR OIL SEAL 1. NFEM0015S03 2. Refer to MA-13. “Removal”. 13.

Assembly should be done within 5 minutes after coating. EC FE CL SEM832EA MT AT AX SU BR ST RS BT HA SC EL IDX EM-49 . ¼ ¼ ¼ Apply liquid gasket to new rear oil seal retainer. GI MA LC 6.OIL SEAL Replacement (Cont’d) 5. Use Genuine RTV Silicone Sealant or equivalent. Wait at least 30 minutes before refilling engine oil and engine coolant. ¼ Remove old liquid gasket on mating surface of cylinder block and oil pan using scraper. Remove old liquid gasket from the bolt hole and thread. Refer to GI-51.

Spark plug 15. 18. 22.CYLINDER HEAD Components Components NFEM0043 SEM965G 1. 19. 10. 2. 5. Spark plug tube 14. Oil filler cap Oil catcher Rocker cover PCV hose Intake valve timing control solenoid valve PCV valve Tensioner sleeve 8. 17. 4. 6. 20. Spring Chain tensioner Valve Cylinder head Camshaft position sensor (PHASE) 13. 3. 7. 16. 9. Valve spring seat Valve spring Valve spring retainer Valve collet Valve lifter Camshaft (Exhaust) Camshaft (Intake) Camshaft bracket EM-50 . 21. 11. 12.

Remove front exhaust tube and its support. chain tensioners.CYLINDER HEAD Components (Cont’d) CAUTION: ¼ When installing camshafts. 9. “Removal and Installation”. Set a suitable transmission jack under transaxle and hoist engine with engine slinger. and camshaft bracket. EC FE CL MT 5. Remove center member. 11. GI MA LC Removal 1. Refer to EM-12. Refer to EM-14. 13. 2. “REMOVAL AND INSTALLATION”. AT AX SU BR SEM716G 6. 10. Drain engine oil. Install center member to support engine temporarily. 12. ST RS BT HA SC EL IDX SEM811E EM-51 . Remove radiator. or other sliding parts. ¼ Attach tags to valve lifters so as not to mix them up. ¼ 3. Loosen front and rear engine mounting nuts and bolts. “Removal”. “Removal”. ¼ Apply new engine oil to threads and seat surfaces when installing cylinder head. never drain the engine oil when the engine is hot. To avoid the danger of being scalded. camshaft sprocket. NFEM0044 Remove engine undercover. Drain engine coolant from radiator. Tighten front and rear engine mounting nuts and bolts. 15. Remove timing chain. lubricate contacting surfaces with new engine oil. crankshaft pulley. Remove crankshaft position sensor (POS) from oil pan. oil seals. Remove exhaust manifolds. 7. Refer to LC-20. 8. 4. “Exhaust Manifold”. Refer to EM-32. Remove aluminum oil pan. Refer to FE-9. Remove transmission jack and hoist that were supporting engine. 14.

Remove intake manifold in reverse order as shown in the figure. SEM709G 18. Remove rear timing chain case. Remove O-rings from cylinder block. SEM735G 19. SEM945G 21. SEM168FA 20. Loosen rear timing chain case bolts in reverse order as shown in the figure. PBIC0788E EM-52 . Remove O-rings from cylinder head. Remove water outlet. 17. ¼ Use seal cutter (SST) or an equivalent tool to cut liquid gasket for removal.CYLINDER HEAD Removal (Cont’d) 16.

¼ Equally loosen camshaft bracket bolts in several steps in the numerical order shown in the figure. Remove intake and exhaust camshafts and camshaft brackets. 24. be sure to put marks on camshaft bracket before removal. Remove RH and LH camshaft chain tensioners from cylinder head. EC FE CL MT AT AX SU BR SEM856E SEM857E 25. and store them without mixing them up. GI MA SEM443GA LC 23. Remove intake valve timing control solenoid valves. Remove valve lifters. For reinstallation. ¼ Remove chain tensioner with its stopper pin attached. ST RS BT HA SEM947G SC EL IDX EM-53 .CYLINDER HEAD Removal (Cont’d) 22. ¼ Identify installation positions. ¼ Stopper pin was attached when secondary timing chain was removed.

“VALVE OIL SEAL”. Refer to EM-47. Loosen cylinder head bolts. NFEM0045 Remove spark plug with spark plug wrench (Commercial service tool). Do not remove it unless absolutely necessary. Remove valve component parts. as necessary. Refer to EM-57. ¼ Cylinder head bolts should be loosened in two or three steps. SEM863E Disassembly 1. ¼ Check the clearance before removing the valve guide. SEM859E SEM860E 27.CYLINDER HEAD Removal (Cont’d) 26. 3. Remove spark plug tube. 2. EM-54 . Remove cylinder head. ¼ Using a pair of pliers. ¼ Once removed. pull spark plug tube out of cylinder head. ¼ A warped or cracked cylinder head could result from removing bolts in incorrect order. a spark plug tube will be deformed and cannot be reused. “VALVE GUIDE CLEARANCE”. CAUTION: ¼ Take care not to damage cylinder head.

972 . and measure camshaft runout on dial gauge. cylinder head must be replaced. Measure camshaft cam height.2 mm (0. seizure and wear.865 . Put V block on precise flat bed.5 mm (4. Resurfacing limit: Amount of cylinder head resurfacing is “A”. Standard cam height: Intake and exhaust 44.CYLINDER HEAD Inspection Inspection CYLINDER HEAD DISTORTION NFEM0046 NFEM0046S01 SEM861E Clean surface of cylinder head. replace camshaft.05 mm (0. Use a reliable straightedge and feeler gauge to check the flatness of cylinder head surface. Turn camshaft to one direction with hands.126. SEM549A EM-55 .004 in) If beyond the specified limit.4. NFEM0046S04 SC EL IDX 2.7763 . Amount of cylinder block resurfacing is “B”. NFEM0046S03 PBIC0929E 4.3 . 4 journal of camshaft.2 mm (0.1 mm (0. If resistance is felt.980 in) GI MA LC EC FE CL MT CAMSHAFT VISUAL CHECK Check camshaft for scratches. 2 and No. Head surface flatness: Limit 0. check that camshaft rotates freely by hand.055 mm (1. replace camshaft.0020 in) If it exceeds the limit.45.008 in) If wear is beyond the limit.008 in) After resurfacing cylinder head. Check along six positions shown in the figure. resurface or replace it. The limit for cylinder head resurfacing is determined by the cylinder block resurfacing. Nominal cylinder head height: 126. Set dial gauge vertically to No. 3 journal. 2. 3.7738 in) Cam wear limit: 0. (Total indicator reading) Runout: Limit (Total indicator reading) 0. and support No.1. NFEM0046S02 AT AX SU BR ST RS BT HA CAMSHAFT RUNOUT 1. CAMSHAFT CAM HEIGHT 1. The maximum limit : A + B = 0.

2.045 .23. 3. Standard inner diameter: No. Measure inner diameter “A” of camshaft bearing.000 . 4. SEM012A Measure outer diameter of camshaft journal. When out of the limit again. EM-56 .9230 .0211 .445 .1.955 mm (1.115 .CYLINDER HEAD Inspection (Cont’d) CAMSHAFT JOURNAL CLEARANCE 1. 2. 3.0. 4: 23.0034 in) No.0.23. 4: 23.021 mm (1. Standard outer diameter: No.0045 .24 mm (0.500 . 1: 26. replace camshaft and/or cylinder head.0. 1: 25.0.0014 . NFEM0046S05 Install camshaft bracket and tighten bolts to the specified torque.076 mm (0.0244 in) No.521 mm (0. replace with new camshaft and measure again.0074 in) Limit 0.0236 .0218 in) No. replace with new cylinder head.086 mm (0. Camshaft journal clearance: Standard No. NFEM0046S06 SEM864E ¼ ¼ Install camshaft in cylinder head.0030 in) Limit 0.9260 in) SEM862E 3. 1: 0.9238 in) If clearance exceeds the limit.9252 .0018 . Measure end play of dial gauge when camshaft is moved forward/backward (in direction to axis).035 .935 . 3.0059 in) CAMSHAFT END PLAY 1. Camshaft end play: Standard 0.0.15 mm (0.26.0.0.25. 4: 0. 2. 2.465 mm (0. 2.0094 in) When out of the limit.188 mm (0. Then install dial gauge in thrust direction on front end of camshaft.1.0.

wear protective equipment to avoid getting burned. Measure camshaft sprocket runout.0 Imp ton) pressure] or hammer and suitable tool. 4 journal of camshaft. b. NFEM0046S08 Measure valve deflection as shown in the figure. (Valve and valve guide mostly wear in this direction.004 in) If it exceeds the limit. 2 and No.28 mm (0.2 US ton.08 mm (0.0094 in) Exhaust 0. replace valve or valve guide.) Valve deflection limit (Dial gauge reading): Intake 0. a. Check that clearance is within specification. replace camshaft sprocket. SEM938C VALVE GUIDE REPLACEMENT 1. PBIC0930E Put V block on precise flat bed. CAUTION: Cylinder head contains heat.0031 in) Exhaust 0. When working.0110 in) EC FE CL SEM178F MT 2. NFEM0046S09 To remove valve guide. 2. check valve to valve guide clearance. and support No.CYLINDER HEAD Inspection (Cont’d) CAMSHAFT SPROCKET RUNOUT 1.0059 in) If it exceeds the limit. ST RS BT HA SEM008A 2. GI MA LC VALVE GUIDE CLEARANCE 1. 2. Valve to valve guide clearance limit: Intake 0. 2. 3.24 mm (0. Runout (Total indicator reading): Less than 0. heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. If it exceeds the limit. SC EL IDX SEM931C EM-57 . NFEM0046S07 4.15 mm (0.1 mm (0. AT AX SU BR c. Install sprocket on camshaft. Drive out valve guide with a press [under a 20 kN (2 ton. Measure valve stem diameter and valve guide inner diameter.

SEM934C REPLACING VALVE SEAT FOR SERVICE PARTS 1.6.496 .2362 . Set the machine depth stop to ensure this. replace them.716 mm (1.4014 in) SEM932C 4.10.8 mm (0. Finished size: 6. 2. 5. Valve guide hole diameter (for service parts): 10. When working.CYLINDER HEAD Inspection (Cont’d) 3. ¼ Before repairing valve seats.2874 .700 .500 .5157 .0.5 mm (0. Oversize [0. lap valve seat with abrasive compound. Ream cylinder head valve guide hole. After cutting. CAUTION: Cylinder head contains heat. wear protective equipment to avoid getting burned. Boring should not continue beyond the bottom face of the seat recess in cylinder head. 4.2880 in) Be sure to ream in circles concentric to the valve guide center.4006 .018 mm (0. When working.000 . wear protective equipment to avoid getting burned. Check valve seating condition. Ream cylinder head recess for service valve seat.1.2369 in) NFEM0046S10 SEM950E VALVE SEATS Check valve seats for any evidence of pitting at valve contact surface.0. check valve and valve guide for wear. 6.0. 3. NFEM0046S11 SEM795A SEM892B Bore out old seat until it collapses. and reseat or replace if they have worn out excessively. Then correct valve seat.38.516 mm (1. Projection “L”: 12.45°45′ EM-58 . Cut or grind valve seat using a suitable tool to the specified dimensions as shown in SDS (EM-92). ¼ Use both hands to cut uniformly.6 .32. Press fit valve seat until it seats on the bottom.020 in)]: Intake 38. Ream valve guide. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.5164 in) Exhaust 32.196 mm (0.12. This will enable valve seat to fit correctly. Heat cylinder head to 110 to 130°C (230 to 266°F) and press service valve guide onto cylinder head.175 .1. 5. Seat face angle “α”: 45°15′ . If they have worn. 7.504 in) CAUTION: Cylinder head contains heat.

00 .6169 .0.0 kg. SEM288A Pressure NFEM0046S1302 SC EL IDX Check valve spring pressure at specified spring height.0 mm (0. refer to SDS (EM-89). When valve head has been worn down to 0.60 mm (1.09 . Out-of-square “S”: Less than 2. Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end.457 in) Valve open More than 433 N (44. If it is longer.41.3 lb) at height 27.0.6142 .2 mm (0. replace the valve seat with a new one.0594 in) GI MA LC 8.2 kg.1 lb) at height 37.0 mm (1.51 mm (0.0508 .CYLINDER HEAD Inspection (Cont’d) Contacting width “W”: Intake 1. Pressure: Installation 196 N (20.094 in) If it exceeds the limit. Valve seat resurface limit “L”: Intake 41. NFEM0046S13 NFEM0046S1301 ST RS BT HA 2.020 in) in margin thickness. If the distance is shorter than specified. 44.41. For dimensions.1.1. Grinding allowance for valve stem tip is 0.0429 .29 .07 . 97. Measure dimension “S”.31 mm (0.0516 in) Exhaust 1.079 in) If it exceeds the limit.5 mm (0. replace spring.1.6405 in) Exhaust 41. replace spring.8 mm (1.67 mm (1.1. EM113 EM-59 . repeat step 5 above to adjust it.008 in) or less. replace valve. AT AX SU BR SEM188A VALVE SPRING Squareness 1.6378 in) EC FE CL MT SEM621F VALVE DIMENSIONS NFEM0046S12 Check dimensions of each valve.

NFEM0047 KBIA1248E Install spark plug tube. Standard press-fit height “H”: : 38. wipe off liquid gasket protruding onto cylinder-head upper face. take care not to deform spark plug tube.55 . Press-fit spark plug tube following procedure below.47 in) from edge of spark plug tube press-fit side.34.977 .1. refer to each specification of outer and inner diameter.5217 in) CAUTION: ¼ When press-fitting. Then replace either or both valve lifter and cylinder head.33.38.987 mm (1.000 . Apply liquid gasket to area within approximately 12 mm (0. Valve lifter outer diameter: 33. Remove old liquid gasket adhering to cylinder-head mounting hole.3377 .CYLINDER HEAD Inspection (Cont’d) VALVE LIFTER 1.3381 in) JEM798G ¼ Lifter guide bore diameter: 34.65 mm (1. ¼ a.1. ¼ Use Genuine Liquid Gasket or equivalent.1. ¼ After press-fitting.5177 .3392 in) When out of specified range. press-fit spark plug tube so that its height “H” is as specified in the figure. b. c. Check diameter of valve lifter and valve lifter guide bore.016 mm (1.3386 . KBIA0182J 2. NFEM0046S14 Check contact and sliding surfaces for wear or scratches. SEM867E Assembly 1. EM-60 . Using a drift.

¼ Before installing the cylinder head gasket. install valve spring seat. Also remove old liquid gasket from mating surface of cylinder block. Refer to “VALVE OIL SEAL”. Install spark plug. Install valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side (paint mark). tap valve stem tip with plastic hammer to assure a proper fit. remove old liquid gasket from mating surface using a scraper. 1 cylinder is at TDC. SC EL IDX SEM532G EM-61 . the crankshaft key should face toward the right bank. AT AX SU BR SEM161F 2. GI MA LC Installation 1. SEM085D Install valve component parts. remove old liquid gasket from mating surface using a scraper. At this time. Before installing cam bracket. ¼ NFEM0048 Before installing rear timing chain case. After installing valve component parts. EC FE CL SEM891E MT ¼ Remove old liquid gasket from the bolt hole and thread. be sure that No.CYLINDER HEAD Assembly (Cont’d) 2. Always use new valve oil seal. EM-47. Before installing valve oil seal. ¼ ¼ ¼ ¼ 3. ST RS BT HA SEM892E 3.

Tightening procedure: Tighten all bolts to 98 N·m (10 kg-m. SEM877EA ¼ Tighten cylinder head outside bolts. Completely loosen all bolts.11 mm (0. c. Do not rotate crankshaft and camshaft separately. d. Turn all bolts 90 to 95 degrees clockwise again [target: 90 degrees (angle tightening)]. use it as d2 point. 72 ft-lb). ¼ a. or valves will strike piston heads. Tighten all bolts to 34. Limit (d1 . b. ¼ Install cylinder heads with new gaskets.5 to 4. 26 to 32 ft-lb). SEM957E 5. e. replace them with new ones.4 kg-m.CYLINDER HEAD Installation (Cont’d) 4. Tighten in numerical order shown in the figure. Whenever the size difference between d1 and d2 exceeds the limit. ¼ Lubricate threads and seat surfaces of the bolts with new engine oil.d2): 0.1 N·m (3. SEM445G CAUTION: Cylinder head bolts are tightened by plastic zone tightening method.0043 in) ¼ If reduction of outer diameter appears in a position other than d2.3 to 44. SEM878EA SEM879EA EM-62 . Turn all bolts 90 to 95 degrees clockwise [target: 90 degrees (angle tightening)].

Install camshaft chain tensioners on both sides of cylinder head. Paint mark Bank INT/EXH INT RH EXH INT LH EXH LH No Yes RE LH No Yes Yes No ID mark M1 RE Yes M2 No AT AX SU BR ST RS BT HA SEM653F ¼ Position camshaft RH exhaust camshaft dowel pin at about 10 o’clock LH exhaust camshaft dowel pin at about 2 o’clock KBIA1072E SC EL IDX EM-63 . Exhaust camshaft has a dowel pin on camshaft sprocket mounting flange. Install it on the exhaust side. GI MA SEM947G LC 7. EC FE CL KBIA1071E MT ¼ Identification marks are present on camshafts. ¼ Install exhaust and intake camshafts and camshaft brackets.CYLINDER HEAD Installation (Cont’d) 6.

SEM446G ¼ Tighten the camshaft brackets in the following steps.11.0 kg-m. Tighten in the order of 1 to 6.104. Refer to GI-51.92 . 74 .011 . then tighten 1 to 6.10.20 kg-m. Align stamp mark as shown in the figure. Use Genuine RTV silicone sealant or equivalent. Tighten in the order of 7 to 10. 1 camshaft bracket. Reference data valve clearance (Cold): Intake 0.91 in-lb) Tightening order Tighten in the order of 7 to 10. ¼ ¼ ¼ ¼ SEM564G ¼ Before installing camshaft brackets.8 N·m (0. Install camshaft brackets in their original positions. If any part of valve assembly or camshaft is replaced.3 .96 N·m (0.88 N·m (0. EM-66 and EM-68. Refer to “Checking” and “Adjusting”.0. Step 1 2 Tightening torque 1.3 N·m (0.02 .013 in) Exhaust 0. After completing assembly check valve clearance.CYLINDER HEAD Installation (Cont’d) 8.0.6 kg-m. 52 in-lb) 9.29 . 79.1. 17 in-lb) 5. Refer to “POSITION FOR APPLYING LIQUID GASKET”.1. SEM885EA SEM886EA EM-64 .37 mm (0. EM-31.9 .9 .015 in) Lubricate threads and seat surfaces of camshaft bracket bolts with new engine oil before installing them.34 mm (0. Tighten in the numerical order. apply sealant to mating surface of No.010 .26 . check valve clearance according to reference data.2 in-lb) 3 8.0.2 kg-m.0.

Align rear timing chain case with dowel pins. EM-31. ¼ Apply continuous bead of liquid gasket to mating surface of rear timing chain case. Refer to “POSITION FOR APPLYING LIQUID GASKET”. EC FE CL PBIC0788E MT 11. then install on cylinder head and block. ¼ Before installation. a. Install O-rings to cylinder block. AT AX SU BR SEM945G 12. GI MA SEM443GB LC 10. wipe off the protruding sealant. Install O-rings to cylinder head. 15. Install intake valve timing control solenoid valves. Apply sealant to the hatched portion of rear timing chain case. ST RS BT HA 13.CYLINDER HEAD Installation (Cont’d) 9. Tighten bolts in numerical order shown in the figure with smaller torque than specified. 14. Reinstall all removed parts in reverse order of removal. Tighten bolts to the specified torque repeating above step a. Tighten rear chain case bolts. b. SC EL IDX SEM735G EM-65 .

¼ Align pointer with TDC mark on crankshaft pulley. “Removal”. Remove RH and LH rocker covers. 1 cylinder at TDC on its compression stroke. harnesses. 3. SEM418G 7. hoses. 6. 1 CYL No. “TIGHTENING PROCEDURES”. 1 cylinder at TDC EXH SEM893E EM-66 . wires. Refer to EM-11. 1. Remove intake manifold collectors. ¼ Check that valve lifters on No. 3 CYL X X No. 4 are tight. Remove ignition coils and spark plugs. 4. 5. connectors and so on. If not. collectors. Refer to EM-21. 2.CYLINDER HEAD Valve Clearance Valve Clearance CHECKING NFEM0049 NFEM0049S01 SEM918G Check valve clearance while engine is cold and not running. 5 CYL Measuring position (RH bank) EXH No. 6 CYL X X No. Check only those valves shown in the figure. 2 CYL No. 1 cylinder at TDC INT Measuring position (LH bank) INT No. Remove ornament cover. turn crankshaft one revolution (360°) and align as shown. 1 cylinder are loose and valve lifters on No. 4 CYL No. Remove air duct with air cleaner case. No. Set No.

3 CYL No.37 mm (0.34 mm (0. 4 CYL No. 9. 5 cylinder at TDC on its compression stroke. 5 cylinder at TDC INT Measuring position (LH bank) INT No. 3 cylinder at TDC INT Measuring position (LH bank) INT No. 10. Turn crankshaft 240° and align as shown in the figure. 1 CYL X No. 1 CYL No.015 in) GI MA SEM139D LC EC FE CL 8. Measuring position (RH bank) EXH No. 2 CYL No. 13. measure clearance between valve lifter and camshaft. 2 CYL X X No. If they are out of specification. Record any valve clearance measurements which are out of specification. ¼ Intake manifold collectors ¼ RH and LH rocker covers ¼ All spark plugs ¼ All ignition coils SEM958E EM-67 . 5 CYL X MT AT AX SU BR SEM894E 11.CYLINDER HEAD Valve Clearance (Cont’d) ¼ ¼ Using a feeler gauge. Valve clearance for checking (Cold): Intake 0.29 .0. 5 cylinder at TDC EXH X No.0. Turn crankshaft 240° and align as shown in the figure. 4 CYL X X No. If all valve clearances are within specification. Check only those valves shown in the figure. Set No.011 . 3 cylinder at TDC on its compression stroke. 3 CYL No. adjust the valve clearances. 6 CYL No.010 . Set No. install the following parts. 3 cylinder at TDC EXH X No.26 . Check only those valves shown in the figure.0.013 in) Exhaust 0. 6 CYL No. Measuring position (RH bank) EXH No. 12.0. 5 CYL ST RS BT HA SC EL IDX 14. They will be used later to determine the required replacement valve lifter.

4.30 mm (0. 3. Unit: mm (in) Stamp mark Starting: 788U or 788R Ending: 840U or 840R Thickness of valve lifter 7.40 (0. After repair.0.33 mm (0.304 . 2.3307 in) [in 0.0.26 . SEM754G ¼ Measure center thickness of removed valve lifter with micrometer. Valve lifter thickness calculation: t = t1 + (C1 − C2) t = Thickness of replacement valve lifter t1 = Thickness of removed valve lifter C1 = Measured valve clearance C2 = Standard valve clearance: Intake: 0. Confirm that valve clearance is within specification.012 .34 (0.02 mm (0.3102) 8.3102 .37 (0.012 in) Exhaust: 0.0.3307) ¼ SEM755G Available thickness of valve lifter (Factory setting): 7. Remove valve lifter at location where measured value is out of specification.29 .432 (0.010 . 6. Valve clearance: Unit: mm (in) Cold Intake Exhaust 0.0.0008 in) step] in 27 sizes (Intake/Exhaust) 5. 9. Use equation below to calculate valve lifter thickness for replacement.013 in) Thickness of new valve lifter can be identified by stamp mark on reverse side (inside cylinder). 2 types of stamp marks are used for manufacturer identification.88 (0.0.012 .0.0.8.CYLINDER HEAD Valve Clearance (Cont’d) ADJUSTING NFEM0049S02 Adjust valve clearance while engine is cold. Rotate crankshaft a few turns by hand. 7.017) *: Approximately 80°C (176°F) EM-68 . 1. Install camshaft.308 .88 . Remove camshaft. confirm that valve clearance is within specification with engine warmed-up.011 .0.015) Hot* (reference data) 0. Install selected valve lifter.016) 0. Perform adjustment by selecting head thickness of valve lifter (Shim adjustment is not used).0.416 (0.40 mm (0. 8.013) 0.

¼ Do not remove engine until exhaust system has completely cooled off. 2. you may burn yourself and/or fire may break out in fuel line. 5. Front engine mounting (Fluid type) Insulator WARNING: ¼ Situate vehicle on a flat and solid surface. LH engine mounting RH engine mounting Mounting bracket 4. 3.ENGINE ASSEMBLY Removal and Installation Removal and Installation NFEM0050 GI MA LC EC FE CL MT AT AX SU BR ST RS BT SEM844G HA SC EL IDX 1. the tension of wires should be slackened against the engine. 8. ¼ For safety during subsequent steps. ¼ Place chocks at front and back of rear wheels. EM-69 . Rear engine mounting (Fluid type) Insulator Center member 7. 6. Otherwise.

Refer to MA-13. ¼ Before separating engine and transaxle. ¼ In removing drive shaft. HA-144 and HA-231. ST-24. Remove vacuum hoses. “Garage Jack and Safety Stand”. “REMOVAL AND INSTALLATION”. “REMOVAL”. Refer to GI-47. AX-10. and brake master cylinder. Remove LH engine mounting. 4. Remove alternator. 7. connectors and so on. fuel hoses. “Components”. Remove front exhaust tubes. Drain coolant from both cylinder block and radiator. Refer to SC-31. wires. ¼ For engines not equipped with engine slingers. place safety stands under designated front supporting points. “Checking Drive Belts”. ball joints and drive shafts. Remove engine undercover and hood. especially the following: accelerator wire casing. Hoist engine with engine slinger. Refer to FE-9. Refer to LC-20. “Changing Engine Coolant”. always use engine slingers in a safe manner. 6. brake lines. compressor and power steering oil pump from engine. 2. “Fuel Pressure Release”. CAUTION: ¼ When lifting engine.ENGINE ASSEMBLY Removal and Installation (Cont’d) ¼ Before disconnecting fuel hose. be careful not to damage grease seal of transaxle. attach proper slingers and bolts described in PARTS CATALOG. Refer to MA-14. release fuel pressure from fuel line. ¼ Be sure to hoist engine and transaxle in a safe manner. REMOVAL 1. ¼ In hoisting the engine. Refer to EC-56. Remove drive belts. SEM807G SEM808G EM-70 . remove the crankshaft position sensor (POS) from the assembly. Set a suitable transmission jack under transaxle. SU-12. Remove radiator and fans. NFEM0050S01 SEM825G 5. “EXHAUST SYSTEM”. ¼ Before removing front axle from transaxle. 3. “Radiator”. harnesses. ¼ Always pay extra attention not to damage edges of crankshaft position sensor (POS) or ring gear teeth. 8. be careful not to strike adjacent parts. “REMOVAL AND INSTALLATION”. 9. “REMOVAL”.

Remove center member and then slowly lower transmission jack. ST RS BT HA SC EL IDX SEM972F EM-71 . GI MA SEM835E LC 12. Disconnect control cable from transaxle (A/T model). EC FE CL SEM836EA MT 13. Remove engine with transaxle as shown.ENGINE ASSEMBLY Removal and Installation (Cont’d) 10. 11. AT AX SU BR SEM837E 14. Remove RH engine mounting. Disconnect control rod and support rod from transaxle (M/T model).

Install the electronically-controlled engine mount harness to match the following values. (Models with electronically-controlled engine mounts) Length between A and B: 170 mm (6.ENGINE ASSEMBLY Removal and Installation (Cont’d) INSTALLATION NFEM0050S02 Installation is in the reverse order of removal.69 in) SEM806G EM-72 .

9. 17. 14. 2. 6. 8.CYLINDER BLOCK Components Components NFEM0051 GI MA LC EC FE CL MT AT AX SU BR ST RS BT SEM066H HA SC EL IDX 1. 11. 19. 23. 20. 3. Oil jet EM-73 . 22. 25. Rear oil seal retainer Cylinder block Knock sensor Upper main bearing Lower main bearing Water drain plug (LH side) Water drain plug (RH side) Water drain plug (Water pump side) Main bearing cap 10. 21. Piston pin Connecting rod bearing Connecting rod Connecting rod bushing Piston Top ring 2nd ring Cylinder block heater (For Canada) 26. 13. 12. 4. 16. 7. 24. 15. 5. Main bearing beam Crankshaft Pilot bushing or pilot converter Flywheel with signal plate (M/T models) Drive plate with signal plate (A/T model) Flywheel reinforcement Drive plate reinforcement Oil ring 18.

CAUTION: ¼ When piston rings are replaced. ¼ Before removing bearing beam and bearing cap. Place engine on a work stand. ¼ Place removed parts such as bearings and bearing caps in their proper order and direction. ¼ When replacing piston rings. Remove oil jets. Drain coolant and oil. ¼ Remove pistons with connecting rods. Refer to EM-84. ¼ Do not allow any magnetic materials to contact the signal plate teeth of flywheel or drive plate. SEM842E 11. measure crankshaft end play. Refer to “Removal and Installation”. 2. SEM454G EM-74 . Refer to “Removal”. 3. SEM190FA NFEM0053 NFEM0053S01 Remove engine. 8. bearing cap and crankshaft. Disassembly PISTON. make sure that piston rings are mounted in their original positions. Remove oil pan. EM-14. SEM965A 9. EM-51. Remove timing chain. 4. 7. 10. Remove rear oil seal retainer. or other sliding parts. CAUTION: Handle the sensor carefully and avoid impact to it. apply new engine oil to threads and seating surfaces. 6. install with either side up. EM-69. Remove knock sensor. Refer to “Removal”. lubricate contacting surfaces with new engine oil. CRANKSHAFT AND OIL JET 1. ¼ When installing connecting rod nuts and main bearing cap bolts. pistons. Loosen bolts in numerical order as shown and remove main bearing beam. EM-32. 5. then heat piston to 60 to 70°C (140 to 158°F). Remove cylinder head. remove snap ring first. When disassembling piston and connecting rod. Refer to “Removal”.CYLINDER BLOCK Removal and Installation Removal and Installation NFEM0052 SEM180FA CAUTION: ¼ When installing bearings. ¼ Bolts should be loosened in two or three steps. if there is no punchmark.

0.0315 in) Oil ring 0. limit of side clearance: Top ring 0. Standard diameter “dp”: Grade No. replace piston.0.22.0.0002 in) If it exceeds the above value.33 .0130 in) 2nd ring 0.1 mm (0.0.8663 in) NFEM0054 NFEM0054S01 GI MA AEM023 LC 2.065 .0.002 . Dp − dp = 0. limit of ring gap: Top ring 0.8659 .0018 .0213 in) 2nd ring 0. 1 21.23 .33 mm (0.0001 .8659 . Calculate interference fit of piston pin to piston.0.993 .999 .0043 in) 2nd ring 0.995 mm (0. Measure outer diameter of piston pin “Dp”.8657 . EC FE CL MT AEM024 PISTON RING SIDE CLEARANCE NFEM0054S02 SEM024AA Side clearance: Top ring 0.989 .0012 .0.0.0189 in) Oil ring 0.22. 1 21.95 mm (0. Measure inner diameter of piston pin hole “dp”.48 mm (0.0. replace piston ring.005 mm (0.0. 0 21.0. AT AX SU BR ST RS BT HA PISTON RING END GAP End gap: Top ring 0.080 mm (0.8661 .0079 .21.0.0028 in) Oil ring 0.0236 in) Max.999 mm (0.21. If clearance exceeds maximum limit with new ring.0026 .0.60 mm (0.8661 in) Grade No.8659 in) Grade No.995 .11 mm (0.0. replace piston assembly with pin.0.0.0.0374 in) SEM599A NFEM0054S03 SC EL IDX EM-75 .030 .0130.8662 in) 3. Standard diameter “Dp”: Grade No.20 .045 .0053 in) Max.135 mm (0.006 mm (0. 0 21.0.CYLINDER BLOCK Inspection Inspection PISTON AND PISTON PIN CLEARANCE 1.54 mm (0.004 in) If out of specification.0031 in) 2nd ring 0.070 mm (0.001 mm (0.0091 .80 mm (0.

4665 in) Refer to SDS (EM-94). If gap still exceeds the limit even with a new ring.0039 in) If out of specification. do the following.2 mm (0. Use a reliable straightedge and feeler gauge to check the flatness of cylinder block surface. ¼ When replacing the piston. replace piston ring.05 mm (8.10 mm (0. replace connecting rod assembly. hone or replace the cylinder block.0118 in) per 100 mm (3. check the cylinder block surface for scratches or seizure. The limit for cylinder block resurfacing is determined by cylinder head resurfacing in engine.215.15 mm (0. Amount of cylinder block resurfacing is “B”.94 in) length Torsion: Limit 0.95 .008 in) Nominal cylinder block height from crankshaft center: 214. Refer to SDS (EM-95). EM-76 . Check along six positions shown in the figure.CYLINDER BLOCK Inspection (Cont’d) If out of specification.94 in) length If it exceeds the limit. replace cylinder block. The maximum limit is as follows: A + B = 0. CONNECTING ROD BEND AND TORSION Bend: Limit 0. SEM038F NFEM0054S04 SEM003F CYLINDER BLOCK DISTORTION AND WEAR ¼ NFEM0054S05 ¼ SEM123C ¼ Clean upper surface of cylinder block. Rebore cylinder and use oversized piston and piston rings. resurface it. Resurfacing limit: Amount of cylinder head resurfacing is “A”. If scratches or seizure is found. Distortion limit: 0. If necessary.0059 in) per 100 mm (3.4626 .30 mm (0.8.

0079 in) 2. Piston-to-bore clearance “B”: 0.0008 in) ST RS BT HA SC EL IDX EM-77 .500 .0006 in) Check for scratches and seizure.010 . Oversize pistons are available for service.3.0006 in) Taper (Difference between A and C): Limit 0. These numbers are punched in either Arabic or Roman numerals. hone it.015 mm (0. 4. Measure piston skirt diameter.95.95. rebore all cylinders.0.510 mm (3.7610 in) Wear limit 0.3.7598 .520 .7606 . Replace cylinder block if necessary.030 mm (0.530 mm (3. 3 SEM843E GI MA Standard inner diameter 95. AT AX SU BR SEM756G 3. out-ofround and taper.20 mm (0.0. SEM258C ¼ 6.520 mm (3. Refer to SDS (EM-95). If it exceeds the limit. Measuring point “a” (Distance from the top): 41. No.015 mm (0.02 mm (0.0004 .61 in) Check that piston-to-bore clearance is within specification. select piston of the same grade number punched on cylinder block rear position.0 mm (1.95. D: Bored diameter A: Piston diameter as measured B: Piston-to-bore clearance C: Honing allowance 0. measure cylinder bore for wear. 1 No. If oversize piston is used.7606 in) 95.0012 in) Determine piston oversize according to amount of cylinder wear. If seizure is found.CYLINDER BLOCK Inspection (Cont’d) PISTON-TO-BORE CLEARANCE 1. Out-of-round (Difference between X and Y): Limit 0.7602 . Cylinder bore inner diameter Grade No.7602 in) 95.510 . 5.3. 2 No. LC EC FE CL SEM321AA MT ¼ If both cylinder block and piston are replaced with new ones. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”. use it for all cylinders with oversize piston rings. Rebored size calculation: D = A + B − C where. Piston diameter “A”: Refer to SDS (EM-95). NFEM0054S06 Using a bore gauge.

SEM346D BEARING CLEARANCE ¼ NFEM0054S08 Use either of the following two methods. Out-of-round (X − Y): Standard 0. all other cylinders must also be bored. Measure finished cylinder bore for out-of-round and taper. ¼ When any cylinder needs boring. CRANKSHAFT 1. With a micrometer.002 mm (0. ¼ Do not cut too much out of cylinder bore at a time. NFEM0054S0801 Set main bearings in their proper positions on cylinder block and main bearing cap. Method A (Using bore gauge & micrometer) Main bearing 1. and tighten to the specified torque. 2. read the movement of the pointer on the dial gauge. 9. Hone cylinders to obtain specified piston-to-bore clearance. ¼ Measurement should be done after cylinder bore cools down. wear or cracks. Install main bearing caps. Place a V-block on a precise flat table to support the journals on both ends of the crankshaft. NFEM0054S07 SEM316A Check crankshaft main and pin journals for score.10 mm (0. method “A” gives more reliable results and is preferable. ¼ ¼ ¼ Measure crankshaft runout.CYLINDER BLOCK Inspection (Cont’d) 7.05 mm (0.0039 in) If it exceeds the limit. Cut only 0. 10. Place a dial gauge straight up on the No. Otherwise.002 mm (0. however.0020 in) or so in diameter at a time. Cut cylinder bores. 3 journal. cylinder bores may be distorted in final assembly. (Total indicator reading) Runout (Total indicator reading): Limit 0.0001 in) 3. SEM175F EM-78 . 8. While rotating the crankshaft.0001 in) Taper (A − B): Standard 0. replace crankshaft. measure journals for taper and out-ofround.

SC EL IDX SEM452G EM-79 . If crankshaft or cylinder block is replaced with a new one. a. These numbers are punched in either Arabic or Roman numerals.1 mm (0. Calculate main bearing clearance. EC FE CL MT ¼ ¼ AEM033 a. grind crankshaft journal and use undersized bearing. c.0026 in) If it exceeds the limit. If measured diameter is out of grade punched. decide suitable grade using table in SDS. These numbers are punched in either Arabic or Roman numerals. Main bearing clearance = A − Dm Standard: 0. If measured diameter is out of grade punched. EM-97. confirm that “L” dimension in fillet roll is more than the specified limit. 5. EM-98. Tighten all bolts in correct order.0.0014 . Measure outer diameters “Dm” of each crankshaft main journal. Select main bearing with suitable thickness according to the following table.045 mm (0.0. Refer to SDS. Grade number of each crankshaft main journal is punched on the respective crankshaft. When grinding crankshaft journal. GI MA SEM845E LC 4. replace bearing.035 .CYLINDER BLOCK Inspection (Cont’d) 2. AT AX SU BR SEM964 6. Refer to “SDS”. b. If clearance cannot be adjusted using any standard bearing grade. 3. Install main bearing cap and bearing beam to cylinder block. select thickness of main bearings as follows: Grade number of each cylinder block main journal is punched on the respective cylinder block. decide suitable grade using table in SDS. Refer to SDS. for available main bearings.0018 in) Limit: 0. ST RS BT HA SEM756G b.004 in) Refer to SDS for grinding crankshaft and available service parts. EM-94. Measure inner diameters “A” of each main bearing.065 mm (0. “L”: 0.

3.CYLINDER BLOCK Inspection (Cont’d) PBIC0814E Connecting Rod Bearing (Big end) 1. Measure inner diameter “C” of connecting rod. AEM027 EM-80 . Tighten bolts to the specified torque. Install connecting rod cap to connecting rod. NFEM0054S0802 Install connecting rod bearing to connecting rod and cap. 2.

Calculate connecting rod bearing clearance.0.017 mm (0. replace bearing. Measure inner diameter “C” of bushing.030 mm (0. 2.0007 in) EL IDX 2.0028 in) If it exceeds the limit.0007 in) Limit: 0.017 mm (0.070 mm (0. replace connecting rod assembly or connecting rod bushing and/or piston set with pin. Connecting rod bearing grade number (Identification color): These numbers are punched in either Arabic or Roman numerals. After driving in small end bushing.0. Drive in small end bushing until it is flush with end surface of rod. This is to ensure the clearance between connecting rod bushing and piston pin is the specified value. Calculate connecting rod bushing clearance. select connecting rod bearing according to the following table. EM142 CONNECTING ROD BUSHING CLEARANCE (SMALL ST END) NFEM0054S09 1.0002 .0. SEM062A EM-81 . ¼ When bearing clearance exceeds the specified limit.005 . EM-78. If incorrect bearing clearance exists. Be sure to align the oil holes. Measure outer diameter “Dp” of each crankshaft pin journal.059 mm (0. 7.0. If clearance cannot be adjusted within the standard of any bearing. ream the bushing. Connecting rod bearing clearance = C − Dp Standard: 0. use a thicker or undersized main bearing to ensure specified clearance.0. Refer to “BEARING CLEARANCE — Main bearing”. 6.0012 in) If it exceeds the limit.0002 . RS BT HA SEM673E REPLACEMENT OF CONNECTING ROD BUSHING SC (SMALL END) NFEM0054S13 1. 3. Measure outer diameter “Dp” of piston pin. Crankshaft pin journal grade number 0 Connecting rod bearing grade number 0 (Black) 1 (Brown) 2 (Green) EC FE CL MT AT AX SU BR SEM452G 1 2 Method B (Using plastigage) CAUTION: ¼ Do not turn crankshaft or connecting rod while plastigage is being inserted. ensure that the proper bearing has been installed. Connecting rod bushing clearance = C − Dp Standard: 0.005 . If crankshaft is replaced with a new one. 5.0013 . grind crankshaft journal and use undersized bearing. GI MA AEM034 LC 8. Clearance between connecting rod bushing and piston pin: 0.034 .0.CYLINDER BLOCK Inspection (Cont’d) 4.0023 in) Limit: 0.

15 mm (0. “Flywheel Deflection”. Tighten bolt at a force of 9.0059 in) CAUTION: ¼ Do not disassemble the flywheel. ¼ ¼ Measure deflection at 210 mm (8.3 mm (0. especially the teeth.27 in) dia. Drive plate (A/T model) Less than 0. NFEM0054S1202 Movement Amount in Rotation Direction PBIC0274E ¼ 1.8 N·m (1 kg-m. Be careful not to damage the signal plate. Flywheel Deflection ¼ NFEM0054S1201 Measure deflection of flywheel contact surface to the clutch with a dial gauge. ¼ The signal plate is built into the drive plate assembly.051 in) or less When measured value exceeds the limit. replace it with a new one. ¼ Check the movement amount in the following procedure. Install a bolt to clutch cover mounting hole. ¼ Never place the flywheel assembly with the signal plate facing down. EM-82 .45 mm (0.0177 in) or less Limit: 1. ¼ Do not allow any magnetic materials to contact the signal plate teeth. ¼ Keep any magnetized objects away from the signal plate. MOVEMENT AMOUNT OF FLYWHEEL (M/T MODELS) NFEM0054S12 SEM760G NOTE: ¼ Inspection for double mass flywheel only.CYLINDER BLOCK Inspection (Cont’d) FLYWHEEL/DRIVE PLATE RUNOUT NFEM0054S10 SEM849EB Runout (Total indicator reading): Flywheel (M/T model) Refer to EM-82. Replace as necessary. ¼ Check the drive plate and signal plate for deformation or cracks. ¼ Do not disassemble double mass flywheel. 87 in-lb) to keep it from loosening. and place a torque wrench on the extended line of the flywheel center line. ¼ Do not resurface flywheel. Standard: 0.

SEM757G ¼ Align piston rings so that end gaps are positioned as shown in the figure. 3. After assembly. ¼ KBIA0297E Put a mating mark on circumference of the two flywheel masses without applying any load (Measurement standard points). ¼ When replacing piston rings. piston pin. SEM454G EM-83 . Insert oil jet knock pin into the cylinder block knock pin hole. replace flywheel. Apply a force of 9. ST RS BT HA SEM160B OIL JET 1. 4. NFEM0055 NFEM0055S01 GI MA LC EC FE CL MT AT AX SU BR Assembly PISTON 1.8 N·m (1 kg-m. ¼ NFEM0055S02 SC EL IDX Install oil jets.94 in) or less When measured value is outside the standard. those without punchmarks present can be mounted with either side up. Align the direction of piston and connecting rod. ¼ ¼ ¼ SEM838F Install new snap ring on one side of piston pin hole. Standard: 24 mm (0. connecting rod and new snap ring. Set piston rings as shown. make sure connecting rod swings smoothly.CYLINDER BLOCK Inspection (Cont’d) 2. and tighten the mounting bolts. 3. make sure that piston rings are mounted in their original positions. Measure dimensions of movement amounts A and B on circumference of the flywheel on the transmission side. and mark the movement amount on the mass on the transmission side. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston. 2. CAUTION: ¼ When piston rings are replaced. Numbers stamped on connecting rod and cap correspond to each cylinder. 87 in-lb) in each direction.

d2): 0. 24 to 28 ft-lb) in several different steps. Prior to tightening bearing cap bolts. d2: Select minimum diameter in the measuring area. Tightening procedure Tighten all bolts to 32 to 38 N·m (3. A plastic zone tightening method is used for tightening main bearing cap bolts. Measure d1 and d2 as shown in the figure.9 kg-m. main bearing beam and bearing cap bolts. Limit (d1 . After securing bearing cap bolts. place bearing beam in its proper position by shifting crankshaft in the axial direction. EM-84 . Refer to “Inspection” of this section.CYLINDER BLOCK Assembly (Cont’d) CRANKSHAFT 1.0043 in) SEM177F SEM456G 3. replace the bolts with new ones. make sure crankshaft turns smoothly by hand. main bearing cap. SEM175F 2. If the difference between d1 and d2 exceeds the limit. ¼ ¼ a) b) SEM851E ¼ ¼ ¼ After installing crankshaft.3 to 3.11 mm (0. tighten bearing cap bolts in numerical order as shown. Confirm that correct main bearings are used. Make sure that the front mark on the main bearing beam faces the front of the engine. ¼ Instructions for reuse of main bearing cap bolts. Lubricate threads and seat surfaces of the bolts with new engine oil. ¼ NFEM0055S03 Set main bearings in their proper positions on cylinder block and main bearing beam. Turn all bolts 90 to 95 degrees clockwise with angle wrench.

10 . EC FE CL MT AT AX SU BR b. GI MA SEM852E LC 5. but thoroughly clean it. ST RS BT HA SEM457G SC EL IDX EM-85 . replace the thrust bearings and measure again. ¼ ¼ SEM620 b. Install connecting rod bearings in connecting rods and connecting rod caps. If it still exceeds the limit. Be careful not to scratch cylinder wall with the connecting rod. replace the crankshaft also.25 mm (0. Lubricate threads and seat surfaces with new engine oil. ¼ ¼ ¼ Install connecting rod caps.0. c. a. SEM455G 6. ¼ a. Arrange so that front mark on piston head faces toward engine front. Refer to EM-80.30 mm (0.0118 in) If the measured value exceeds the limit. align the connecting rod bearing stopper protrusion with the cutout of the connecting rod to install. “Connecting Rod Bearing (Big end)”. Measure crankshaft end play.0039 . Do not apply oil to the back surface. Check the oil hole on the connecting rod and that on the corresponding bearing are aligned. Crankshaft end play: Standard 0. Confirm that correct bearings are used.0. When installing the connecting rod bearings. When installing. Install pistons with connecting rods. Make sure that front mark on the connecting rod cap faces the front of the engine.0098 in) Limit 0. apply engine oil to the bearing surface (inside).CYLINDER BLOCK Assembly (Cont’d) 4. Install so that the cylinder number stamped on the connecting rod agrees with that stamped on cap side. Install them into corresponding cylinders with Tool.

9 to 2. and lay it out to rear of engine.0138 in) Limit 0. 14 to 15 ft-lb).3150 in) Limit 7. connect sub-harness. ¼ SEM027H Install knock sensor. “REAR OIL SEAL”. If it still exceeds the limit. Connecting rod side clearance: Standard 0. replace it with new one.8. If not. CAUTION: If any impact by dropping is applied to the knock sensor. (2) Turn nuts 90 to 95 degrees clockwise with angle wrench.00 mm (0.0.3110 .75 mm (0.35 mm (0. replace the connecting rod and measure again.3051 in) Tighten connecting rod cap bolts to the specified torque. ¼ After installing knock sensor.0079 .0. NFEM0055S09 KNOCK SENSOR 1.1 kg-m. Install rear oil seal retainer.0. Make sure that there is no foreign material on the cylinder block mating surface and the back surface of the knock sensor.0157 in) If the measured valve exceeds the limit. ¼ Install knock sensor so that connector faces rear of engine. Make sure that the bolts can be smoothly screwed in to the end manually. Reuse connecting rod cap bolts as follows.20 .90 . ¼ Make sure that the knock sensor does not interfere with other parts. EM-86 .40 mm (0. Connecting rod cap bolt: (1) Tighten nuts to 19 to 21 N·m (1. SEM954E 8. Measure connecting rod side clearance. SEM953E 7. replace the crankshaft also.CYLINDER BLOCK Assembly (Cont’d) c. Refer to EM-48. ¼ Do not tighten the mounting bolts while holding the connector. ¼ ¼ SEM538G d. measure the outer diameter “d” shown in the figure. Outer diameter “d” of connecting rod cap bolt: Standard 7.

¼ Secure the crankshaft using a ring gear stopper. ¼ When installing flywheel to crankshaft. Install pilot bushing or pilot converter as shown. be sure to correctly align crankshaft side dowel pin and flywheel side dowel pin hole. ¼ Install the drive plate and reinforce plate in the direction shown in the figure.CYLINDER BLOCK Assembly (Cont’d) REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT CONVERTER (A/T) NFEM0055S04 1. EC FE CL SEM163B MT FLYWHEEL NFEM0055S08 Install flywheel. AT AX SU BR SEM916G DRIVE PLATE NFEM0055S07 Install drive plate. ¼ Align dowel pin of crankshaft rear end with pin holes of each parts. GI MA SEM005G LC 2. PBIC0910E ST RS BT HA SC EL IDX EM-87 . ¼ Tighten the installation bolts crosswise over several times. Remove pilot converter using tool or suitable tool.

185) 981 (10.0012) Limit 0.760 x 3.275 (13.4 (3.205) DOHC 1-2-3-4-5-6 Compression Number of piston rings Oil Number of main bearings Compression ratio 1 4 10.3 2 NFEM0056 Bore and stroke Valve arrangement Firing order Compression Pressure Standard Compression pressure Minimum Differential limit between cylinders 1.0.45) 95.SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications General Specifications Cylinder arrangement Displacement cm3 (cu in) mm (in) V-6 3. 14) Unit: kPa (kg/cm2. psi)/300 rpm NFEM0057 Cylinder number SEM713A Cylinder Head Standard Head surface distortion Less than 0. 142) 98 (1.03 (0.0.004) NFEM0058 Unit: mm (in) SEM949E EM-88 .1 (0.0.5 x 81.498 (213.

3386 .016 (1.079) 45.26 .094) Less than 2.308 .62 (3.012 .0.5.62 (1.7842 .965 .977 .416 (0. lb) at height mm (in) Valve open Out-of-square mm (in) 433 (44.0.2 .5 (0.37.0.3 (1.2 (0.0.980 (0.0.5.12 .1 (0.34 (0.015) Hot* (reference data) 0.96.3392) 0.1.45°45′ 1.3381) 34.457) NFEM0059S04 BT HA SC VALVE LIFTER Valve lifter outer diameter Lifter guide inner diameter Clearance between lifter and lifter guide 33.051) More than 0.987 (1.0.240) 96.1.0015) NFEM0059S05 Unit: mm (in) EL IDX EM-89 .3377 .228 .304 .8 (1.2350) 45°15′ .000 .SERVICE DATA AND SPECIFICATIONS (SDS) Valve Valve VALVE NFEM0059 NFEM0059S01 Unit: mm (in) GI MA LC EC FE CL MT AT AX SU NFEM0059S02 SEM188 Intake Valve head diameter “D” Exhaust Intake Valve length “L” Exhaust Intake Valve stem diameter “d” Exhaust Intake Valve seat angle “α” Exhaust Intake Valve margin “T” Exhaust Valve margin “T” limit Valve stem end surface grinding limit 37.043) 1.15 (3.37 (0.2344 .0.6870 .34.0 (0.3.020) Less than 0.2354) 5.0005 .432 (0.008) VALVE CLEARANCE Cold Intake Exhaust 0.0.955 .970 (0.2348 .7067) 5.94.4685) 31.1.7961) 196 (20.0 (1.3) at 27.33.016) 0.4567 . 97.017) BR ST RS Unit: mm (in) *: Approximately 80°C (176°F) VALVE SPRING Free height Pressure mm (in) Installation N (kg.1) at 37.010 .039 (0.013) 0.29 .0.5 (1.0.0.2.011 .0 .31.0. 44.3.8039) 93.65 .013 .012 .0.1.3 (0.

04 (0.14 (0.02 (0.88 (0.30 (0.3181) 8.3205) 8.3213) 8.3260) 8.36 (0.3299) 8.3142) 8.3110) 7.38 (0.3276) 8.3307) SEM758G EM-90 .98 (0.94 (0.3189) 8.34 (0.3173) 8.20 (0.96 (0.16 (0.18 (0.3252) 8.28 (0.90 (0.3150) 8.3283) 8.3197) 8.3291) 8.SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d) Identification mark 788U or 788R 790U or 790R 792U or 792R 794U or 794R 796U or 796R 798U or 798R 800U or 800R 802U or 802R 804U or 804R 806U or 806R 808U or 808R 810U or 810R 812U or 812R 814U or 814R 816U or 816R 818U or 818R 820U or 820R 822U or 822R 824U or 824R 826U or 826R 828U or 828R 830U or 830R 832U or 832R 834U or 834R 836U or 836R 838U or 838R 840U or 840R Thickness mm (in) 7.40 (0.3228) 8.08 (0.92 (0.32 (0.3165) 8.24 (0.22 (0.3220) 8.3236) 8.3118) 7.00 (0.3126) 7.3268) 8.3134) 7.26 (0.06 (0.10 (0.3102) 7.12 (0.3157) 8.3244) 8.

996 (0.0.234 (0.975 .3927 .0021) 0.000 .6 .063 (0.059 (0.SERVICE DATA AND SPECIFICATIONS (SDS) Valve (Cont’d) VALVE GUIDE NFEM0059S06 Unit: mm (in) GI MA LC SEM950E EC FE CL MT AT AX SU BR ST RS BT HA SC EL IDX Standard Valve guide Valve guide Outer diameter Inner diameter (Finished size) 10.0012 .3946 .28 (0.08 (0.0.0.020 .0031) 0.0.223 .4029) 6.0.018 (0.4006 .496 .0110) 12.0023) Standard Intake 0.0011 .0.023 .12.0094) 0.0035) 0.9.4014) Cylinder head valve guide hole diameter Interference fit of valve guide 0.196 (0.0.2362 .0.4025 .504) Stem to guide clearance Exhaust Intake Valve deflection limit Exhaust Projection length “L” EM-91 .0025) — — Max.24 (0.3950) Service 10.10.2369) 9.034 (0.10.0.10.175 .3935) 10.0.09 (0. tolerance 0.030 .0008 .6.0.027 .8 (0.053 (0.0.

67 (1.0.597 .1.0044) 38.00 .236) 32.4961 .0.232 .32.4999 .9 .5.0.6405) EM-92 .6169 .5202) 32.280 .500 .1.064 .1988) 5.0 (0.6378) 5.113 (1.1.796 (1.016 (1.41.2905 .716 (1.096 (0.1.1.1.700 .1.613 (1.5157 .240) 41.000 .0.0.200 .0.113 (0.6.216 (1.2709 .5196 .05 (0.0.1988 .1.32.2715) 5.232 .232 .6142 .1949 .05 .097 .5164) 32.32.5.0.236) 0.0 (0.2874 .2683) 38.081 .4967) Service 38.9 .1 (0.1.2880) 0.38.0038) 38.0.5005) 32.38.15 (0.32.0025 .0032 .41.2028) 4.60 (1.38.6.2677 .95 .780 .6.9 .296 (1.SERVICE DATA AND SPECIFICATIONS (SDS) Valve Seat Valve Seat NFEM0060 Unit: mm (in) SEM021EC SEM621F Standard Intake Cylinder head seat recess diameter (D) Exhaust Intake Valve seat interference fit Exhaust Intake Valve seat outer diameter (d) Exhaust Intake Height (h) Exhaust Depth (H) Intake Depth (L) Exhaust 41.38.516 (1.2912) 5.07 .1.

0. 1 26. 1 25.0018 .1.0074) Limit =NFEM0061 Unit: mm (in) GI MA Camshaft journal to bearing clearance 0.500 .25.935 .076 (0.0218) No.0. 4 23.9230 .1.008) Wear limit of cam height Valve timing BT HA PBIC0187E Unit: degree a Intake valve timOFF ing control 240 b 238 c −6 d 64 e 8 f 52 SC EL IDX EM-93 .0.0034) No.188 (0.9252 .0211 .7663 .0. 2.02 (0. 3.0059) Inner diameter of camshaft bearing — LC — Outer diameter of camshaft journal EC FE CL MT AT AX EM671 Camshaft runout [TIR*] Camshaft sprocket runout [TIR*] Camshaft end play 0.0030) No.26.045 .24 (0.865 .23.1.521 (0.0. 2.05 (0.15 (0.086 (0. 1 0.0045 .0.035 .0.955 (1.055 (1.0008) Less than 0.445 .0059) 0. 4 23.115 .45.0236 .0.15 (0.SERVICE DATA AND SPECIFICATIONS (SDS) Camshaft and Camshaft Bearing Camshaft and Camshaft Bearing Standard No.7738) 0.2 (0.9238) Less than 0. 3.0094) *: Total indicator reading SU BR ST RS Cam height “A” Intake and exhaust 44. 4 0.021 (1. 2. 3.9260) No.000 .0020) — 0.0244) No.23.0014 .465 (0.

004 .008 .5201 .520 (3. 1 Standard Cylinder bore Inner diameter Grade No.2. L No.5196) 63.10 (0.64.012 (2.7610) 0.510 .2.5197 .2.2. R No. E No.64.015 (2.996 (2.997 (2.015 (0.5200) 64.64.7598 .5203) 64. P No.005 (2.5199) 64.003 .5200 .5202 .64.008 (2.5202) 64.500 .015 (0.004 (2.5195 .520 .995 (2.2.994 . S No. 3 Wear limit Out-of-round (Difference between X and Y) Taper (Difference between A and C) Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade No. 7 Grade No.011 .5195) 63.95.03 (0.7606) 95.5198 .64.5194 .014 .007 (2.64.2.010 .5199 .002 (2.5196 . D No.5194) 63.63.993 .2.3.0006) 63.7606 .5198 . Y No.5203) 64.5203 .64.5199) 64.5196) 63.002 .5198) 64.5200) 64.63.2.5200 . A No.95.5202 .5197) 64.007 .2.5196 .5198) 64.2.5197 .5200 .5201) 64.2.5194 .5202) 64.016 (2.009 (2.995 .5201) 64.996 .2.64. U No. N No.005 .530 (3.003 (2.0006) Less than 0. V No.2.2.2.64. W No.64.0012) 0.2.998 (2.95.5198) 64.7602 .5199 .2.2.5203) Main journal inner diameter grade (Without bearing) Difference in inner diameter between cylinders Standard Less than 0.015 . M No.64. B No.7602) 95. X No.5203 .014 (2.010 (2. 2 Less than 0.5195 .994 (2.5201 .SERVICE DATA AND SPECIFICATIONS (SDS) Cylinder Block Cylinder Block NFEM0062 Unit: mm (in) SEM022EA Standard Surface flatness Limit Grade No. H No.64. G No.017 (2.63.63.001 (2.64.5202) 64.006 (2.63.2.0012) EM-94 .006 .64. 4 No.5202 .5195) 63.64.5200) 64.000 (2.2. K No.5197) 64.5196 .64. F No.2.63.2.013 .011 (2.3. J No.999 .3.20 (0.998 .2.64.013 (2.012 .001 .5196) 63.0039) 95.016 . C No. T No.000 .0079) Less than 0.009 .2.997 .5198 .999 (2.03 (0.64.510 (3.

22. 1 Grade No.0 (1.993 .3.8661) 21.490 (3.010 .999 . 1 Piston clearance to cylinder block 95.95.3.8659 .7590 .7681) 41.95.7594 . Piston Ring and Piston Pin Piston.8663) 0.005 (0.3.7598 .7669 .0.680 .8661 .7598) 95.0.999 (0. 3 0. 0 Piston pin hole diameter Grade No.030 (0.7602) 95.0012) FE CL MT AT AX SU BR ST RS BT HA SC EL IDX EM-95 .21.SERVICE DATA AND SPECIFICATIONS (SDS) Piston.710 (3.0004 .0079) oversize (Service) “a” dimension Grade No.0.0.490 .500 .95. Piston Ring and Piston Pin AVAILABLE PISTON NFEM0063 NFEM0063S01 Unit: mm (in) GI MA LC EC SEM882E Grade No.614) 21.480 .20 (0.7594) 95.95.510 (3. 2 Piston skirt diameter “A” Standard Grade No.3.500 (3.

006 .20 .30 (0.0002) 0.0.8664 .0.0.6752 .0.8659 .0.0031) 0.0.8657 .8659) 21.0.995 (0.0.002 .0028) 0.21.0. 1 Interference fit of piston pin to piston Standard Piston pin to connecting rod bushing clearance Limit 0.40 (0.144.030 (0. 1 Connecting rod big end inner diameter Standard Side clearance Limit *: After installing in connecting rod EM-96 .0.1654 .0018 .20 .0118) 23.030 .070 (0. 0 Piston pin outer diameter Grade No.005 .8661 .SERVICE DATA AND SPECIFICATIONS (SDS) Piston.0. 0 Piston pin bushing inner diameter* Grade No.989 .0.000 .0189) 0.0059) 0.54 (0.48 (0.995 .94)] Limit Limit 144.001 (0.0091 .006 (0.0.0002 .8664) 22.0012) NFEM0063S03 Unit: mm (in) 21.0.0374) =NFEM0063S02 Unit: mm (in) PISTON PIN Grade No.013 (2.980 .004) — 0.006 (0.0007) *: Values measured at ambient temperature of 20°C (68°F) Connecting Rod Center distance Bend [per 100 (3.95 (0.0130 .55.0157) NFEM0064 Unit: mm (in) Connecting rod small end inner diameter Grade No.8662) 0.15 (0.6791) 0.135 (0.22.0.0.94)] Torsion [per 100 (3.24.35 (0.1 (0.0138) 0.0079 .000 (0.045 .25 (5.000 .9449) 22.0053) 0.080 (0.11 (0.0026 .065 .33 .60 (0.0.1659) 0.0.22.0. Piston Ring and Piston Pin (Cont’d) PISTON RING Standard Top Side clearance 2nd Oil ring Top End gap 2nd Oil (rail ring) 0.0130) 0.0.0236) Limit 0.0043) 0.5.0213) 0.0.8666) 55.0079 .0001 .0.2.012 (0.0315) 0.0.80 (0.0012 .23 .017 (0.33 (0.15 .22.9441 .

970 .59.0457 .3605 .2.3606) 59. V No.SERVICE DATA AND SPECIFICATIONS (SDS) Crankshaft Crankshaft Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade No.3611 .973 (2.3605 .961 (2.974 (2.002 (0.0460) 51.59.2.3612 . W No.30 (0.960 (2.954 .952 .3607) 59.59.3604) 59.967 .2. T No.2.3609) 59.10 (0.3605) 59.2.3612 .59.3608) 59.969 (2.2.3610 .962 (2.3608) 59.962 (2.59.2.59.2.3608 .2.3603 .3607 .3607) 59.2.3609) 59.1.3609 .3612) 59.955 .51.59.0.59.002 (0.2.59.954 (2.3610) 59.969 . 0 Pin journal dia. G No.2.59.59.0039 .975 .3609 .0462) 51.3609 .957 (2.59. S No. M No.2.2.3603) 59.974 (2. A No.3611) 59.956 .973 .2.2.959 .971 .962 .2.3603) 59. E No.3605) 59.971 (2.3611) 59.956 (2.965 .51.957 .5890 .964 .3606 . B No.0445 .963 . L No.59.0457) 40.59.2.2.958 (2.963 (2. R No.953 . X No.3607) 59. “Dm” grade Grade No.0039) 0. H No.3611 .958 . 2 Center distance “r” Out-of-round (X − Y) Taper (A − B) Runout [TIR*] SEM645 EM715 SC *: Total indicator reading EL IDX EM-97 .59.3610 . U No.970 (2. 7 59.968 .10 . Y No.51.959 (2.966 .59.59.955 (2.2.968 (2.59. 4 No.2.3603 .2.972 . K No. F No.25 (0.0001) Less than 0.2.3610) 59.59.3609) 59.0001) Less than 0.0460 .964 (2.3605 .965 (2.2.59. D No.59.974 .967 (2.0.3607 .3606 .966 (2.953 (2.3611) 59.968 (2.40.36 .961 .2.59.0098) NFEM0065 Unit: mm (in) GI MA LC EC FE CL MT AT AX SU BR ST RS BT HA Main journal dia.951 (2.59. P No. C No.3604 .3608 .3605) 59. N No.3604) 59.972 (2.3607 .3604 .956 .44 (1.962 . J No.960 .3611 .59. “Dp” Grade No.0118) Less than 0.2.952 (2.2.3603) 51.968 .3606) 59. 1 Grade No.5921) Standard Standard Limit Standard Free end play Limit 0.

0794) Pink/Blue 2.0789 .003 (0.0843) Main journal diameter “Dm” NFEM0066S01 Unit: mm (in) Grind so that bearing clearance is the specified value.0792) 2.132 . UNDERSIZE Thickness 0.021 .2.0796) Purple/Pink 2.021 (0.0792 .2.009 (0.0794 .0792) 19.0.0789 .0.140 (0. EM-98 .018 .012 (0.0.0.25 (0.012 .0.003 .0792 .0796 .024 (0.20.0791 .0.0796) 2.0793 .0.018 (0.0098) 2.006 .0.0793 .000 .2.0.0.012 .009 .2.0794) 2.2.015 .0796) Grade is different for upper and lower bearings.000 .0.006 .0794 .0.003 .2.2.003 .0794) 2.0793) Blue/Yellow 2.2.009 .9 .018 (0. Green/Brown Yellow/Green 2.012 (0.012 (0.0.0.0789 .0.0.783 .0.2.0790 .015 (0.009 .2.0787 .0.2.006 (0.0797) White/Purple 2.003 (0.015 (0.0791) 2.0789) 2.0.0791 .018 (0.0.0.006 (0.015 .0793) 2.2.2.012 .1 (0.0791 .2.2.0792) 2.0789) 2.0790) 2.2.006 .024 (0.0792 .018 .0.0.021 (0.0790) 2.021 (0.015 .0790 .2.0794 .0790) 2.0796 .015 (0.2.2.0790 .2.2.0791) 2.SERVICE DATA AND SPECIFICATIONS (SDS) Available Main Bearing Available Main Bearing NFEM0066 SEM175F Grade number 0 1 2 3 4 5 6 7 UPP 01 LWR UPR 12 LWR UPR 23 LWR UPR 34 LWR UPR 45 LWR UPR 56 LWR UPR 67 LWR Thickness “T” mm (in) Width “W” mm (in) Identification color (UPR/LWR) Black Brown Green Yellow Blue Pink Purple White Brown/Black Remarks 2.0793 .0793) 2.0787 .021 .018 .009 (0.2.006 (0.2.009 (0.791) Grade is the same for upper and lower bearings.0839 .0.0791) 2.0797) 2.

0592) 1.0593 .0.1.0098) 1.0594) UNDERSIZE Thickness 0.0018) NFEM0068S01 Unit: mm (in) AX SU BR ST RS BT HA SC EL IDX EM-99 .94) Less than 0.0059) Less than 24 (0.0026) 0.0.506 .0.0640 .0591 .0014 .506 (0.0.25 (0.051) Less than 0.045 (0.626 .0.065 (0.634 (0.034 .0.45 (0.1. LC EC FE CL MT AT Miscellaneous Components Standard Flywheel deflection [TIR]* Limit Drive plate runout [TIR]* Flywheel movement in radial (rotation) direction 1.509 (0.035 .0.0028) 0.500 .0177) NFEM0068 Unit: mm (in) *: Total indicator reading BEARING CLEARANCE Standard Main bearing clearance Limit Standard Connecting rod bearing clearance Limit 0.15 (0.503 .0593) 1.SERVICE DATA AND SPECIFICATIONS (SDS) Available Connecting Rod Bearing Available Connecting Rod Bearing CONNECTING ROD BEARING Grade number 0 1 2 Thickness “T” mm (in) Identification color (mark) Black Brown Green NFEM0067 NFEM0067S01 GI MA 1.0013 .0023) 0.503 (0.3 (0.1.070 (0.059 (0.0.0592 .1.0643) NFEM0067S02 Unit: mm (in) Crank pin journal diameter “Dp” Grind so that bearing clearance is the specified value.

NOTES .