Em2008 PDF

ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
YD25DDTi FOR EUROPE Exploded View .........................................................25 F
Removal and Installation .........................................26
SERVICE INFORMATION ............................ 5
INTAKE MANIFOLD ......................................... 27
G
PRECAUTIONS ................................................... 5 Component ..............................................................27
Precaution for Supplemental Restraint System Removal and Installation .........................................28
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................... 5 CATALYST ........................................................ 30 H
Precautions for Removing Battery Terminal ............. 5 Component ..............................................................30
Precautions For Engine Service ................................ 6 Removal and Installation .........................................30
Parts Requiring Angle Tightening ............................. 6 I
TURBO CHARGER ........................................... 31
Precaution for Liquid Gasket ..................................... 7
Component ..............................................................31
PREPARATION ................................................... 8 Removal and Installation .........................................32
Special Service Tool ................................................. 8 J
EXHAUST MANIFOLD ...................................... 35
Commercial Service Tool ........................................ 10
Component ..............................................................35
NOISE, VIBRATION AND HARSHNESS Removal and Installation .........................................35
K
(NVH) TROUBLESHOOTING ............................13 OIL PAN AND OIL STRAINER ......................... 37
NVH Troubleshooting - Engine Noise ..................... 13 Component ..............................................................37
Use the Chart Below to Help You Find the Cause Removal and Installation .........................................37 L
of the Symptom ....................................................... 13
GLOW PLUG ..................................................... 42
ENGINE COVERS ..............................................15 Component ..............................................................42
Component (Double Cab Only) ............................... 15 M
Removal and Installation ......................................... 16
VACUUM PUMP ................................................ 44
DRIVE BELTS ....................................................17 Component ..............................................................44 N
Checking Drive Belts ............................................... 17
Deflection Adjustment ............................................. 18
Removal and Installation ......................................... 20 INJECTION TUBE AND FUEL INJECTOR ...... 46
Exploded View .........................................................46 O
AIR CLEANER AND AIR DUCT ........................21 Removal and Installation .........................................47
Component .............................................................. 21 Inspection ................................................................49
Removal and Installation ......................................... 21
P
Changing Air Cleaner Filter ..................................... 22 FUEL PUMP ...................................................... 51
Component ..............................................................51
CHARGE AIR COOLER .....................................23 Removal and Installation .........................................51
Component .............................................................. 23
Removal and Installation ......................................... 23 FUEL PUMP SUCTION CONTROL VALVE ..... 58
Component ..............................................................58
EGR SYSTEM ....................................................25 Removal and Installation .........................................58
EM-1
ROCKER COVER .............................................. 61 NOISE, VIBRATION AND HARSHNESS
Component ............................................................. 61 (NVH) TROUBLESHOOTING ........................... 157
Removal and Installation ........................................ 61 NVH Troubleshooting - Engine Noise ................... 157
Use the Chart Below to Help You Find the Cause
CAMSHAFT ....................................................... 64 of the Symptom ..................................................... 157
Component ............................................................. 64
Removal and Installation ........................................ 64 ENGINE COVERS ............................................ 159
Valve Clearance ..................................................... 71 Component (Double Cab Only) ............................. 159
Removal and Installation ....................................... 160
OIL SEAL ........................................................... 75
Removal and Installation of Valve Oil Seal ............. 75 DRIVE BELTS .................................................. 161
Removal and Installation of Front Oil Seal ............. 75 Checking Drive Belts ............................................. 161
Removal and Installation of Rear Oil Seal .............. 76 Deflection Adjustment ........................................... 162
SECONDARY TIMING CHAIN .......................... 78
Component ............................................................. 78 AIR CLEANER AND AIR DUCT ....................... 164
Removal and Installation ........................................ 78 Component ........................................................... 164
Inspection ............................................................... 83 Removal and Installation ....................................... 164
Changing Air Cleaner Filter ................................... 165
PRIMARY TIMING CHAIN ................................. 84
Component ............................................................. 84 CHARGE AIR COOLER ................................... 166
Removal and Installation ........................................ 85 Component ........................................................... 166
Inspection ............................................................... 95 Removal and Installation ....................................... 166
CYLINDER HEAD .............................................. 97 INTAKE MANIFOLD ......................................... 168
On-Vehicle Service ................................................. 97 Component ........................................................... 168
Exploded View ........................................................ 98 Removal and Installation ....................................... 171
Removal and Installation ........................................ 99
Disassembly and Assembly ...................................102 CATALYST ....................................................... 176
Inspection ..............................................................104 Component ........................................................... 176
ENGINE ASSEMBLY ....................................... 109
Component ............................................................109 TURBO CHARGER .......................................... 178
Removal and Installation (Single Cab) ..................109 Component (for VIN<VWA***F24**033633) ......... 178
Removal and Installation (Double Cab) .................111 Component (for VIN>VWA***F24**033633) ......... 179
CYLINDER BLOCK ......................................... 115
Component ............................................................115 EXHAUST MANIFOLD ..................................... 183
Disassembly and Assembly ...................................116 Component ........................................................... 183
Inspection ..............................................................124 Removal and Installation ....................................... 183
How to Select Piston and Bearing .........................133
OIL PAN AND OIL STRAINER ........................ 185
SERVICE DATA AND SPECIFICATIONS Component ........................................................... 185
(SDS) ................................................................ 139 Removal and Installation ....................................... 185
Standard and Limit ................................................139
GLOW PLUG .................................................... 189
YD25DDTi FOR GENERAL AREAS Component ........................................................... 189
SERVICE INFORMATION .......................... 149
VACUUM PUMP ............................................... 190
PRECAUTIONS ............................................... 149
Component ........................................................... 190
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................149 INJECTION TUBE AND FUEL INJECTOR ...... 192
Precautions for Removing Battery Terminal ..........149 Component ........................................................... 192
Precautions For Engine Service ............................150 Removal and Installation ....................................... 192
Parts Requiring Angle Tightening ..........................150
Precaution for Liquid Gasket .................................151 FUEL PUMP ..................................................... 197
Component ........................................................... 197
PREPARATION ............................................... 152 Removal and Installation ....................................... 197
Special Service Tool ..............................................152
Commercial Service Tool ......................................154 ROCKER COVER ............................................. 204
EM-2
Component ............................................................ 204 NVH Troubleshooting - Engine Noise .................... 296
Removal and Installation ....................................... 204 Use the Chart Below to Help You Find the Cause A
of the Symptom ..................................................... 296
CAMSHAFT ...................................................... 207
Component ............................................................ 207 ENGINE COVERS ........................................... 298
Removal and Installation ....................................... 207 Component (Double Cab Only) ............................. 298 EM
Valve Clearance .................................................... 213 Removal and Installation ....................................... 299
OIL SEAL ......................................................... 218 DRIVE BELTS ................................................. 300 C

Removal and Installation of Valve Oil Seal ........... 218 Checking Drive Belt ............................................... 300
Removal and Installation of Front Oil Seal ............ 218 Tension Adjustment ............................................... 300
Removal and Installation of Rear Oil Seal ............ 220 Drive Belt Auto Tensioner ...................................... 301
D
SECONDARY TIMING CHAIN ......................... 221 AIR CLEANER AND AIR DUCT ..................... 303
Component ............................................................ 221 Component ............................................................ 303
Removal and Installation ....................................... 221 Removal and Installation ....................................... 304 E
Changing Air Cleaner Filter ................................... 305
PRIMARY TIMING CHAIN ............................... 227
Component ............................................................ 227 CHARGE AIR COOLER .................................. 306
Removal and Installation ....................................... 228 Component ............................................................ 306 F
CYLINDER HEAD ............................................ 238
On-Vehicle Service ............................................... 238 EGR SYSTEM ................................................. 308 G
Component ............................................................ 239 Removal and Installation ....................................... 308
Component ............................................................ 244 CATALYST ...................................................... 310
Component ............................................................ 310 H
Disassembly and Assembly .................................. 244
ENGINE ASSEMBLY ....................................... 251
Component ............................................................ 251 INTAKE MANIFOLD ....................................... 313 I
Removal and Installation (Single Cab) .................. 251 Removal and Installation ....................................... 313
Removal and Installation (Double Cab) ................ 254 Disassembly and Assembly ................................... 314
CYLINDER BLOCK .......................................... 257 TURBO CHARGER ......................................... 316 J

Component ............................................................ 257 Removal and Installation ....................................... 316
Disassembly and Assembly .................................. 258
EXHAUST MANIFOLD .................................... 322 K
How to Select Piston and Bearing ......................... 266
Inspection After Disassembly ................................ 270
OIL PAN AND OIL STRAINER ....................... 324
SERVICE DATA AND SPECIFICATIONS L
(SDS) ................................................................ 281
Standard and Limit ................................................ 281 GLOW PLUG ................................................... 327
ZD30DDTi Removal and Installation ....................................... 327
M
SERVICE INFORMATION ......................... 290 VACUUM PUMP .............................................. 329
PRECAUTIONS ................................................ 290 N
Precautions for Removing Battery Terminal ......... 290 INJECTION TUBE AND COMMON RAIL AS-
Precaution for Supplemental Restraint System SEMBLY .......................................................... 332
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation ....................................... 332
O
SIONER" ............................................................... 290
Precautions For Engine Service ............................ 291 FUEL INJECTOR ............................................ 336
Parts Requiring Angle Tightening ......................... 291 Removal and Installation ....................................... 336
Precaution for Liquid Gasket ................................. 292 P
FUEL SUPPLY PUMP ..................................... 338
PREPARATION ................................................ 293 Removal and Installation ....................................... 338
Special Service Tool ............................................. 293
ROCKER COVER ........................................... 341
Commercial Service Tool ...................................... 294
NOISE, VIBRATION AND HARSHNESS
CAMSHAFT ..................................................... 344
(NVH) TROUBLESHOOTING .......................... 296 Removal and Installation ....................................... 344
EM-3
Valve Clearance ....................................................348 ENGINE ASSEMBLY ....................................... 374
Component ........................................................... 374
TIMING CHAIN ................................................ 353 Removal and Installation (Single Cab) .................. 374
Removal and Installation .......................................353 Removal and Installation (Double Cab) ................ 377
TIMING GEAR ................................................. 357 CYLINDER BLOCK .......................................... 381
Removal and Installation .......................................357 Disassembly and Assembly .................................. 381
CYLINDER HEAD ............................................ 363 How to Select Piston ............................................. 388
On-Vehicle Service ................................................363 SERVICE DATA AND SPECIFICATIONS
Removal and Installation .......................................364 (SDS) ................................................................ 398
Disassembly and Assembly ...................................369
Standard and Limit ................................................ 398
EM-4
PRECAUTIONS
< SERVICE INFORMATION > [YD25DDTi FOR EUROPE]
SERVICE INFORMATION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000014718210
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the I
battery, and wait at least 3 minutes before performing any service.
Precautions for Removing Battery Terminal INFOID:0000000014718211
J
When disconnecting the battery terminal, pay attention to the following.
• Always use a 12V battery as power source.
• Never disconnect battery terminal while engine is running. K
• When removing the 12V battery terminal, turn OFF the ignition
switch and wait at least 30 seconds.
• For vehicles with the engine listed below, remove the battery termi-
L
nal after a lapse of the specified time:
BR08DE : 4 minutes YD25DDTi : 2 minutes

D4D engine : 20 minutes YS23DDT : 4 minutes M
HRA2DDT : 12 minutes YS23DDTT : 4 minutes
K9K engine : 4 minutes ZD30DDTi : 60 seconds
M9R engine : 4 minutes ZD30DDTT : 60 seconds N
SEF289H
R9M engine : 4 minutes
V9X engine : 4 minutes
O
NOTE:
ECU may be active for several tens of seconds after the ignition switch is turned OFF. If the battery terminal
is removed before ECU stops, then a DTC detection error or ECU data corruption may occur.
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait P
for at least 15 minutes to remove the battery terminal.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after the ignition switch is turned OFF.
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more.
- Driving for 30 minutes or more on a steep slope.
EM-5
PRECAUTIONS
• For vehicles with the 2-batteries, be sure to connect the main battery and the sub battery before turning ON
the ignition switch.
NOTE:
If the ignition switch is turned ON with any one of the terminals of main battery and sub battery discon-
nected, then DTC may be detected.
• After installing the 12V battery, always check "Self Diagnosis Result" of all ECUs and erase DTC.
NOTE:
The removal of 12V battery may cause a DTC detection error.
Precautions For Engine Service INFOID:0000000013949665
DISCONNECTING FUEL PIPING

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

Drain engine coolant and engine oil when the engine is cooled.
INSPECTION, REPAIR AND REPLACEMENT

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
REMOVAL AND DISASSEMBLY

• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Must cover openings of engine system with a tape or equivalent, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
ASSEMBLY AND INSTALLATION

• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• After disassembling and opening the engine, change engine oil and replace oil filter with a new one.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle Tightening INFOID:0000000013949666
• Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
EM-6
PRECAUTIONS
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step. A
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000013949667
EM
REMOVAL OF LIQUID GASKET
• After removing the mounting bolts and nuts, separate the mating
surface using the seal cutter (SST) and remove the old liquid gas- C
ket sealing.
CAUTION:
Be careful not to damage the mating surfaces. D
• Tap seal cutter to insert it, and then slide it by tapping on the side
as shown in the figure.
• In areas where seal cutter (SST) is difficult to use, use plastic ham-
mer to lightly tap the parts, to remove it. E
CAUTION:
If for some unavoidable reason tool such as screwdriver is
PBIC0275E
used, be careful not to damage the mating surfaces. F
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface. G
• Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes. H
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials. I
PBIC0003E
J
3. Attach the liquid gasket tube to the tube presser (SST).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location K
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove. L
M
PBIC2160E
• As for the bolt holes, normally apply the liquid gasket inside N
the holes. If specified, it should be applied outside the holes.
Check that the text of this manual is read.
• Within five minutes of liquid gasket application, install the mat- O
ing component.
• If the liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
• After 30 minutes or more pass from the installation, fill the P
engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
SEM159F
EM-7
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000013949668
Tool number
Description
Tool name
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
NT603
f: 5 (0.20)
Unit: mm (in)
KV10107902 Removing valve oil seal
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
S-NT605
KV11103000 Removing crankshaft pulley

Pulley puller
NT676
ED19600610 Checking compression pressure

Compression gauge adapter
ZZA1188D
KV101056S0 Preventing crankshaft from rotating

Ring gear stopper a: 3 (0.12)
1. KV10105630 b: 6.4 (0.252)
Adapter c: 2.8 (0.110)
2. KV10105610 d: 6.6 (0.260)
Plate e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
NT617
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0 Changing adjusting shim
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopper
NT041
EM-8
PREPARATION
Tool number
Description
Tool name A
KV10116200 Disassembling and assembling valve mecha-
Valve spring compressor nism
1. KV10115900 Part (1) is a component of KV10116200, but EM
Attachment Part (2) is not so.
2. KV10109220
Adapter
C
PBIC1650E
ST16610001 Removing crankshaft pilot bush

Pilot bushing puller D
NT045
F
KV10111100 Removing oil pan upper, oil pan lower and rear
Seal cutter chain case, etc.
H
NT046
WS39930000 Pressing the tube of liquid gasket

Tube presser
I
NT052
KV10112100 Tightening bolts for bearing cap, cylinder K

Angle wrench head, etc.
NT014 M
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
N
O
NT044
KV11106010 Removing and installing chain tensioner

Hexagon wrench a: 5 mm (0.20 in) (Face to face) P
b: 20 mm (0.79 in)
NT801
EM-9
PREPARATION
Tool number
Description
Tool name
KV11106020 Removing and installing slack guide
Hexagon wrench a: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
NT803
KV11106030 Fixing fuel pump sprocket

Positioning stopper pin a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
NT804
KV11106040 Removing and installing fuel pump sprocket

TORX wrench nut
a: T70
b: 26 mm (1.02 in)
NT805

Hexagonal wrench a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
SBIA0224E
KV11106060 Holding fuel pump sprocket

Sprocket holder
SBIA0225E
Commercial Service Tool INFOID:0000000013949669
EM-10
PREPARATION
Tool name Description
A
Valve seat cutter set Finishing valve seat dimensions
EM
C
NT048
Piston ring expander Removing and installing piston ring
NT030
Valve guide reamer Reaming valve guide with (1) or hole for over- F
size valve guide with (2)
Intake and Exhaust:
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia. G
NT016
H
Valve guide drift Removing and installing valve guide
Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia. I
J
NT015
TORX socket Loosening and tightening fuel pump mounting

bolt K
Size: E10
NT807
TORX socket Loosening and tightening drive plate and fly- M

wheel mounting bolt
Size: E20
N
NT807
O
EM-11
PREPARATION
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with angle wrench [SST:
KV10112100]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583
TORX socket Loosening and tightening main bearing cap

bolt
Size: E14
NT807
EM-12
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting - Engine Noise INFOID:0000000013949670
EM
E1BIA0268GB O
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000013949671
P
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.
EM-13
Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-71
gine clicking noise
Rocker
cover Camshaft
Camshaft oil clearance EM-71
Cylinder Rattle C A — A B C bearing
Camshaft runout EM-71
head noise
Piston to piston pin

Slap or Piston pin clearance EM-139
— A — B B —
knock noise Connecting rod bushing EM-139
oil clearance
Piston to cylinder bore
Crank- clearance
shaft pul- Piston ring side clear- EM-124
Slap or Piston
ley A — — B B A ance EM-124
rap slap noise
Cylinder Piston ring end gap EM-139
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-139
Knock A B C B B B
bearing Connecting rod bearing EM-133
noise oil clearance (Big end)
Main bearing oil clear-
Main bear- EM-133
Knock A B — A B C ance
ing noise EM-139
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-139
Timing ticking Timing chain tensioner
sioner
chain case operation
noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-139
ping)
Front of
Drive belts Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-17
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related
EM-14
ENGINE COVERS
ENGINE COVERS
A
Component (Double Cab Only) INFOID:0000000013949672
EM
MBIB9173E
P
1. Front engine cover (LHD models) 2. Front engine cover (RHD models) 3. Front cover sealing (LHD models)
4. Front cover sealing (RHD models) 5. Seal cover 6. Front floor assembly (LHD models)
7. Front floor assembly (RHD models) 8. Rear engine cover 9. Rear engine cover sealing
10. Rear floor assembly
EM-15
ENGINE COVERS
Removal and Installation INFOID:0000000013949673
REMOVAL
1. Remove front seats.
2. Remove front floor trim.
3. Remove rear floor trim.
4. Remove mountings bolts and remove covers.
INSTALLATION
Install in the reverse order of removal.
EM-16
DRIVE BELTS
DRIVE BELTS
A
Checking Drive Belts INFOID:0000000013949674
EM
E1BIA0262ZZ
E
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
A/C compressor (Models with A/C)
4. Crankshaft pulley 5. 6. Alternator F
Dummy pulley (Models without A/C)
7. Idler pulley 8. Fan pulley 9. Automatic tensioner
10. Drive belt
G
• Before inspecting engine, check engine has cooled down, wait approximately 30 minutes after engine has
been stopped.
• Visually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
• Measure deflection at the marked point ( ). H
CAUTION:
• When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation I
in deflection between pulleys.
• Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection: J
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
New Adjusted Limit for re-adjusting
K
Alternator and water pump belt or A/C
compresseor, alternator and water Automatic adjustment. Refer to EM-18, "Deflection Adjustment"
pump belt
4.6 - 5.4 7.1 - 7.7 L
Power steering oil pump belt 11.3 (0.445)
(0.181 - 0.213) (0.280 - 0.303)
*: When engine is cold.
M
Belt Frequency:
Belt frequency (Hertz)

Applied belt
New Adjusted Limit for re-adjusting N
Power steering oil pump belt 290±7 245±7 162
O
EM-17
DRIVE BELTS
Deflection Adjustment INFOID:0000000013949675
E1BIA0352ZZ
4. Crankshaft pulley 5. 6. Alternator
7. Idler pulley 8. Water pump pulley 9. Automatic tensioner
10. A/C compressor, alternator and wa- A. Adjusting bolt B. Idler pulley lock nut
ter pump belt
• Adjust belts with the parts shown below.
Applied belt Belt adjustment method

Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
Automatic adjustment
water pump belt
CAUTION:
• When a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
• If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid varia-
tion in deflection between pulleys.
• Check the belts are fully fitted into the pulley grooves during installation.
• Handle with care to avoid smearing the belts with engine oil or engine coolant.
• Never twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT
1. Loosen idler pulley lock nut (B) and tighten it temporary at 4,5 ±
2. Turn adjusting bolt (A) to adjust.
3. Tighten idler pulley lock nut (B).
Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT
EM-18
DRIVE BELTS
EM
E1BIA0285ZZ
D
1. Water Pump 2. Automatic tensioner 3. Idler pulley
4. Alternator 5. Crankshaft pulley 6.
E
A/C compressor, alternator and wa- Range when new drive belt is in-
7. Retaining pin 8. A.
ter pump belt stalled
B. Possible use range C. Indicator D. View
F
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(B). G
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (A) in the fig- H
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
I
CAUTION:
Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
CAUTION: J
• Replace the drive belt that has been removed with a new one.
• Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced. K
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
1. Insert a stopper pin (A) in diameter such as short-length screw- L
driver into the hole of the retaining boss to fix drive belt auto-ten-
sioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive M
belt is removed.
NOTE:
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin. N
JPBIA0661ZZ O
2. Remove drive belt.

P
INSTALLATION
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
EM-19
DRIVE BELTS
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-18, "Deflection Adjustment".
REMOVAL
1. Loosen each belt. Refer to EM-18, "Deflection Adjustment".
2. Remove power steering oil pump belt. Refer to EM-18, "Deflection Adjustment".
3. Remove A/C compressor, alternator and water pump belt. Refer to EM-18, "Deflection Adjustment".
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt deflection. Refer to EM-18, "Deflection Adjustment".
3. Tighten nuts provided for adjustment to the specified torque.
4. Check again that each belt deflection is as specified.
EM-20
AIR CLEANER AND AIR DUCT
A
Component INFOID:0000000013949677
EM
E1BIA0713GB
N
1. Air duct 2. Air tube 3. Air duct outlet
4. Air cleaner case (upper) 5. Air cleaner filter 6. Air cleaner case (lower)
7. Air duct side 8. Air cleaner bracket O
A. Air cleaner assembly B. To turbocharger C. To rocker cover
D. Air flow meter
• Refer to GI-9, "Component" for symbol marks in the figure. P
REMOVAL
1. Disconnect the air flow meter harness connector.
2. Remove air cleaner case/air flow meter assembly and air duct assembly disconnecting their joints.
EM-21
3. Add marks as necessary for easier installation.
CAUTION:
Handle air flow meter with care.
• Do not shock it.
• Do not disassemble it.
• Do not touch its sensor.
INSPECTION AFTER REMOVAL
Inspect air duct for crack or tear.
• If anything found, replace air duct.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
• Tighten mounting bolts to the specified torques.
Changing Air Cleaner Filter INFOID:0000000013949679
REMOVAL
1. Unhook clips, and lift air cleaner case (upper).
2. Remove air cleaner filter.
INSTALLATION
Installation is the reverse order of removal.
EM-22
CHARGE AIR COOLER
CHARGE AIR COOLER
A
EM
J
E1BIA1661GB
1. Clamp 2. Intake manifold 3. Bolt K

4. Bolt 5. Bracket 6. Tube
7. Clamp 8. Air hose 9. Bolt
10. Inlet tube 11. Bolt 12. Air Hose L
13. Braket Silencer 14. Bolt 15. Bolt
16. Charge air cooler 17. Air hose 18. Clamp
19. Clamp 20. Air Hose 21. Radiator M
22. Water outlet 23. Air hose 24. Boost pressure sensor
25. O-ring
A. View A B. View B N
Refer to GI-9, "Component" for symbol marks in the figure.
Removal and Installation INFOID:0000000013949681 O
REMOVAL
1. Remove clamps from air hose between charge air cooler and tubes. P
2. Remove bracket from the radiator.
3. Remove lower mountings bolts.
4. Remove upper mountings bolts and remove charge air cooler.
• If required locate the position of air hoses and air tubes on their connection by meaning of paint marks, and
remove air hoses and tube hoses.
CAUTION:
EM-23
CHARGE AIR COOLER
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Be careful not to deform core fins.
INSTALLATION
• Pay attention to identification mark color and direction when installing air inlet hose.
Tighten bolts and nuts to the specified torques.
EM-24
EGR SYSTEM
EGR SYSTEM
A
Exploded View INFOID:0000000013949682
EM
E1BIA0786GB
P
1. EGR cooler 2. Gasket 3. Cover
4. EGR guide tube 5. Gasket 6. EGR control valve
7. Gasket 8. EGR tube 9. Gasket
Refer to GI-9, "Component" for symbols in the figure.
EM-25
EGR SYSTEM
REMOVAL
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
1. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
2. Remove battery. Refer to SC-24, "Removal and Installation".
3. Remove Air duct. Refer to EM-21, "Component".
4. Disconnect water hoses from EGR cooler tube.
5. Remove EGR tube (front) and EGR volume control valve assembly.
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.
6. Remove exhaust pressure sensor tube and bracket. Refer to EM-31, "Component".
7. Remove Turbocharger heat cover. Refer to EM-31, "Component".
8. Disconnect and put aside the vaccum hose.
9. Remove EGR guide tube. Refer to EM-25, "Exploded View".
10. Remove EGR cooler. Refer to EM-25, "Exploded View"
INSTALLATION
CAUTION:
Clean each joint surface before installation.
EGR Volume Control Valve
Perform “EGR Volume Control Valve Closed Position Learning Value Clear” and “EGR Volume Control Valve
Closed Position Learning” after repair when removing or replacing EGR volume control valve. Refer to EC-
151, "Description" .
EM-26
INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
E1BIA0353GB
P
1. Cylinder head 2. Gasket 3. Intake manifold
4. Gasket 5. Collector intake manifold 6. Air intake temperature sensor
7. Gasket 8. Electric throttle control actuator 9. Gasket
10. Bracket 11. Bracket 12. EGR tube
• Refer to GI-9, "Component" for symbol marks in the figure.
EM-27
INTAKE MANIFOLD
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Disconnect air inlet hose from throttle chamber. Refer to EM-21, "Component".
2. Remove fuel filter. Refer to FL-5, "Removal and Installation".
3. Remove oil level gauge guide. Refer to EM-37.
4. Remove fuel hoses and fuel gallery. Refer to EM-46, "Exploded View".
• To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
• Add marks as necessary for easier installation.
5. Remove vacuum hoses.
6. Disconnect heater feed hose, water hoses, and remove heater feed pipe.
7. Remove intake manifold bracket, and put aside wire.
8. Remove EGR tube.
9. Remove injection tube center. Refer to EM-47, "Removal and Installation".
CAUTION:
10. Disconnect air intake temperature sensor.
11. Remove collector intake manifold.
12. Loosen bolts and nuts in the reverse order of that shown in the figure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
E1BIA0282ZZ
13. Remove throttle chamber from intake manifold.

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

• If it exceeds the limit, replace intake manifold.
PBIC3411E
INSTALLATION
EM-28
INTAKE MANIFOLD
1. Install intake manifold. A
• Tighten fixing bolts and nuts in numerical order as shown in
the figure.
• If stud bolts were removed, tighten them to the specified EM
torque.
: 10.8 N·m (1.1 kg-m, 8 ft-lb) C
D
E1BIA0282ZZ
2. Before starting engine, bleed air from fuel piping. Refer to FL-7, "Air Bleeding". E
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION: F
Never touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight. G
EM-29
CATALYST
CATALYST
E1BIA0665GB
1. Cylinder block 2. Yoke washers 3. Bolts

4. Yoke washers 5. Nuts 6. Bolts
7. Nuts 8. Catalyst cover 9. Gasket
10. Catalyst 11. Catalyst bracket
A. To DPF

REMOVAL
1. Remove catalyst cover.
2. Remove exhaust front tube. Refer to EX-3, "Component".
3. Remove air inlet hose and air inlet tube. Refer to EM-21, "Component".
4. Remove catalyst and exhaust outlet.
INSTALLATION
• If stud bolts of turbocharger were removed, tighten them to the specified torque.
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
• If stud bolts of catalyst were removed, tighten them to the specified torque.
: 45.0 N·m (4.6 kg-m, 33 ft-lb)
• Pushing bracket against the cylinder block and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.
EM-30
TURBO CHARGER
TURBO CHARGER
A
EM
L
E1BIA0284GB
1. Turbocharger 2. Exhaust manifold 3. Nut M

4. Gasket 5. Stud 6. Stud
7. Heat insulator 8. Clip 9. Turbocharger pressure sensor
10. Clamp 11. Hose 12. Bracket N
13. Bolt 14. Tube 15. Bolt
16. Gasket 17. Oil pipe 18. Eye-bolt
19. Gasket 20. Clamp 21. Oil connector O
22. Gasket 23. Clamp 24. Clamp
25. Clamp 26. Water pipe return 27. Clamp
28. Water hose feed 29. Clamp 30. Gasket P
31. Water pipe feed 32. Gasket 33. Nut
34. Catalyst 35. Bolt
A. To air inlet hose B. To cylinder block C. To cylinder block
D. To Water outlet E. To water pipe
EM-31
TURBO CHARGER
REMOVAL
• After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and then
loosen the nuts to remove.
1. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant"
2. Remove air inlet hose and air inlet pipe. Refer to EM-21, "Component".
3. Remove air duct and air inlet pipes. Refer to EM-21, "Component".
4. Remove exhaust manifold cover. Refer to EM-35, "Removal and Installation".
5. Remove catalyst. Refer toEM-30, "Removal and Installation"EM-30, "Removal and Installation".
6. Remove eye bolts and water hose from water tube and oil feed tube and oil return tube.
7. Disconnect connector from turbocharger.
8. Remove turbocharger with water tube and oil feed tube and oil return tube.
CAUTION:
• Be careful not to deform water tube and oil-feed-and-return tube.
• Never disassemble or adjust the turbocharger.
• Be careful not to contact with the vehicle.
• Never hold turbocharger boost control actuator and actuator rod.
9. Remove water tube and oil feed tube and oil return tube from turbocharger.
10. Remove turbocharger.
CAUTION:
Oil Tube and Water Tube
• Clean inside of oil feed tube and oil return tube and water tube, and check tubes for clogging.
• Replace oil feed tube and oil return tube and/or water tube if clogging still exists after cleaning.
E1BIA1664ZZ
1. Compressor housing 2. Turbocharger boost control actuator 3. Turbine housing

A. Check for charge air pressure leaks B. Check for exhaust gas leaks C. Check for engine coolant leaks
D. Check for engine oil leaks
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
Suction side : Between turbocharger and charge air cooler

Exhaust side : Between turbocharger and catalyst
Rotor Shaft Clearance
EM-32
TURBO CHARGER
• Check that the rotor shaft (1) rotates smoothly without any resis-
tance when it is rotated by your fingertips. A
• Check that the rotor shaft is not loose when it is moved vertically or
horizontally.
• Measure looseness with a dial gauge inserting its measuring rod
EM
through oil drain hole of turbocharger.
Standard : 0.086 - 0.111 mm (0.0034 - 0.0044 in)

C
• Replace turbocharger if out of standard.
E1BIA0290ZZ
D
Rotor Shaft End Play
• Place a dial gauge (A) at the rotor shaft (1) end in the axial direc-
tion to measure the end play.
E
Standard : 0.030 - 0.111 mm (0.0012 - 0.0044 in)
F
G
E1BIA0292ZZ
Turbine Wheel H
• Check that there is no engine oil adhesion.
• Check that there is no carbon accumulation.
• Check that blades of turbine wheel (1) are not bent or broken.
• Check that turbine wheel does not interfere with turbine housing I
(2).
K
E1BIA0291ZZ
Compressor Wheel
• Check that there is no engine oil adhesion inside the air inlet. L
• Check that compressor wheel (1) does not interfere with compres-
sor housing (2).
• Check that compressor wheel is not bent or broken.
M
E1BIA0293ZZ O
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
• Check that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil amount is P
more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbocharger is mis-
judged malfunction.)
• Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
• Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
EM-33
TURBO CHARGER
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
Symptom
Inspection item Inspection result
(when each inspection item meets each inspection result)
Engine oil Insufficient power/accel-
Smoke Noise
leakage eration malfunction
Engine oil leaks C A C C
Carbon is accumulated C A B B
Turbine wheel
Friction with housing C B A B
Blades are bent or broken — — A A
Inside the air inlet is seriously contam-
B B — —
inated by engine oil.
Compressor wheel
There is resistance when the rotor
— C C B
shaft is rotated by your fingertips.
After checking both turbine and
compressor, inspect rotor shaft The rotor shaft sometimes does not
— — — A
end play. rotate by your fingertips.
There is too much play in the bearing. C C B C
Carbon or sludge is accumulated in
Oil return port C A C C
the waste oil hole.
A: Large possibility
B: Medium possibility
C: Small possibility
INSTALLATION
• When a stud bolt is pulled out, replace it with a new one and tighten it to the following torque.
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
EM-34
EXHAUST MANIFOLD
EXHAUST MANIFOLD
A
EM
I
E1BIA0271GB
1. Turbocharger 2. Exhaust manifold cover RH 3. Exhaust manifold cover LH J

4. Cylinder head 5. Gasket 6. EGR cooler tube
7. Gasket 8. Exhaust manifold 9. Gasket
10. Exhaust temperature sensor K
A. No. 1 port B. No. 2 port C. No. 3 port
D. No. 4 port E. Alignment protrusion
: Vehicle front L

Removal and Installation INFOID:0000000013949691 M
REMOVAL
1. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant". N
2. Remove exhaust manifold cover.
3. Remove turbocharger. Refer to EM-35, "Removal and Installation".
O
4. Remove EGR cooler. Refer to EM-26, "Removal and Installation".
EM-35
EXHAUST MANIFOLD
5. Loosen exhaust manifold mounting nuts in the reverse order in
the figure.
E1BIA0272ZZ
6. Remove exhaust temperature sensor.

7. Remove exhaust manifold.
Surface Distortion
• Use a reliable straight edge and feeler gauge to check the flatness
of exhaust manifold fitting surface.
Limit : 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.
PBIC2210E
INSTALLATION
• If stud bolts were removed, replace them with new ones, and tighten them to the specified torque:
: 14.7 N·m (1.5 kg-m, 11 ft-lb)

• Tighten the exhaust manifold mounting nuts in the following procedure:
1. Install gasket so that the alignment protrusion faces the No. 4 port. Refer to "Removal and Installation".
2. Tighten the nuts in order specified in the figure.
3. Re-tighten the nuts 1 to 8.
4. Install in the reverse order of removal.
E1BIA0272ZZ

Start engine and raise engine speed to check no exhaust gas and engine oil leaks.
EM-36
OIL PAN AND OIL STRAINER
A
EM
J
PBIC3424E
1. Oil level gauge 2. Oil level gauge guide 3. Oil level sensor K
4. O-ring 5. O-ring 6. O-ring
7. Oil pan upper 8. Crankshaft position sensor 9. O-ring
10. Rear plate 11. Rear plate cover 12. Oil strainer L
13. Oil pan drain plug 14. Drain plug washer 15. Oil pan lower
• Refer to GI-9, "Component" for symbol marks in the figure. M

REMOVAL N
WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
1. Drain engine oil. Refer to LU-8, "Changing Engine Oil". O
EM-37
2. Remove oil pan lower bolts. Loosen bolts in the reverse order of
that shown in the figure.
: Vehicle front
PBIC3425E
3. Remove oil pan lower.

a. Insert the seal cutter (SST) between oil pan upper and oil pan
lower.
CAUTION:
• Be careful not to damage aluminum mating surface.
• Never insert screwdriver, or oil pan flange will be
deformed.
b. Slide the seal cutter by tapping on the side of the seal cutter with
a hammer.
c. Remove oil pan lower.
SEM365EA
4. Remove oil strainer.

5. Remove radiator lower shroud. Refer to EM-37.
6. Remove power steering oil pump belt. Refer to EM-17.
7. Remove power steering oil pump bracket and move power steering oil pump aside with its piping con-
nected. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to PS-13,
"Removal and Installation".
8. Disconnect oil return hose (vacuum pump) from oil pan upper. Refer to EM-44, "Component".
9. Remove the oil level gauge guide. Refer to EM-115, "Component"
10. Remove A/C compressor bracket mounting bolts (A).
1 : Oil pan upper

2 : A/C compressor bracket
: Vehicle front
PBIC3426E
11. Remove the drive belt. Refer to EM-20, "Removal and Installation"
12. Remove the crankshaft pulley. Refer to EM-115, "Component".
13. Remove the front cross member. Refer to FSU-5, "Component" .
14. Remove the oil level sensor.
CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble.
• Keep it away from metal particles.
• Never place sensor close to magnetic materials.
15. Remove front propeller shaft. Refer to PR-4, "Removal and Installation".
EM-38
16. Remove RH and LH front drive shaft. Refer to FAX-5, "Removal and Installation".
17. Remove front final drive assembly. Refer toRFD-10, "Removal and Installation" . A
18. Remove rear plate cover and transmission joint bolts.
19. Loosen bolts in the reverse order of illustration to remove oil pan
upper. EM
: Vehicle front
C
PBIC3431E
E
20. Remove oil pan upper.
• Insert the seal cutter (SST) between oil pan upper and cylinder
block. Slide the seal cutter by tapping on the side of the seal F
cutter with a hammer. Remove oil pan upper.
CAUTION:
G
• Never insert screwdriver, or oil pan flange will be
deformed.
SEM365EA
I
Clean oil strainer if any object attached.
J
INSTALLATION
• Install oil pan upper with the following procedure.
- Use the scraper (A) to remove old liquid gasket from mating sur- K
face of oil pan upper (1).
CAUTION:
• Also remove old liquid gasket from mating surface of cylin- L
der block and rear chain case.
• Remove old liquid gasket from the bolt hole and thread.
M
PBIC3432E
N
- Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to areas shown in the figure. O
: Vehicle front
P
CAUTION:
• At the 2 bolt holes marked , liquid gasket should be
applied outside holes.
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) or
4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that the
PBIC3433E
diameter of the liquid gasket bead is different around the
front.)
EM-39
• Attaching should be done within 5 minutes after coating.
- Install oil pan upper.
CAUTION:
Install avoiding misalignment of O-ring.
• Tighten bolts in numerical order to the specified torque.
: Vehicle front
• Bolt dimensions vary depending on the installation location. Refer

to the following and use appropriate bolts.
M6 x 30 mm (1.18 in) : Bolt No. 15, 16

M8 x 25 mm (0.98 in) : Bolt No. 2, 4, 5, 8, 9, 10, 14
M8 x 60 mm (2.36 in) : Bolt No. 1, 3, 6, 7, 11, 12, 13, 17
PBIC3431E
• The shank length under the bolt neck above is the length of the
threaded part (pilot portion not included).
• Install oil pan lower with the following procedure.
- Use a scraper (A) to remove old liquid gasket from mating surface
of oil pan lower (1).
CAUTION:
• Also remove old liquid gasket from mating surface of oil pan
upper.
• Remove old liquid gasket from bolt hole and thread.
PBIC3430E

(commercial service tool) as shown in the figure.
: Vehicle front

CAUTION:
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
PBIC3434E
SEM159F
- Install oil pan lower.
EM-40
A
: Vehicle front
NOTE:
Pour engine oil or start engine at least 30 minutes after oil pan is EM
installed.
PBIC3425E
D
1. Check engine oil level and add engine oil. Refer to LU-7, "Inspection".
2. Check for leakage of engine oil when engine is warmed. E
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-7, "Inspection" .
F
EM-41
GLOW PLUG
GLOW PLUG
E1BIA0785GB
1. Glow plug (Ceramic or Metal)

: Engine front A. Refer to. EM-42, "Removal and In-
stallation"
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Remove engine cover.
2. Disconnect air inlet hose from electric throttle control actuator.
3. Disconnect glow plug connector.
4. Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
CAUTION:
• Replace with a glow plug of the same type describedin the list.
• For the identification of glow plug, refer to the figure.
EM-42
GLOW PLUG
Type Resin ring colour (C) A

A Ceramic Translucent
B Metal Yellow
EM
JPBIA5676ZZ
D
3. Torque tighten glow plug.
Ceramic type : 16.5 N·m (1.7 kg-m, 12 E

ft-lb)
Metal type : 11.1 N·m (1.1 kg-m, 8 ft-lb) F
4. Install remaining parts in the reverse order of removal.

G
EM-43
VACUUM PUMP
VACUUM PUMP
PBIC3435E
1. O-ring 2. Vacuum pump 3. Bracket

4. Oil feed tube 5. Cooper washer 6. Eye-bolt
7. Oil return hose
: Vehicle front

INSPECTION BEFORE REMOVAL

1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-
tor.
2. Start engine and measure generated vacuum at idle speed.
Standard:
–94.0 to –96.1 kPa (–940 to –961 mbar, –705 to –721 mmHg, –27.76 to –28.38 inHg)
• If out of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump.
REMOVAL
1. Drain engine oil. Refer to LU-8, "Changing Engine Oil"
2. Remove primary timing chain. Refer to EM-85, "Removal and Installation".
3. Disconnect vacuum hose from vacuum pump side.
4. Remove oil feed tube and oil return hose.
5. Remove bracket.
EM-44
VACUUM PUMP
6. Remove vacuum pump and O-ring.
A
INSTALLATION
Bracket EM
Tighten fixing bolts in numerical order as shown in the figure.
: Cylinder block side

C
E
PBIC4907E
EM-45
INJECTION TUBE AND FUEL INJECTOR
JPBIA3691GB
1. Nozzle oil seal 2. Injection tube No. 1 - 4 3. Protector

4. Cooper washer 5. Eye-bolt 6. Spill tube
7. Gasket 8. Fuel rail 9. Connector tube
10. Gasket 11. Clamp 12. Return hose
13. Injection tube 14. Clip 15. Spill hose
16. Clamp 17. Spill tube retaining bolt 18. Clamp
19. Fuel feed hose 20. Fuel pump 21. Clamp
22. Spill hose 23. Fuel gallery 24. Clamp
25. Air bleed hose 26. Air bleed tube 27. Quick connector
28. Nozzle gasket 29. O-ring 30. Nozzle support
31. Fuel injector 32. Rocker cover
A. To fuel filter
: Engine front
EM-46
A
REMOVAL
1. Remove engine cover
EM
2. Remove injection tube. Refer to EM-46, "Exploded View".
CAUTION:
3. Disconnect harness connector from fuel injector. C
4. Remove spill hose.
5. Following steps below, remove injection tubes.
D
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method.
b. Remove injection tubes in order of 3-2-1-4 individually.
E
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator
clear of fuel. F
: Engine front
G
JPBIA3753ZZ
H
6. Remove nozzle oil seal.

• Using the flat-bladed screwdriver, pry flange to remove oil
seal. I
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil J
seal replacement is not required.
PBIC0944E
7. Remove rocker cover. Refer to EM-61, "Component". L
EM-47
8. Remove spill tube mounting bolts and nut.
• Loosen bolts and nut to the reverse order in the figure and
remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with span-
ner.
B : Gasket position
C : Spill tube retaining bolt
: Engine front
JPBIA3889ZZ
9. Remove fuel injector as follows.
1 : Fuel injector
2 : O-ring
3 : Nozzle gasket
4 : Nozzle support
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION: PBIC4852E
• Handle fuel injector carefully without giving any impact.
• Never disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
d. Remove O-ring from fuel injector.
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface when replacing fuel injector.
• Refer to EC-40, "Injector Adjustment Value Registration" .
JPBIA3754ZZ
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6

2. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
b. Tighten injection tubes temporarily in the order of 1-2-3-4.
c. Be sure to fit nozzle support and pin without looseness.
d. Tighten nozzle support bolts.
EM-48
e. Loosen injection tubes in the order of 3-2-1-4.
3. Connect spill tube. A
• Tighten fixing bolts and nut in numerical order shown in the fig-
ure.
CAUTION: EM
When tightening nut, fix spill tube retaining bolt with
spanner.
NOTE:
Connection of spill tube gasket may be broken, even if it is C
tighten to the specified torque. It does not affect performance.
B : Gasket position D
C : Spill tube retaining bolt
: Engine front
E
JPBIA3889ZZ
4. Perform air tightness test for spill tube. H

• Connect a handy vacuum pump to spill connector. Check that
vacuum is retained while applying following vacuum.
I
Standard:
–53.3 to –66.7 kPa (–533 to –667 mbar, –400 to –
500 mmHg, –15.75 to –19.69 inHg) J
• If outside of standard, reconnect spill tube. (Replace gasket in
this case.)
5. Install rocker cover. Refer to EM-61, "Removal and Installation". JEF250Z
K
6. Install nozzle oil seal.
• Apply engine oil to the rocker cover nozzle oil seal contact surface and the nozzle oil seal fuel injector
contact surface before installation. L
• Insert it straight until its flange fully contacts rocker cover.
CAUTION:
• Check gutter spring in nozzle oil seal on fuel injector for missing. M
7. Connect injection tubes individually to each cylinder in order of
1-2-3-4.
N
: Engine front
P
JPBIA3753ZZ
8. Install in the reverse order of removal after this step.
Inspection INFOID:0000000013949700
EM-49
• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing to the vehicle when replacing fuel injector.
Refer to EC-40, "Injector Adjustment Value Registration".
JPBIA3754ZZ
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6

• Start engine and increase engine speed to check for fuel leak.
CAUTION:
Never touch engine immediately after stopped as engine becomes extremely hot.
EM-50
FUEL PUMP
FUEL PUMP
A
EM
I
E1BIA0274GB
1. Washer 2. Fuel pump sprocket 3. Seal washer J

4. O-ring 5. Adjusting shim 6. Sprocket nut
7. Coupling 8. Oil seal 9. Spacer
10. Key 11. Fuel pump 12. Fuel pump bracket K
13. Fuel pump bracket
: Engine front
L
M
CAUTION:
• Before removing and installing fuel pump, be sure to remove sprocket. Never loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis- N
ton heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil. O
• When fuel pump is replaced with new one or another one, perform fuel pump learning value clearing
before starting engine. Refer to EC-41, "Fuel Pump Learning Value Clearing" .
REMOVAL P
1. Remove engine cover, vacuum gallery and heater feed pipe. Refer to EM-27, "Component" .
2. Remove fuel hose and spill hose from fuel pump. Refer to EM-47, "Removal and Installation".
CAUTION:
3. Disconnect harness connectors from fuel pump.
4. Remove injection tube center, clip and insert rubber. Refer to EM-46, "Exploded View".
EM-51
FUEL PUMP
CAUTION:
5. Remove secondary timing chain. Refer to EM-78.

6. Hold fuel pump sprocket and remove bolt.
a. Insert the positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel pump sprocket.
b. Using the TORX wrench (SST), turn pump shaft little by little to
adjust the position of fuel pump sprocket so that the holes align.
c. Push the positioning stopper pin (SST) through fuel pump
sprocket to fuel pump body to hold fuel pump sprocket.
MBIA0049E
• Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket.
PBIC2535E
7. Using the hexagon wrench (SST) remove tightening bolts of fuel

pump sprocket.
PBIC2404E
MBIA0074E
EM-52
FUEL PUMP
8. Using the sprocket holder (SST), hold fuel pump sprocket to pre-
vent falling. A
• Rework sprocket holder (SST) to use, as shown in the figure.
EM
SBIA0217E
D
• When the sprocket holder is installed, if the positioning stopper
pin (SST) interferes, pull out the positioning stopper pin
approximately 10 mm (0.39 in), then install it. E
• After the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) (commercial service tool) insert into the machined
bore. F
• The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
• Check that the a- and b-faces of the sprocket holder contact G
the bottom side of the sprocket (small diameter side).
PBIC2534E
CAUTION:
Never remove the sprocket holder (SST) until fuel pump is installed. H
• After the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.
K
MBIA0075E
9. Using the extension bar and the TORX socket (size: E10) (com-
mercial service tool), remove the tightening bolts. L
CAUTION:
Never disassemble or adjust fuel pump.
M
PBIC2405E
O
10. Remove the fuel pump toward the rear of engine.
CAUTION:
For removal, be careful not to drop the seal washer into the engine. P
NOTE:
The seal washer of the tightening bolts cannot be reused.
11. Remove adjusting shim.
12. Attach a suitable tool in the M8 bolt hole on coupling.
EM-53
FUEL PUMP
13. Loosen sprocket nut with the TORX wrench (SST).
MBIA0013E
14. Remove coupling with a suitable puller.
MBIA0014E
15. Remove spacer from fuel pump.

16. Remove oil seal from spacer.
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
SEM984C
INSTALLATION
1. Install new oil seal to spacer.
MBIA0045E
2. Install spacer to fuel pump.
EM-54
FUEL PUMP
3. Install coupling to fuel pump of spacer.
• Using the TORX wrench (SST), tighten the sprocket nut to fix A
the coupling.
EM
MBIA0013E
D
4. Install adjusting shim.
• For shim adjustment, measure dimension L [Distance between
front surface of coupling and the fuel pump flange (spacer)] at
E
two opposing points near the coupling bolt center. Use the
average of these two measurements to select the shim grade
that marked on adjusting shim.
F
G
MBIA0077E
• The shim adjustment is required only when the fuel pump is H

replaced.
PBIC3439E K
Part No. of adjusting shim Grade number Measuring dimension L mm (in) Type L
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657) A
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445) B
M
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A+C N
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B+B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C+B
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D+B O
EM-55
FUEL PUMP
5. Before fuel pump is installed, check that spacer and the 6 mm
(0.24 in) dia. hole on coupling are aligned.
MBIA0016E
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION:
Be careful not to drop the seal washer into engine.
PBIC2438E
mercial service tool), tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder (SST).
PBIC2405E
9. Using the TORX wrench (SST), turn the pump shaft gradually to
adjust the position of fuel pump sprocket. Then, insert the posi-
tioning stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the
fuel pump sprocket through the pump body.
10. Remove the TORX wrench (SST).
MBIA0049E
11. Using the hexagon wrench (SST), tighten the sprocket tighten-
ing bolt.
• When the washer of the fuel pump sprocket is removed, install
it with the marking “F” (front) facing the front of the engine.
12. Pull out the positioning stopper pin (SST).
PBIC2404E
EM-56
FUEL PUMP
13. Install secondary timing chain. Refer to EM-78, "Removal and Installation".
A
14. Following steps below, install injection tube center. Refer to EM-46, "Exploded View".
a. Pre-set clip and insert rubber to injection tube center.
b. Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
EM
c. Adjust clip dimension and tight bolt for clip to intake manifold by tool.
d. Tight nut of injection tube center to fuel pump by tool.
e. Tight nut of injection tube center to fuel rail by tool. C
15. Connect the harness connector to fuel pump.
16. Install fuel hoses. Refer to EM-46, "Exploded View".
17. Hereafter, install in the reverse order of removal. D
CAUTION:
When fuel pump is replaced with new one or another one, perform fuel pump learning value clear-
ing before starting engine. Refer to EC-41, "Fuel Pump Learning Value Clearing". E
EM-57
FUEL PUMP SUCTION CONTROL VALVE
E1BIA0296GB
1. Suction control valve 2. Bolt 3. Small O-ring

4. Gasket 5. O-ring

REMOVAL
1. Disconnect wiring harness from Fuel pump suction control valve.
1 : Fuel pump suction control valve
E1BIA0297ZZ
2. Take note of the connector's orientation. The new valve will have to be fitted in the same way as the old
one.
3. Clean the pump with brake cleaner around fuel pump suction control valve contact surface.
4. Remove fixating bolt of the suction valve and remove the suction valve.
NOTE:
• The large O-ring says inside. Do not pull the valve with twisting or try pying it out with any tool. Carefully pull
the valve straight up.
• Do not use work gloves to prevent foreign substances entering the fuel injection pump.
NOTE:
INSTALLATION
1. Remove large O-ring.
EM-58
A
1 : Large O-ring
NOTE:
• Do not use any tool to remove the O-ring. EM
• Do not allow any foreign substances to enter into the fuel
injection pump.
C
E1BIA0298ZZ
D
2. Ensure that the groove of the pump side housing is contamination free, then place the large new O-ring
into the groove.
E
1 : Large O-ring
NOTE:
F
• Apply clean engine oil around the small O-ring, then fit it to the
groove. Otherwise the O-ring may fall off.
E1BIA0299ZZ
H
3. Insert the new gasket.

4. Apply clean engine oil around the small O-ring on the new suction control valve for sealing. I
1 : Small O-ring
J
NOTE:
• Make sure the suction control valve is clean and no debris
sticks to the O-Ring.Any contamination or damage to the O-
ring will cause the fuel injection pump not to work properly. K
L
E1BIA0300ZZ
5. Insert the new suction control valve by hand until you feel a click. Make sure the connector faces into the M
same direction as before removal.
NOTE: N
• Do not try to twist the suction control valve in, just push it straight.
E1BIA0301ZZ
6. Tighten bolt by hand and then use the torque wrench. Refer to EM-58, "Component".
7. Connect the suction control valve to the wiring harness.
EM-59
8. Clean the suction control valve fitting area with a degreasing spray.
9. Bleed the air from fuel lines. Refer to FL-7, "Air Bleeding".
10. Start engine and check there is no fuel leakage.
EM-60
ROCKER COVER
ROCKER COVER
A
EM
I
E1BIA0358ZZ
1. Nozzle oil seal 2. Oil filler cap 3. Rocker cover J

4. Gasket
A. Refer to EM-61, "Removal and Installation" B. To Intake air duct
• Refer to GI-9, "Component" for symbol marks in the figure. K
L
REMOVAL
1. Remove engine cover.
2. Remove vacuum gallery and engine cover bracket on rocker cover and ventilation hose. M
3. Disconnect harness connector from fuel injector. Refer to EM-46, "Exploded View".
4. Following steps below, remove injection tube. Refer to EM-47, "Removal and Installation".
a. Put a paint mark or tag on injection tubes to identify each cylinder. N
O
JPBIA3753ZZ
EM-61
ROCKER COVER
CAUTION:
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
5. Remove injection nozzle oil seal.
• Using the flat-bladed screwdriver, pry flange to remove nozzle
oil seal.
PBIC0944E
6. Remove rocker cover.

• Loosen holding bolts in the reverse order of that shown in the
figure and remove.
: Engine front
JPBIA3760ZZ
7. Remove gasket from rocker cover.

INSTALLATION
1. Install new gasket to rocker cover.
2. Apply liquid gasket with tube presser (commercial service tool)
on locations shown in the figure.
1 : Cylinder head
2 : Cylinder head rear cover
a : 10 mm (0.394 in)
b : φ 3.0 mm (0.118 in)
: Engine front
• Use Genuine Liquid Gasket or equivalent.

JPBIA3761ZZ
3. Tighten holding bolts.

• Tighten all bolts in numerical order as shown in the figure.
: Engine front
: 7.8 N·m (0.8 kg-m, 69 in-lb)

• Re-tighten to the same torque in the same order as above.
JPBIA3760ZZ
EM-62
ROCKER COVER
• Insert it straight until flange fully contacts rocker cover. A
6. Before starting engine, bleed air from fuel piping. Refer to FL-7, "Air Bleeding".
EM
Start engine and increase engine speed to check for fuel leak and engine oil leak.
CAUTION:
Never touch the engine immediately after stopped as engine becomes extremely hot. C
EM-63
CAMSHAFT
CAMSHAFT
JPBIA3695GB
1. Camshaft bracket 2. Intake camshaft 3. Exhaust camshaft

4. Adjusting shim 5. Valve lifter 6. Knock pin
7. Camshaft sprocket 8. Cylinder head 9. O-ring
10. Camshaft position sensor 11. Bracket 12. Cylinder head rear cover
13. Rubber washer 14. Signal plate
A. Comply with the installation proce-
dure when tightening. Refer to EM-
64, "Removal and Installation"
REMOVAL
1. Drain engine oil. Refer to LU-8, "Changing Engine Oil".
2. Remove the following parts:
• Vacuum pump. Refer to EM-44, "Component".
• Fuel injector. Refer to EM-46, "Exploded View".
• Rocker cover. Refer to EM-61, "Component".
• Secondary timing chain. Refer to EM-78, "Component".
3. Remove cylinder head rear cover, camshaft position sensor and rubber washer.
EM-64
CAMSHAFT
Loosen cylinder head rear cover mounting bolts in the reverse
order shown in the figure. A
EM
JPBIA3893ZZ
D
4. Remove camshaft sprockets and signal plate.
• Loosen the camshaft sprocket mounting bolts and signal plate
mounting bolt by fixing the hexagonal portion of camshaft. E
JEM159G
H
5. Remove camshaft.
• Place distinguishing marks on the right and left sides with paint.
• Loosen and remove the camshaft sprocket bolts in the reverse
I
order shown in the figure.
: Engine front
J
JPBIA3771ZZ
L
6. Remove adjusting shim and valve lifter.
• Remove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion. M
Visual Check of Camshaft
N
• Check the camshaft for one sided wear or scratches.
• Replace the camshaft if there are abnormalities.
Camshaft Runout O
• Prepare V-block on a flat surface and secure camshaft journals No.
2 and No. 5.
• Set the dial gauge (A) vertically on journal No. 3.
• Rotate camshaft in one direction by hand, then read needle move- P
ment on dial gauge. (Total indicator reading)
Limit : Refer to EM-139, "Standard and Limit".

• If it exceeds the limit, replace camshaft.
JPBIA3895ZZ
EM-65
CAMSHAFT
Height of Cam Nose
• Measure the height of cam nose using the micrometer.
Standard : Refer to EM-139, "Standard

and Limit".
• If out of the standard, replace camshaft.
SEM549A
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER

• Measure outer diameter of camshaft journal with micrometer.

and Limit".
SEM012A
CAMSHAFT BRACKET INNER DIAMETER

• Install camshaft bracket and tighten bolts to the specified torque. Refer to "INSTALLATION" for the tighten-
ing procedure.
• Measure inner diameter of camshaft bracket using the inside
micrometer.

and Limit"
JEM162G
CAMSHAFT OIL CLEARANCE CALCULATIONS

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

and Limit" .
• If out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head.
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the camshaft
bracket.
Camshaft End Play
EM-66
CAMSHAFT
• Install dial gauge in thrust direction on front end of camshaft. Mea-
sure end play of dial gauge when camshaft is moved forward/back- A
ward (in direction to axis).
Standard : Refer to EM-139, "Standard EM

and limit and Limit".
PBIC0366E
D
• Measure the following parts if out of the standard.
- Dimension “A” for camshaft
E
Standard : 6.882 - 6.930 mm (0.2709 - 0.2728 in)
- Dimension “B” for cylinder head
F
Standard : 7.000 - 7.030 mm (0.2756 - 0.2768 in)
• Refer to the standards above, and then replace camshaft and/or
cylinder head. G
PBIC2320E
Camshaft Sprocket Runout

H
1. Install camshaft in cylinder head. Refer to "INSTALLATION" for the tightening procedure.
2. Install sprocket on camshaft. Refer to "INSTALLATION".
3. Measure camshaft sprocket runout. (Total indicator reading) I
Limit : Refer to EM-139, "Standard

and Limit" .
J
• If it exceeds the limit, replace camshaft sprocket.
JEM164G
Visual Inspection of Valve Lifter and Adjusting Shim L

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

P
VALVE LIFTER OUTER DIAMETER
EM-67
CAMSHAFT
• Measure the outer diameter of the valve lifter with the micrometer.

and Limit".
SEM961E
VALVE LIFTER BORE DIAMETER

• Measure the bore diameter of the cylinder head valve lifter with the
inside micrometer.

and Limit".
PBIC0367E
VALVE LIFTER CLEARANCE CALCULATIONS

• (Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)

and Limit".
• If out of standard, refer to the outer diameter and bore diameter standard values and replace valve lifter and/
or cylinder head.
INSTALLATION
1. Install valve lifter and adjusting shim.
• Check that these are installed in the same position as before the removal process.
2. Install camshaft.
1 : Intake camshaft
2 : Exhaust camshaft
: Engine front
• Identify camshafts by the paint position.
A : White
B : Green
JPBIA3894ZZ
EM-68
CAMSHAFT
• Install so that knock pins (A) are positioned in the directions
shown in the figure. A
B : Intake camshaft
C : Exhaust camshaft EM
d : Approx. 65°
: Up
C
JPBIA3909ZZ
D
3. Install camshaft brackets.
• Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cylin-
der head.
• Install correctly, identifying brackets by the journal No. and E
front mark on top surface.
JEM175G
H
4. Tighten camshaft bolts in numerical order as shown in the figure

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

K
• Check camshaft thrusting parts (on rear side) securely fit in
their mating parts on the cylinder head.
JPBIA3771ZZ
b. Tighten No. 1 to 12. L
: 1.96 N·m (0.20 kg-m, 1 ft-lb)

c. Tighten all bolts. M
: 5.88 N·m (0.60 kg-m, 4 ft-lb)

N
d. Tighten all bolts.
: 12.8 N·m (1.3 kg-m, 9 ft-lb) O
5. Install camshaft sprockets and signal plate.

• Camshaft sprockets are commonly used for right side and left side. P
• Align camshaft sprocket and knock pin on camshaft, and install.
• Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprockets and sig-
nal plate.
6. Install rubber washer to cylinder head rear side.
EM-69
CAMSHAFT
7. Apply liquid gasket to cylinder head rear cover as shown in the
figure.
Use Genuine Liquid Gasket or Equivalent.
a : 4.0 - 5.6 mm (0.157 - 0.220 in)

b : φ 3.4 - 4.4 mm (0.134 - 0.173 in)
JPBIA3772ZZ
8. Install cylinder head rear cover and tighten mounting bolts in

numerical order shown in the figure.
M8 × 50 mm (1.97 in) : Bolt No. 1

M8 × 20 mm (0.79 in) : Bolt No. 2 - 6
JPBIA3893ZZ
9. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to EM-71, "Valve Clearance".
Inspection for Leakage
The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-17, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission / AT Models Leakage Level / Leakage Leakage

transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.
EM-70
CAMSHAFT
Valve Clearance INFOID:0000000013949709
A
INSPECTION
• When the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the miss adjustment of the valve clearance, EM
inspect as follows.
• Inspect and adjust when the engine is cool (at normal temperature).
C
1. Remove rocker cover. Refer to EM-61, "Component".
2. Remove fuel injector. Refer to EM-46, "Exploded View".
3. Set the No. 1 piston to TDC on its compression stroke. D
• Turn crankshaft pulley clockwise so that the cam nose (A) on
exhaust camshaft (1) faces straight above ( ). (No position
indicator, etc. is provided on the crankshaft pulley.) E
G
JPBIA4521ZZ
4. While referring to the figure, measure the valve clearance H

marked in the table below.
: Vehicle front
I
Measuring position No.1 No.2 No.3 No.4
No. 1 cylinder at compression INT (A) (D) J

TDC EXH (B) (C)
JPBIA3758ZZ
K
NOTE:
Use a feeler gauge (A), measure the clearance between valve
lifter and camshaft. L
JPBIA3759ZZ
O
5. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
EM-71
CAMSHAFT
6. While referring to the figure, measure the valve clearance
: Vehicle front
Measuring position No.1 No.2 No.3 No.4
No. 4 cylinder at compression INT (A) (D)

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

ADJUSTMENTS
• Remove adjusting shim for parts which are outside the specified valve clearance.
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward.
1 : Round hole
: Facing straight above
JPBIA3883ZZ
3. Grip camshaft with the camshaft pliers (A) [SST: KV10115110],

then using camshaft as a support point, push adjusting shim
downward to compress valve spring. Then move the camshaft
pliers handle in the direction of arrow ( ).
CAUTION:
Never damage camshaft, cylinder head and the outer cir-
cumference of valve lifter.
JPBIA3884ZZ
4. With valve spring in a compressed state, remove the camshaft

pliers (A) [SST: KV10115110] by securely setting the outer cir-
cumference of the valve lifter with the end of the lifter stopper (B)
[SST: KV10115120].
• Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Never retrieve the camshaft pliers forcefully, as camshaft
will be damaged.
JPBIA3885ZZ
5. Move the round hole of adjusting shim to the front with the very thin screwdriver or like that.
• When adjusting shim on valve lifter will not rotate smoothly, restart from step 3 to release the end of the
lifter stopper [SST: KV10115120] from touching adjusting shim.
EM-72
CAMSHAFT
6. Remove adjusting shim from valve lifter by blowing air through
the round hole (1) of the adjusting shim with the air gun (B). A
A : Lifter stopper
CAUTION: EM
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles.
C
JPBIA3886ZZ
D
7. Remove adjusting shim (1) by using the magnet hand (B).
A : Lifter stopper
E
G
JPBIA3887ZZ
8. Measure the thickness of adjusting shim using the micrometer.

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

R = Thickness of removed shim
N = Thickness of new shim
M
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0110 in)] N
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
O
• New adjusting shims have the thickness stamped (A) on the
rear side.
• Shims are available in 33 size from 2.10 mm (0.0827 in) to
2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in). Refer to P
EM-139, "Standard and Limit".
B : Thickness
JPBIA3912ZZ
EM-73
CAMSHAFT
10. Fit the selected adjusting shim to valve lifter.
A : Lifter stopper
B : Suitable tool
CAUTION:
Place the stamped side of adjusting shim to valve lifter.
JPBIA3888ZZ
11. Compress valve spring using the camshaft pliers [SST: KV10115110] and remove the lifter stopper [SST:
KV10115120].
12. Rotate crankshaft 2 to 3 turns by hand.
13. Confirm that the valve clearance is within the specification.
15. Warm up engine, and check for unusual noise and vibration.
EM-74
OIL SEAL
OIL SEAL
A
Removal and Installation of Valve Oil Seal INFOID:0000000013949710
REMOVAL EM
1. Turn crankshaft until the cylinder requiring new valve oil seals is at TDC. This will prevent valve from drop-
ping into cylinder.
2. Remove camshafts. Refer to EM-64, "Removal and Installation". C
3. Remove adjusting shims and valve lifters. Refer to EM-64, "Removal and Installation".
• Check the installation positions, and keep them to avoid being confused.
4. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve D
from dropping into cylinder.
5. Remove valve collet.
• Compress the valve spring with valve spring compressor, E
attachment and adapter (SST). Remove valve collet with a
magnet hand.
CAUTION: F
When working, be careful not to damage valve lifter holes.
PBIC2388E
H
6. Remove valve spring retainer and valve spring.

7. Remove valve oil seal with the valve oil seal puller (SST). I
JEM153G L
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
M
2. Using the valve oil seal drift (SST), install valve oil seals refer-
ring to the dimension shown in the figure.
N
P
JEM165G

Removal and Installation of Front Oil Seal INFOID:0000000013949711
REMOVAL
EM-75
OIL SEAL
1. Remove the following parts.
• Drive belt. Refer to EM-20, "Removal and Installation".
• Crankshaft pulley. Refer to EM-84, "Component".
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
JPBIA3762ZZ
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
A : Oil seal lip

B : Dust seal lip
: Engine inside
: Engine outside
JPBIA0054ZZ
• Using the suitable drift [60 mm (2.36 in) dia.] (A), press fit the
oil seal (2) so that the dimension is as specified in the figure.
1 : Oil pump housing
b : 0 - 0.5 mm (0 - 0.020 in)

CAUTION:
Never touch lips of oil seal. Check seal surfaces are free
of foreign materials.
JPBIA3763ZZ

Removal and Installation of Rear Oil Seal INFOID:0000000013949712
REMOVAL
EM-76
OIL SEAL
1. Remove engine and transaxle from vehicle. Refer to EM-109, "Component".
2. Remove transaxle. A
3. Remove drive plate.
4. Remove rear oil seal with a suitable tool.
CAUTION: EM
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
C
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure. D
A : Oil seal lip
B : Dust seal lip
E
: Engine inside
: Engine outside
JPBIA0054ZZ
G
• Press in rear oil seal (2) to rear oil seal retainer (1) as shown in
the figure.
H
b : 0 - 0.5 mm (0 - 0.020 in)
• Using the drift [100 mm (3.94 in) dia.] (A), press fit so that the
dimension is as specified in the figure.
I
• Avoid inclined fitting. Force fit perpendicularly.
JPBIA3764ZZ
N
EM-77
SECONDARY TIMING CHAIN
JPBIA3694GB
1. Chain tensioner 2. Slack guide 3. Front chain case

4. Tension guide 5. Gasket 6. Secondary timing chain
7. Tension guide
A. Oil pump housing side B. Comply with the installation proce-
CAUTION:
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis-
ton heads.
surfaces with new engine oil.
REMOVAL
1. Remove RH engine mounting bracket (lower). Refer to EM-109, "Component".
2. Remove front chain case.
EM-78
• Loosen fixing bolts in reverse order of that shown in the figure
and remove them. A
CAUTION:
• While front chain case is removed, cover openings to
prevent entry of foreign material into engine.
EM
JPBIA3769ZZ
D
• Never remove mass damper (2) on the back of cover.
1 : Tension guide E
G
JPBIA3892ZZ
3. Set the No. 1 piston to TDC on its compression stroke. H

• Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
• No position indicator is provided on crankshaft pulley. I
• When installing, color coded links on secondary timing
chain can be used as alignment marks. Marking may not
be necessary for removal, however, make alignment J
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see.
K
SEM515G
4. Remove chain tensioner.

L
a. Push the plunger of chain tensioner and keep it pressed with a
push pin.
O
JEM124G
EM-79
b. Using the hexagon wrench [SST: KV11106010], remove bolts to
remove chain tensioner.
SBIA0227E
5. Remove slack guide.

• Using the hexagon wrench [SST: KV11106020], remove bolt to
remove slack guide.
SBIA0228E
6. Remove tension guide.

7. Remove secondary timing chain.
• Timing chain alone can be removed without removing sprock-
ets.
JEM127G
INSTALLATION
1. Install secondary timing chain.
EM-80
• When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the timing A
chain.
1 : Secondary timing chain EM

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

guide. H
SBIA0228E
K
4. Install chain tensioner.
a. Push the plunger of chain tensioner. While holding it with a push
pin, install chain tensioner. L
b. Using the hexagon wrench [SST: KV11106010], tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
• Check again that the alignment marks on the sprockets M
and the colored alignment marks on the timing chain are
aligned.
N
SBIA0227E
5. Install front chain case. O
EM-81
a. Install tension guide (1) on the back surface of front chain case.
2 : Mass damper
• Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted.
JPBIA3892ZZ
b. Apply a continuous bead of liquid gasket on both ends of arched area (locations where rear chain case is
adjoined) as shown in the figure.
JPBIA3770ZZ
1. Oil pump housing 2. Rear chain case

b. φ 19 mm (0.75 in) c. 10 mm (0.39 in) e. φ 3.4 - 4.4 mm (0.13 - 0.17 in)
f. 5 mm (0.20 in)
CAUTION:
• For (A), the overlap of the liquid gasket starting point and end-point must be minimized and
faced outward.
c. Install front chain case.

• When installing, align dowel pin on oil pump housing with the pin hole.
• Install No. 6, 10 and 11 bolts with the rubber washer to front chain case.
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
JPBIA3769ZZ
EM-82
A
Timing Chain
EM
E
SEM984C

Inspection for Leakage F
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the G
check for fuel leakage at connection points. H
NOTE: I
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and J
engine coolant.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to K
Items Before starting engine Engine running After engine stopped L
M
Other oils and fluids* Level Leakage Level N
*: Power steering fluid, brake fluid, etc. O
EM-83
PRIMARY TIMING CHAIN
JPBIA3696GB
1. Fuel pump 2. O-ring 3. Rear chain case

4. O-ring 5. Fuel pump sprocket 6. Washer
7. Tension guide 8. Primary timing chain 9. Chain tensioner
10. Slack guide 11. Crankshaft sprocket 12. Crankshaft pulley
13. Front oil seal 14. Oil pump housing 15. Crankshaft gear
16. Key 17. Balancer unit 18. Seal washer
A. Comply with the installation proce- B. Comply with the installation proce-
dure when tightening. Refer to EM- dure when tightening. Refer to EM-
85, "Removal and Installation". 85, "Removal and Installation".
EM-84
A
CAUTION:
ton heads. EM
• When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
REMOVAL C
• Drive belt auto-tensioner and idler pulley. Refer to EM-20, "Removal and Installation". D
• Vacuum pump. Refer to EM-44, "Component" .
• Fuel injector. Refer to EM-46, "Exploded View".
E
• Oil pan (upper and lower). Refer to EM-37, "Component".
3. Remove crankshaft pulley.
F
a. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in). G
I
PBIC3469E
c. Using the pulley puller [SST: KV11103000], remove crankshaft

pulley. J
• Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
K
JEM132G
M
4. Remove oil pump housing.
• Loosen bolts in reverse order of that shown in the figure and
remove them. N
• Use the seal cutter [SST: KV10111100] etc. for removal.
JPBIA3773ZZ
EM-85
5. Remove crankshaft gear (1) with the following procedure.
a. Check that No.1 piston is TDC on its compression stroke.
b. Turn the idler sub gear (3) counterclockwise with snap ring plier
(B) or suitable tool for aligning idler sub gear and idler main gear
(2).
• If idler gear rotates, hold the flat faces on balancer drive shaft
front end (4).
c. Install internal mechanism securing bolt and plate (Service part:
13012 EB30A and 13013 EB30A) (A) and tighten to the speci-
fied torque.
: 4.0 N·m (0.41 kg-m, 35 in-lb)
CAUTION:
• Never loosen idler gear mounting bolt (5).
• Only use the genuine internal mechanism securing bolt
and plate, or the idler gear and will be damaged.
• Never remove internal mechanism securing bolt and plate
from idler gear and until crankshaft gear and all of the
parts in connection have been installed.
• If internal mechanism securing bolt and plate is not
installed, internal mechanism of idler gear and will disen-
gage after crankshaft gear is removed. This will prohibit JPBIA3914ZZ
the balancer unit from being reusable.

d. Apply mating marks (C) to crankshaft gear and idler sub gear.
e. Remove crankshaft gear.
6. Remove front oil seal from oil pump housing.
• Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage oil pump housing.
7. Remove chain tensioner (1).

• When removing chain tensioner, push the plunger of chain
tensioner and keep it pressed with a push pin (2).
8. Remove slack guide (3).
JPBIA3774ZZ
9. Hold fuel pump sprocket (1) and remove bolt.

a. Insert positioning stopper pin (A) [SST: KV11106030] on fuel
pump sprocket.
c : φ 6 mm (0.24 in)
d : 80 mm (3.15 in)
b. Using the TORX wrench (B) [SST: KV11106040], turn pump
shaft little by little to adjust the position of fuel pump sprocket so
that the holes align.
JPBIA3775ZZ
e : 26 mm (1.02 in)
c. Push positioning stopper pin through fuel pump sprocket to fuel pump body to hold fuel pump sprocket.
EM-86
• Insert the positioning stopper pin [SST: KV11106030] until its
flange contacts fuel pump sprocket. A
EM
PBIC2535E
D
10. Using the hexagon wrench [SST: KV11106050] remove tighten-
ing bolts to fuel pump sprocket.
E
G
PBIC2404E
K
MBIA0074E
11. Remove primary timing chain (2) with fuel pump sprocket (1)
L
and crankshaft sprocket (3).
JPBIA3776ZZ
O
EM-87
12. Remove tension guide (1).
JPBIA3777ZZ
13. Remove fuel pump. Refer to EM-51, "Component".

14. Remove camshaft sprockets. Refer to EM-64, "Component".
15. Remove rear chain case.
• Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
• Use the seal cutter [SST: KV10111100] for removal.
JPBIA3778ZZ
16. Remove balancer unit.

• Loosen mounting bolts in the reverse order as shown in the
figure.
: Engine front
PBIC4049E
INSTALLATION
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.
EM-88
EM
JPBIA3779ZZ F
1. Secondary timing chain 2. Chain tensioner 3. Slack guide

4. Fuel pump sprocket 5. Chain tensioner 6. Slack guide
G
7. Primary timing chain 8. Crankshaft sprocket 9. Tension guide
10. Tension guide 11. Camshaft sprocket 12. Tension guide
13. Front chain case H
A. Alignment mark (dark blue link) B. Alignment mark (yellow link) C. Alignment mark (punched mark)
D. Alignment mark (punched mark) E. Alignment mark (punched mark)
CAUTION: I
Before starting work, check that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten mounting bolts in numerical
order as shown in the figure. J
: Engine front
CAUTION: K
If mounting bolts are re-used, check their outer diameter
before installation. Refer to "Balancer Unit Mounting Bolt
Outer Diameter". L
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
PBIC4049E
b. Tighten all bolts. M
: 29.4 N·m (3.0 kg-m, 22 ft-lb)

N
c. Turn all bolts 65 degrees clockwise (angle tightening).
1 : Balancer unit
O
CAUTION:
Check tightening angle with an angle wrench [SST:
KV10112100] (A) or a protract. Never make judgement by
visual check alone. P
d. Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb) PBIC3474E
CAUTION:
In this step, loosen bolts in the reverse order as shown in the figure.
e. Tighten all bolts.
EM-89
: 29.4 N·m (3.0 kg-m, 22 ft-lb)
f. Turn them another 65 degrees clockwise (angle tightening).

CAUTION:
Check tightening angle with an angle wrench [SST: KV10112100] or a protractor. Never make judg-
ment by visual check alone.
2. Install rear chain case.
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) on locations shown in the figure.
CAUTION:
• Never allow liquid gasket to stick out to the oil passage
(C).
• For (A), the overlap of the liquid gasket starting point and
end-point must be minimized and faced outward.
• For (B), the starting point and the end-point of the liquid
gasket must stick out from the case rim.
1 : O-ring
d : 4.0 - 5.6 mm (0.16 - 0.22 in)
e : φ3.4 - 4.4 mm (0.13 - 0.17 in)
JPBIA3780ZZ
b. Install new O-ring (1) to the grooves of fuel pump bracket.
JPBIA3781ZZ
c. Install rear chain case.

• When installing, align the dowel pin with the pin hole.
EM-90
d. Tighten bolts in numerical order shown in the figure.
• Install the following two types of bolts, referring to the figure. A
M8 × 16 mm (0.63 in) : Bolt No. 1, 2, 8, 9, 10, 11, 12, 13,

17, 18 EM
M8 × 20 mm (0.79 in) : Bolt No. 3, 4, 5, 6, 7, 14, 15, 16,
19, 20
• The shank length under the bolt neck above is the length of C
D
G
JPBIA3778ZZ
3. Install fuel pump. Refer to EM-51, "Component".

• Before installing, check that spacer and the hole 6 mm (0.24 in) in diameter on coupling are aligned. H
4. Install tension guide (1).
K
JPBIA3777ZZ
5. Install crankshaft sprocket (3), aligning it with crankshaft key on L

the far side.
6. Install primary timing chain (2) with fuel pump sprocket (1).
• When installing, match the alignment marks on sprockets with M
color coded alignment marks (colored links) on primary timing
chain.
• Install fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine. N
JPBIA3776ZZ O
EM-91
7. Use the positioning stopper pin (A) [SST: KV11106030] to hold
the fuel pump sprocket (1) and install the bolt.
c : φ 6 mm (0.24 in)
d : 80 mm (3.15 in)
• Using the TORX wrench (B) [SST: KV11106040], turn the fuel
pump shaft little by little to adjust the position of the fuel pump
sprocket. Insert positioning stopper pin into the hole 6 mm
(0.24 in) in diameter on fuel pump sprocket so that the stopper
pin goes through the fuel pump body. While the stopper pin is
in place, install the bolt. JPBIA3775ZZ
e : 26 mm (1.02 in)
PBIC2404E
8. Install timing chain slack guide (3).

9. Install chain tensioner (1).
• Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin (2), install chain ten-
sioner.
• After installation, pull out the push pin holding the plunger.
CAUTION:
Check again that the alignment marks on sprockets and the
colored alignment marks on timing chain are aligned.
JPBIA3774ZZ
10. Install front oil seal (1) to oil pump housing (2).
• Using the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION:
Never touch lips of oil seal. Check seal surfaces are free of
foreign materials.
PBIC3448E
11. Install crankshaft gear.
EM-92
• Align crankshaft gear (1) mating mark and idler sub gear (3)
mating mark (C). A
2 : Idler main gear

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

each gear as shown in the figure.
- Remove securing-bolt-and-plate (A) and securing pin (C) after
installing crankshaft gear (1).
I
N
PBIC3475E
12. Install oil pump housing. O
EM-93
(commercial service tool) as shown in the figure.
• Leave the start and end areas (A) of the bead slightly protrud-
ing from the surface.
• Apply liquid gasket along upper end surface of oil pump hous-
ing.
b : φ3.4 - 4.4 mm (0.13 - 0.17 in)

c : 4.0 - 5.6 mm (0.16 - 0.22 in)
d : 0.5 - 2.1 mm (0.02 - 0.08 in)
JPBIA3782ZZ
b. Install new O-rings into the groove of rear chain case.
c. Install oil pump housing.

• When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
JPBIA3773ZZ
13. Check gaps on upper oil pan mounting surface.

• Using straightedge and feeler gauge, measure gaps between
the locations of the following parts:
Oil pump housing and rear chain case:

Standard : (–0.09) – (+0.09) mm [(–0.0035) – (+0.0035)
in]
Rear chain case and cylinder block:
Standard : (–0.19) – (+0.07) mm [(–0.0075) – (0.0028)
in] JEM146G
• If the measured value is out of the standard, install again.
14. Install crankshaft pulley, refer to the following:

CAUTION:
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
EM-94
c. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool). A
d. Tighten crankshaft pulley fixing bolt.
: 75.0 N·m (7.7 kg-m, 55 ft-lb) EM
e. Completely loosen.
C
: 0 N·m (0 kg-m, 0 ft-lb)
PBIC3469E
f. Tighten crankshaft pulley bolt.
D
: 75.0 N·m (7.7 kg-m, 55 ft-lb)

g. Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt. E
h. Tighten fixing bolt another 120 degrees (angle tightening) (turn

by 2 notch). F
A : Indicate embossments
B : Alignment mark
G
PBIC3476E
I
J
Timing Chain
Check for cracks and excessive wear at roller links. Replace K
N
SEM984C
Balancer Unit Mounting Bolt Outer Diameter

• Measure the outer diameters (“d1”, “d2”) at two positions as shown
O
in the figure.
• If reduction appears in “A” range, regard it as “d2”.
Limit (“d1 ” - “d2 ”) : 0.15 mm (0.0059 in) P

• If it exceeds the limit (large difference in dimensions), replace it
with a new one.
PBIC1137E
EM-95
NOTE:
engine coolant.

EM-96
CYLINDER HEAD
CYLINDER HEAD
A
On-Vehicle Service INFOID:0000000013949719
CHECKING COMPRESSION PRESSURE EM

1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT, check no error codes are indicated for self-diagnosis items. Refer to EC-43, "Introduc-
tion". C
• Do not disconnect CONSULT until the end of this operation, it will be used to check engine rpm and for
error detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal. D
4. Remove the engine cover and bracket. Refer to EM-21, "Component"
5. To prevent fuel from being injected during inspection, disconnect
all the connectors of the fuel injector. E
A : Connector
B : Injector F
JPBIA3881ZZ
H
6. Wind the insulating tape around the electrode of the discon-
nected connectors. Tie them together and fix them on the har-
ness side. I
A : Connector
J
K
PBIC4772E
7. Remove glow plugs from all the cylinders. Refer to EM-42, "Component". L
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage. M
• Handle with care to avoid applying any shock to glow plugs.
8. Install compression gauge adapter [SST: ED19600610] to instal-

lation holes of glow plugs and connect compression gauge for N
diesel engine.
: 20.0 N·m (2.0 kg-m, 15 ft-lb) O

9. Connect the battery cable to the negative terminal.
10. Turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine P
rpm. Perform these steps to check each cylinder.
• Always use a fully-charged battery to obtain specified engine SEM112G
speed.
Compression pressure : Refer to EM-139, "Standard and Limit".
EM-97
CYLINDER HEAD
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
• If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
• If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
- If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring.
- If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
• If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be leak-
ing from gasket. In this case, replace cylinder head gasket.
11. Complete this operation as follows:
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Connect all the connectors of the fuel injector.
e. Connect the battery cable to the negative terminal.
f. Check DTC. If DTC is displayed, erase it. Refer to EC-52, "Trouble Diagnosis Introduction".
REMOVAL
JPBIA3698GB
1. Bracket 2. Slinger bracket 3. Cylinder head assembly

4. Gasket 5. Dowel pin
A. Comply with the installation proce-
99, "Removal and Installation".
EM-98
CYLINDER HEAD
DISASSEMBLY
A
EM
JPBIA3699GB
1. Adjusting shim 2. Valve lifter 3. Valve collet I

4. Valve spring retainer 5. Valve spring (intake) 6. Valve oil seal
7. Valve spring seat 8. Valve guide 9. Cylinder head
10. Valve seat 11. Valve (intake) 12. Valve (exhaust) J
13. Valve spring (exhaust)
K
REMOVAL L
1. Drain engine coolant from radiator and cylinder block. Refer to CO-10, "Changing Engine Coolant" and
CO-10, "Inspection".
2. Remove the following parts: M
• EGR system. Refer to EM-25, "Exploded View".
• Turbocharger. Refer to EM-31, "Component".
• Exhaust manifold. Refer to EM-35, "Component". N
• Intake manifold. Refer to EM-27, "Component".
• Vacuum pump. Refer to EM-44, "Component" .
• Glow plug. Refer to EM-42, "Component".
• Injection tube and fuel injector. Refer to EM-46, "Exploded View". O
• Camshaft. Refer to EM-64, "Component". P
3. Remove cylinder head assembly.
• Remove bolts between rear chain case and cylinder head. Refer to EM-98, "Exploded View".
EM-99
CYLINDER HEAD
• Remove cylinder head bolts in the reverse order as shown in
the figure with the cylinder head bolt wrench (commercial ser-
vice tool).
: Engine front
• Lift up cylinder head assembly to avoid interference with dowel

pins located between the cylinder block and cylinder head,
and remove cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder JPBIA3785ZZ
head, or, place wood blocks beneath both ends of cylin-

der head to keep the cylinder bottom from any contact.
• For glow plug removal, the following shall be noted.
CAUTION:
• To avoid breakage, never remove glow plug unless necessary.
• Perform continuity test with glow plug installed.
• Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
• Never use air impact wrench.
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
1. Install cylinder head gasket.
• Cylinder head gasket to be installed is selected by its thickness through the following procedure.
- When replacing gasket alone:
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of ID marks on
the front LH side.
: Engine front
Gasket thickness* mm (in) Number of grade Number of ID marks

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

1.000 (0.0394) 5 1+2+3+4
1.025 (0.0404) 6 1+2+3+4+5
*: Measured with head bolts tightened
• Heater return tube is omitted for explanation.

NOTE:
Use mirrors for checking at points out of clear sight.
- When the following parts have been repaired/replaced:
• With cylinder block upper surface and/or crankshaft pin journal ground.
• With cylinder block, pistons, connecting rods, and/or crankshaft replaced.
a. Set piston at a point close to TDC.
EM-100
CYLINDER HEAD
b. Set the dial gauge at the location as shown in the figure. Turning
crankshaft gradually, set the gauge scale to “0” where the piston A
protrusion is maximized.
c. Move the dial gauge stand so that the tip of dial gauge can con-
tact cylinder block. Read the difference. EM
d. Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.
C
SEM507G
Identification
Piston protrusion mm (in) Gasket thickness* mm (in) E
Number of ID marks
0.161 - 0.186 (0.0063 - 0.0073) 0.900 (0.0354) 0
0.186 - 0.211 (0.0073 - 0.0083) 0.925 (0.0364) 1 F
0.211 - 0.236 (0.0083 - 0.0093) 0.950 (0.0374) 1+2
0.236 - 0.261 (0.0093 - 0.0103) 0.975 (0.0384) 1+2+3
0.261 - 0.286 (0.0103 - 0.0113) 1.000 (0.0394) 1+2+3+4 G
0.286 - 0.331 (0.0113 - 0.0130) 1.025 (0.0404) 1+2+3+4+5
*: Measured with head bolts tightened H
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure. I
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca- J
tion but cannot be viewed externally after engine is assembled.
PBIC1256E
L
3. Install cylinder head assembly.
• Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure:
M
: Engine front
a. Apply engine oil to bolt threads and seat surfaces. N

b. Tighten all bolts.
: 39.2 N·m (4.0 kg-m, 29 ft-lb) O
JPBIA3785ZZ
EM-101
CYLINDER HEAD
c. Tighten all cylinder head bolts (clockwise).
Angle tightening : 180 degrees

CAUTION:
• When the angle wrench [SST: KV10112100] is not used,
paint an alignment mark on the head of cylinder head bolt
and cylinder head surface before tightening. Check the
angle with a protractor.
d. Loosen completely in the reverse order of that shown in the fig-
ure.
JEM166G
: 0 N·m (0 kg-m, 0 ft-lb)

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

f. Tighten all cylinder head bolts (clockwise).

g. Tighten all cylinder head bolts (clockwise).

CAUTION:
• When the angle wrench [SST: KV10112100] is not used, paint an alignment mark on the head of
cylinder head bolt and cylinder head surface before tightening. Check the angle with a protrac-
tor.
4. Tighten bolts between rear chain case and cylinder head. Refer to EM-98, "Exploded View".
5. After installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head (If rear
chain case is removed).
Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in)

• If out of the standard, check fitting of dowel pins and cylinder
head.
JEM172G

CAUTION:
• To avoid damage, glow plugs should be removed only when required.
• Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one.
• Before installing, remove carbon depositing on mounting hole of glow plug with a reamer.
7. Install engine coolant temperature sensor. Refer to EM-98, "Exploded View".
Disassembly and Assembly INFOID:0000000013949722
DISASSEMBLY
1. Remove adjusting shims and valve lifters.
EM-102
CYLINDER HEAD
• Using the valve spring compressor [SST: KV10116200], com- A
press valve spring. Using magnet hand, remove valve collets.
EM
PBIC2388E
D
3. Remove valve spring retainers and valve springs.
4. Remove valves as pressing valve stems toward combustion chamber.
• Before removing valve, check the valve guide clearance. Refer to EM-104, "Inspection". E
5. Remove valve oil seals using the valve oil seal puller [SST:
KV10107902].
F
6. Remove valve spring seats.
7. Remove valve seats.
• Before removing valve seats, perform valve seat contact
check. Refer to EM-104, "Inspection". G
8. Remove valve guides.
JEM153G
ASSEMBLY I
1. Install valve guides. Refer to EM-104, "Inspection".
2. Install valve seats. Refer to EM-104, "Inspection".
3. Using the valve oil seal drift [SST: KV10115600], install valve oil J
seals referring to the dimension shown in the figure.
4. Install valve spring seats.
K
M
JEM165G
5. Install valves.
• Install the valves with bigger outer diameter to intake valve side. N
6. Install valve spring.

7. Install valve spring retainers. O
EM-103
CYLINDER HEAD
8. Using the valve spring compressor [SST: KV10116200], com-
press valve springs.
Then install valve collets using magnet hand.
• After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
PBIC2388E
9. Install valve lifters and adjusting shims to the same positions as before.

Cylinder Head Bolt Deformation
• Using micrometer, measure the outer diameters “d1” and “d2” of
bolt thread as shown in the figure.
• If the necking point can be identified, set it as measuring point d1.
• Calculate the difference between “d1” and “d2”.
Limit : 0.15 mm (0.0059 in)

• If it exceeds the limit, replace cylinder head bolt.
JEM171G
Cylinder Head Distortion

1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure distortion in six directions (A - F).
Limit : Refer to EM-139, "Standard and Lim-

it".
• If it exceeds the limit, replace cylinder head.
JPBIA0176ZZ
INSPECTION AFTER DISASSEMBLY

Valve Dimension
• Check dimensions of each valve. For dimensions, refer to EM-139,
"Standard and Limit".
• If dimensions are out of the standard, replace valve.
SEM188A
EM-104
CYLINDER HEAD
Valve Guide Clearance
A
Valve Stem Diameter
• Measure diameter of valve stem with micrometer (A).
Standard : Refer to EM-139, "Standard and EM

Limit".
D
JPBIA0183ZZ
E
Valve Guide Inner Diameter
• Measure inner diameter of valve guide with inside micrometer.
Standard : Refer to EM-139, "Standard and F

Limit".

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter). G
Standard and limit : Refer to EM-139, "Standard and

Limit" . H
• If it exceeds the limit, replace valve and/or valve guide.
Valve Guide Replacement I
When removing valve guide, replace it with oversized [0.2 mm (0.008 in)] valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A). J
JPBIA0184ZZ
M
2. Using the valve guide drift (commercial service tool), tap valve
guides out from the combustion chamber side.
WARNING:
Cylinder head contains heat, when working, wear protective N
equipment to avoid getting burned.
P
SEM931C
EM-105
CYLINDER HEAD
3. Ream cylinder head valve guide hole with the valve guide
reamer (commercial service tool) (A).
Valve guide hole diameter : Refer to EM-139, "Standard

(for service parts) and Limit".
JPBIA0185ZZ

heated oil (A).
JPBIA0184ZZ
5. Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension
Projection (L) : Refer to EM-139, "Standard and Lim-

it".
WARNING:
Cylinder head contains heat, when working, wear protective
PBIC2497E
6. Using the valve guide reamer (commercial service tool), perform

reaming to the press-fitted valve guides.
Reaming specifications : Refer to EM-139, "Stan-

dard and Limit".
JPBIA0185ZZ
Valve Seat Contact

• Before starting this check, confirm that the dimension of valve
guide and valves are as specified.
A : OK
B : NG
• Apply red lead primer on contacting surfaces of valves seat and of
valve face to examine the conditions of contacting surfaces.
• Check that the paint on contacting surfaces is continuous along the
entire circumference.
JPBIA0187ZZ
EM-106
CYLINDER HEAD
• If there are abnormal indications, grind the valve and check the contact again. If malfunction indications still
persist, replace valve seat. A
Valve Seat Replacement
When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess EM
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-139, "Standard and Limit".
2. Ream cylinder head recess diameter (a) for service valve seat.
C
Oversize [0.5 mm : Refer to EM-139, "Standard and
(0.020 in)] Limit".
• Be sure to ream in circles concentric to the valve guide center. D
• This will enable valve seat to fit correctly.
JPBIA0188ZZ
F
heated oil (A).
4. After cooling valve seats sufficiently with dry ice, press fit it to G
cylinder head.
WARNING:
Cylinder head contains heat, when working, wear protective H
CAUTION:
Never touch the cooled valve seats directly by hand.
I
JPBIA0184ZZ
5. Using the valve seat cutter set (commercial service tool), finish J
processing referring to the dimensions shown in the figure.
Refer to EM-139, "Standard and Limit".
CAUTION:
When using the valve seat cutter set, grasp cutter handle K
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or
repeatedly, the valve seat surface may be damaged. L
SEM934C M
6. Using compound, perform valve fitting.
7. Check again to check that contacting status is satisfactory.
N
For details, refer to "Valve Seat Contact".
8. Use the depth gauge to measure the distance between the

mounting surface of cylinder head spring seat and the valve O
stem end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace valve seat with a new
one.
P
Valve seat resurface : Refer to EM-139, "Standard and

limit (L) Limit".
JEM253G
Valve Spring Square
EM-107
CYLINDER HEAD
• Position the try square to valve spring, turn the spring, and mea-
sure the maximum clearance value between top surface of spring
and the try square.
Limit : Refer to EM-139, "Standard and Limit".

• If it exceeds the limit, replace valve spring.
PBIC0080E
Valve Spring Dimensions and Valve Spring Pressure Load

• Using intake valve spring tester, check the following.
Standard : Refer to EM-139, "Standard and

Limit".
• If out of the standard, replace the valve spring.
SEM113

NOTE:
engine coolant.

EM-108
ENGINE ASSEMBLY
ENGINE ASSEMBLY
A
EM
J
MBIB9169E
1. Engine mounting bracket RH 2. Engine mounting bracket LH 3. Engine mounting insulator RH K

4. Engine mounting insulator LH 5. Heat shield plate 6. Suspension member
Refer to GI-9, "Contents"for symbol marks in the figure.
L
Removal and Installation (Single Cab) INFOID:0000000013949725
WARNING: M
• Place chocks at front and back of rear wheels.
• Never start working until exhaust system and engine coolant are cool enough.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG. N
• Ensure that the engine and transmission are lowered and raised safely.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations. O
• If items or work required are not covered by the engine main body section, refer to the applicable
sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. P
• Before raising the engine, check that all the connections of the hoses, tubes and cables, are loose,
and connectors removed.
• When raising or lowering the engine, take care not to hit it against nearby parts, especially brake
pipes, clutch pipes, etc.
• When raising the engine, always use the engine slings safely.
REMOVAL
EM-109
ENGINE ASSEMBLY
Description of Work
Separate the engine from transmission and hoist the engine upward.
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-16.
2. Drain engine coolant. Refer to CO-10.
3. Disconnect clutch piping as follow:
a. Drain clutch fluid. Refer to CL-8..
b. Remove hydraulic lines.
Engine Room Front
1. For models with A/C, remove drive belts.
2. Disconnect radiator upper and lower hose.
3. Disconnect charge air cooler hoses.
4. Remove radiator, and charge air cooler as assembly. Refer to CO-13 and EM-23
Engine Room LH
1. Disconnect alternator harness connector.
2. Remove A/C compressor without disconnecting pipes and temporally secure them on body with a rope to
avoid putting load on them. Refer to MTC-66, "Removal and Installation of A/C Compressor".
3. Disconnect glow plug harness. Refer to EM-42, "Component".
4. Remove hose blow-by.
Engine Room RH
1. Remove power steering pump without disconnecting pipes.
2. Injectors and fuel pump harness connectors.
3. Disconnect oil pressure switch harness connector. Refer to LU-7, "Inspection" for location.
4. Disconnect heater hoses from heater feed tube.
5. Disconnect fuel feed and fuel return hoses, and plug them to prevent fuel from draining. Refer to EM-47,
6. Disconnect vacuum hoses.
7. Disconnect starter harness connector.
Engine Room Rear
1. Disconnect shift cable. Refer to MT-14, "Removal and Installation".
2. Disconnect crank shaft position sensor. Refer to EM-115, "Component".
Vehicle Under Body
1. Remove exhaust front tube. Refer to EX-4, "Removal and Installation".
2. Remove catalyst. Refer to EM-30, "Component".
3. Remove clutch operating cylinder from transmission, and move it aside. Refer to CL-11
Removal
1. Install engine slingers into front right of cylinder head (A) and
rear left of cylinder head (B).
1 : Engine slinger (front)

2 : Engine slinger (rear)
: Engine front
PBIC3480E
2. Support engine with a hoist and remove LH and RH engine mounting insulator mounting nuts.
3. Support the transmission with a suitable jack.
EM-110
ENGINE ASSEMBLY
4. Remove the starter motor and separate the engine from the gearbox. Refer to SC-41 and MT-27,
"Removal and Installation from Vehicle". A
CAUTION:
• During the operation, check that no part interferes with body side.
• Before and during this lifting, always check that harnesses are not connected. EM
Engine slinger bolts:

: 28.0 N·m (2.9 kg-m, 21 ft-lb) C
INSTALLATION
• Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator. D
• When installation directions are specified, install parts according to the direction marks on them referring to
figure of components. Refer to EM-109.
• Check that each mounting insulator is seated normally, and tighten mounting bolts and nuts. E
• Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stopper
is provided at vacuum gallery.
• Insert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery.
F
Inspection for Leaks
G
The following are procedures for checking fluid leakage, lubricate leakage and exhaust gas leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-17, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage. H
- Before starting engine, check for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. I
• Warm up engine thoroughly to check that there is no leakage of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
J
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
K
Engine oil Level Leakage Level (*2) L
Other oils and fluid (*1) Level Leakage Level
Exhaust gases — Leakage — M
*1: Transmission fluid, power steering fluid, brake fluid, etc.
*2: Check engine oil level 10 minutes after engine stopped.
N
Removal and Installation (Double Cab) INFOID:0000000013949726
WARNING: O
• Park the vehicle over an inspection pit, apply the parking.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS P
CATALOG.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
sections.
EM-111
ENGINE ASSEMBLY
• Use either 2-pole lift type or separate type lift as best you can.
REMOVAL
Description of Work
Support the engine, then remove engine and transmission from vehicle downward.
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-16.
2. Drain engine coolant. Refer to CO-10.
3. Remove front seats. Refer toSE-12, "Component Parts Drawing"
4. Tilt up rear seats.
5. Disconnect transmission shift cable from inside cab. Refer to MT-14, "Removal and Installation"
6. Disconnect parking brake cable from inside cab. Refer to PB-11
7. Remove front and rear floor trim. Refer to EI-29
8. Remove engine covers. Refer to EM-15.
9. For models equipped with air conditioner system, discharge refrigerant and disconnect refrigerant lines
from the cabin. Refer to MTC-64.
a. Drain clutch fluid. Refer to CL-8.
b. Remove hydraulic lines. Refer to CL-13
Engine Room Front
1. Remove radiator reservoir tank.
2. Radiator fan. Refer to CO-16
3. Drive belt. Refer to EM-20, "Removal and Installation".
Engine Room LH
1. Disconnect charge air cooler hoses and tubes. Refer to EM-23
2. Remove radiator upper and lower hose.
3. Remove alternator SC-33
4. Disconnect A/C piping and temporally secure them on body with a rope to avoid putting load on it. Refer to
MTC-66
5. Remove air conditioner compressor and its bracket as assembly.
6. Disconnect glow plug harness. Refer to EM-42, "Removal and Installation".
7. Remove blow-by hose.
Engine Room RH
1. Disconnect power steering fluid piping at a point between body and engine. Refer to PS-15.
2. Disconnect injector harness connectors and fuel pump harness connectors.
3. Disconnect oil pressure switch harness connector. Refer to LU-7 for location.
5. Disconnect air hose from intake manifold.
6. Disconnect oil cooler hose from heater pipes.
7. Remove EGR exhaust tube. Refer to EM-25, "Exploded View".
8. Remove EGR cooler. Refer to EM-25, "Exploded View".
9. Remove EGR volume control valve. Refer to EM-25, "Exploded View".
10. Disconnect fuel feed and fuel return hoses, and plug them to prevent fuel from draining. Refer to EM-51,
EM-112
ENGINE ASSEMBLY
12. Remove oil level tube.
13. Disconnect starter harness connector. A
Engine Room Rear
1. Remove shift cable. Refer to MT-14, "Removal and Installation" EM
2. Disconnect crank shaft position sensor. Refer to EM-115, "Component" .
Vehicle Under Body
1. Disconnect ABS harness connector. C
2. Disconnect wheel sensor harness connector and brake pads limit wear harness connector. Refer to BRC-
3. Remove exhaust front tube. Refer to EX-4, "Removal and Installation". D
4. Remove catalyst. Refer to EM-30, "Component" .
5. Remove propeller shaft. Refer to PR-4
E
6. Remove clutch operating cylinder from transmission, and move it aside. Refer to CL-11.
7. Disconnect manual transmission harness connector.
8. Remove fender protector LH and RH. Refer to EI-18 F
9. Remove stabilizer. Refer to FSU-10
10. Remove air guide and charge air cooler. Refer to EM-23
11. Remove charge air cooler tubes from the radiator. Refer to EM-23. G
12. Separate radiator shroud, and remove radiator. Refer to CO-13
Removal
H

I
: Engine front
J
K
PBIC3480E
2. Support the engine by a crane and loosen LH and RH engine mounting insulator mounting nuts.
L
3. Lower the engine and gearbox with the lifting table while loosening the slings on the crane supporting the
upper part of the engine.
4. Loosen and remove the nuts fixing the gearbox bracket to the chassis.
M
5. Remove engine and transmission from the vehicle underbody.
6. Remove the starter motor and separate the engine from the gearbox. Refer to SC-41 and MT-27,
"Removal and Installation from Vehicle".
N
CAUTION:
• Before and during this lifting, always check that harnesses are not connected.
O
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
P
INSTALLATION
• Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
figure of components. Refer to EM-109, "Component".
• Check that each mounting insulator is seated normally, and tighten mounting bolts and nuts.
EM-113
ENGINE ASSEMBLY
• Use procedure below to check for fuel leakage.
- Before starting engine, check for fuel leakage at connection points.
EM-114
CYLINDER BLOCK
CYLINDER BLOCK
A
EM
E1BIA1658GB
N
1. Cylinder block 2. Copper washer 3. Oil jet relief valve
4. Alternator bracket 5. Drain plug 6. Top ring
7. Second ring 8. Oil ring 9. Snap ring O
10. Piston 11. Piston pin 12. Connecting rod
13. Connecting rod bearing 14. Connecting rod cap 15. Main bearing cap
16. Main bearing lower 17. Pilot bushing 18. Flywheel P
19. Crankshaft 20. Key 21. Main bearing upper
22. Thrust bearing 23. Oil jet 24. Rear oil seal retainer
25. Rear oil seal 26. Rear cover 27. Oil pressure switch
28. Knock sensor
EM-115
CYLINDER BLOCK
A. Comply with the installation proce- B. Comply with the installation proce-
dure when tightening. Refer to EM- dure when tightening. Refer to EM-
116, "Disassembly and Assembly". 116, "Disassembly and Assembly".
DISASSEMBLY
1. Install engine to engine stand as per the following items:
a. Remove flywheel.
• Secure ring gear with the ring gear stopper (A) (SST), then
loosen mounting bolts with TORX socket (B) (commercial ser-
vice tool) and remove them. As an alternative method hold
crankshaft pulley with the pulley holder (commercial service
tool) to remove flywheel.
1 : Flywheel
A : KV10105630
CAUTION:
• Never disassemble flywheel.
• Never place flywheel with signal plate facing down. PBIC3482E
• When handling signal plate, take care not to damage or

scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
b. Hoist engine and install it to the engine stand (commercial ser-

vice tool).
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.
PBIC0085E

• EGR system. Refer to EM-25, "Exploded View".
• Turbocharger. Refer to EM-31, "Component".
• Exhaust manifold. Refer to EM-35, "Component".
• Intake manifold. Refer to EM-27, "Component".
• Vacuum pump. Refer to EM-44, "Component".
• Glow plug. Refer to EM-42, "Component".
• Injection tube and fuel injector. Refer to EM-46, "Exploded View".
• Camshaft. Refer to EM-64, "Component".
• Cylinder head assembly. Refer to EM-98, "Exploded View" .
• Oil pan and oil strainer: Refer to EM-37, "Component".
• Water pump. Refer to CO-17, "Component".
• Thermostat. Refer to CO-19, "Component".
• Water piping. Refer to EM-116, "Disassembly and Assembly".
• Fuel pump and fuel pump bracket. Refer to EM-51, "Component".
• Oil cooler. Refer to LU-12, "Component".
• A/C compressor. Refer to MTC-66, "Removal and Installation of A/C Compressor" .
• Alternator. Refer to SC-33, "Removal and Installation".
3. Remove rear oil seal retainer.
• Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
EM-116
CYLINDER BLOCK
4. Remove rear oil seal from rear oil seal retainer. Refer to EM-76, "Removal and Installation of Rear Oil
Seal". A
• Punch out with a flat-bladed screwdriver.
CAUTION:
Be careful not to damage rear oil seal retainer.
EM
5. Remove piston and connecting rod assembly.
• Before removing piston and connecting rod assembly, check
connecting rod side clearance. Refer to EM-139, "Standard
and Limit". C
a. Move crankshaft pin to be removed to approximately BDC.
b. Remove connecting rod caps.
D
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
CAUTION:
• Be careful not to damage the cylinder wall and crankshaft E
pin, resulting from an interference of the connecting rod JEM195G
big end.
• When removing piston and connecting rod assembly, pre- F
vent the big end of connecting rod from interfering with
oil jet (1).
G
JPBIA3896ZZ I
6. Remove connecting rod bearings from connecting rods and caps.
CAUTION:
• Be careful not to drop connecting rod bearing, and to scratch the surface. J
• Identify installation positions, and store them without mixing them up.
7. Remove piston rings from pistons using the piston ring expander K
(commercial service tool) (A).
CAUTION:
• When removing, prevent pistons from being damaged.
• Never expand piston rings excessively. This may damage L
piston rings.
PBIC3233J N
8. Remove pistons from connecting rods.

a. Using the snap ring pliers (A), remove snap rings. O
PBIC3230J
EM-117
CYLINDER BLOCK
b. Using the industrial use dryer (A), heat pistons up to 60 to 70°C
(140 to 158°F).
PBIC3231J
c. Using rod with outer diameter of 26 mm (1.02 in), press piston

pins out.
EMM0072D
9. Loosen and remove main bearing cap bolts in reverse order as

: Engine front
• Use TORX socket (size: E14) (commercial service tool).

• Before loosening main bearing cap bolts, measure crankshaft
end play. Refer to EM-124, "Inspection".
JPBIA3788ZZ
10. Remove main bearing caps.

• Insert bolts (1) into bolt holes, and then remove main bearing
cap (2) by lifting up and shaking forward and backward.
11. Remove crankshaft.
12. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
CAUTION:
Check the correct installation locations of removed parts.
Store them so they never get mixed up.
13. Remove oil jet.
JPBIA2478ZZ
14. Remove oil jet relief valve.
ASSEMBLY
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
EM-118
CYLINDER BLOCK
2. Install drain plug to cylinder block (1).
• Apply liquid gasket to drain plug (2). A
Use Genuine Liquid Gasket or equivalent
• Tighten drain plug.
EM
: 46.6 N·m (4.8 kg-m, 34 ft-lb)
PBIC3483E
D
3. Install oil jet relief valve.
4. Install oil jet.
• Align knock pin on back of oil jet with hole on block when E
installing oil jet.
PBIC0389E
H
5. Install main bearings and thrust bearings.
a. Remove contamination, dust and engine oil from bearing mount-
ing positions on cylinder block and main bearing caps. I
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
• Install thrust bearings with oil groove facing to crankshaft arm J
(outside).
K
JEM224G
c. Being careful with the direction, install main bearings. L

• Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the main cap side.
• While installing bearings, apply engine oil to bearing surfaces M
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
• Align stopper notches on bearings to install them. N
• Check that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
6. Install crankshaft to cylinder block. JEM213G
• Check crankshaft rotates smoothly by hand. O
EM-119
CYLINDER BLOCK
7. Install main bearing caps.
• Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
• Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer to EM-
124, "Inspection".
JEM225G
9. With the TORX socket (size: E14) (commercial service tool),

tighten the main bearing cap bolts according to the following
procedure:
: Engine front
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.
: 27.0 N·m (2.8 kg-m, 20 ft-lb) JPBIA3788ZZ
c. Put alignment marks (with paint) on each bolt and the main bearing cap, all in the same direction. (When
using a protractor)
d. Then, tighten 90 degrees. (angle tightening)

CAUTION:
Always use either the angle wrench [SST: KV10112100] or
protractor during angular tightening. Avoid tightening
based on visual checks alone.
• After tightening bolts to specified torque, check that crankshaft
rotates smoothly.
• Check crankshaft end play. Refer to EM-124, "Inspection".
10. Check the outer diameter of connecting rod bolts. Refer to EM-
124, "Inspection".
11. Install piston to connecting rod. JEM226G
a. Using the snap ring pliers, install snap rings to groove on piston
rear side.
• Fit snap ring correctly into grooves.
b. Install pistons to connecting rods.
• Using the industrial use dryer (A), heat pistons up to approx.
60 to 70°C (140 to 158°F) until piston pin can be pressed
down by finger touch. Then insert piston pin into piston and
connecting rod from front side of piston toward rear.
PBIC3231J
EM-120
CYLINDER BLOCK
• Assemble piston and connecting rod with front mark of piston
head and cylinder No. stamped on connecting rod being posi- A
tioned as shown in the figure.
c. Install snap ring to front side of piston.
• Refer to above step a for precaution on snap ring installation. EM
• After installation, check connecting rods for smooth move-
ment.
C
MBIA0024E
D
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged.
E
• Install top ring and second ring with punched mark surfaces
facing upward.
Punched mark: F
Top ring : RTOP
Second ring : R2ND
G
• Install rings so that three closed gap position 120 degrees
apart one another.
• Closed gaps do not need to face in a specific directions, as
H
long as each are positioned 120 degrees apart. JEM228G
13. Install connecting rod bearing to connecting rod and cap.

• While installing connecting rod bearing, apply engine oil to I
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
• Align protrusions on connecting rod bearings with connecting J
rod cut-outs to install connecting rod bearings.
JEM229G
L
14. Install piston and connecting rod assembly to crankshaft.
• Move crankshaft pin to be assembled to BDC.
• Align cylinder position with cylinder No. on connecting rod to M
install piston and connecting rod assembly.
• Using the piston ring compressor [SST: EM03470000] or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine. N
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with O
oil jet.
PBIC1619E
EM-121
CYLINDER BLOCK
15. Install connecting rod caps and mounting nuts.
• Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
• Check that the front mark on connecting rod cap faces
towards the front of the engine.
MBIA0024E
16. Tighten connecting rod nuts according to the following procedure:

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

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

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

e. Tighten bolts.

• Always use either the angle wrench [SST: KV10112100] or
protractor during angular tightening. Avoid tightening
based on visual checks alone.
• After tightening nuts, check that crankshaft rotates smoothly.
• Check connecting rod side clearance. Refer to EM-124,
"Inspection".
JEM231G
17. Press fit rear oil seal into rear oil seal retainer.
• Using the drift [105 mm (4.13 in) dia.], press fit so that the
JEM232G
EM-122
CYLINDER BLOCK
18. Install rear oil seal retainer to cylinder block.
• Apply new engine oil to the oil and dust seal lips. A
• Apply liquid gasket to rear oil seal retainer using the tube
presser (commercial service tool) as shown in the figure.
EM
JEM233G
D
19. Install fuel pump bracket (1).
• Align the bracket with the dowel pins (A) on cylinder block to
install.
E
G
JPBIA3897ZZ
20. Assemble in the reverse order of disassembly.

H
21. Remove engine from engine stand in the reverse order of assembly.
22. Install flywheel.
• Ensure the dowel pins install in the crankshaft. I
• When installing flywheel to crankshaft, check that crankshaft
side dowel pin and flywheel side dowel pin hole are correctly
aligned.
CAUTION: J
If these are not aligned correctly, engine runs roughly and
“MI” turns on.
K
L
PBIC2538E
• There is a mating mark on the clutch cover side of flywheel. M

Refer it during installation.
PBIC1112E
P
EM-123
CYLINDER BLOCK
• Holding ring gear with ring gear stopper (SST), tighten secur-
ing bolts with TORX socket.
• Tighten bolts uniformly in a crisscross manner.
PBIC3482E
- If these are not aligned correctly, engine runs roughly and “MI” turns on.
CRANKSHAFT END PLAY

• Using dial gauge, measure crankshaft travel amount by moving the
crankshaft forward or backward.

Limit".
• If the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft
with a new one.
JEM202G
CONNECTING ROD SIDE CLEARANCE

• Using feeler gauge, measure side clearance between connecting
rod and crankshaft arm.

Limit".
• If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
JEM203G
PISTON TO PISTON PIN CLEARANCE

Piston Pin Bore Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
Standard : Refer to EM-139, "Standard and Limit".
JPBIA0217ZZ
Piston Pin Outer Diameter
EM-124
CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer (A).
A
EM
JPBIA0218ZZ
D
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)
Standard : Refer to EM-139, "Standard and Limit". E
• If out of the standard, replace piston/piston pin assembly.

NOTE:
Piston is available together with piston pin as assembly. F
PISTON RING SIDE CLEARANCE

• Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C). G
A : NG
B : OK
H

Limit".
I
J
JPBIA2276ZZ
• Align top ring and external surface of piston. Measure lower side
K
clearance of top ring with top ring pressed onto upper side of ring
groove.
• If side clearance exceeds the limit, replace piston ring.
• Check clearance again. If side clearance still exceeds the limit, L
replace piston.
FEM100
N
PISTON RING END GAP
• Check that the cylinder bore inner diameter is within the specifica-
tion. O
• Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with a feeler gauge (B).
P
A : Press-fit

Limit".
JPBIA2277ZZ
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, re-bore cylinder and use oversize piston and piston rings.
EM-125
CYLINDER BLOCK
CONNECTING ROD BEND AND TORSION
• Check with a connecting rod aligner.
A : Bend
B : Torsion
C : Feeler gauge
Bend limit : Refer to EM-139, "Standard and

Torsion limit Limit".
• If it exceeds the limit, replace connecting rod assembly.
JPBIA0221ZZ
CONNECTING ROD BIG END DIAMETER

• Install connecting rod bearing cap without installing connecting rod
bearing, and tighten connecting rod bolts to the specified torque.
Refer to EM-116, "Disassembly and Assembly" for the tightening
procedure.
1 : Connecting rod
• Measure the inner diameter of connecting rod big end with an
inside micrometer.

JPBIA0222ZZ
• If out of the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing with an inside
micrometer (A).
JPBIA0223ZZ
EM-126
CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer (A).
A
EM
JPBIA0218ZZ
D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
Standard and limit : Refer to EM-139, "Standard and Limit".
• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly. F
• If replacing piston and piston pin assembly, refer to EM-116, "Disassembly and Assembly".
• If replacing connecting rod assembly, refer to EM-139, "Standard and Limit" to select the connecting rod
bearing. G
CYLINDER BLOCK DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination. H
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some I
different points in six directions (C), (D), (E), (F), (G) and (H) with a
straightedge (A) and a feeler gauge (B).
Limit : Refer to EM-139, "Standard and Limit". J
• If it exceeds the limit, replace cylinder block.

K
JPBIA0224ZZ L
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap (2) without installing main bearings, and
tighten main bearing cap bolts to the specified torque. Refer to EM- M
116, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge. N
• If out of the standard, replace cylinder block (1) and main bearing O
cap as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is JPBIA0225ZZ
machined together with main bearing cap. P
PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter
EM-127
CYLINDER BLOCK
• Using a bore gauge, measure the cylinder bore for wear, out-of
round and taper at six different points on each cylinder. [(A) and (B)
directions at (C), (D), and (E)] [(A) is in longitudinal direction of
engine]
f : 10 mm (0.39 in)
g : 85 mm (3.35 in)
h : 160 mm (6.30 in)

JPBIA2059ZZ
Limit".
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or bore the inner wall.
• Oversize piston is provided. When using oversize piston, hone the cylinder so that the clearance between
piston and cylinder satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with oversize piston rings.
Oversize (O/S) : Refer to EM-139, "Standard and

Limit".
Piston Outer Diameter
Measure the outer diameter of piston skirt with a micrometer (A).
Measurement position : Refer to EM-139, "Standard

Standard and Limit".
JPBIA0227ZZ
Piston to Cylinder Bore Clearance

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

Limit".
• If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-116, "Disassembly and Assem-
bly".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
EM-128
CYLINDER BLOCK
Re-bore size calculation: A

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

• If out of the standard, measure the main bearing oil clearance. I
Then use the under size bearing. Refer to EM-133, "How to Select
Piston and Bearing".
J
FEM114
K
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).
L
• If out of the standard, measure the connecting rod bearing oil M
clearance. Then use under size bearing. Refer to EM-133, "How to
Select Piston and Bearing".
JPBIA0228ZZ
CRANKSHAFT OUT-OF-ROUND AND TAPER O
EM-129
CYLINDER BLOCK
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in the dimensions
between (d) and (c) at (a) and (b).
• Taper is indicated by the difference in the dimensions between.
Out-of-round (Difference : Refer to EM-139, "Stan-

between c and d) dard and Limit".
Taper (Difference between
a and b)
JPBIA0229ZZ
• If the measured value exceeds the limit, correct or replace crank-
shaft.
• If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to EM-133, "How to Select Piston and Bearing" and/or EM-139,
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on
both ends of crankshaft.
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on a
dial indicator. (Total indicator reading)

Limit".
• If it exceeds the limit, replace crankshaft.
SEM346D
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
• Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-116, "Disassembly and Assembly" for the
tightening procedure.
JPBIA0230ZZ
• Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)
Standard and limit : Refer to EM-139, "Standard and Limit".

• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-124, "Inspection".
Method of Using Plastigage
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-116, "Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
EM-130
CYLINDER BLOCK
Never rotate crankshaft.
• Remove connecting rod bearing cap and bearings, and using the A
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
EM
same as that described in the “Method by Calculation”.
JPBIA0231ZZ D
MAIN BEARING OIL CLEARANCE
Method by Calculation E
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-116, "Disassembly and Assembly" for the tightening
procedure. F
• Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter) G

Limit". H
• If the calculated value exceeds the limit, select proper main bear- JPBIA0232ZZ
ing according to main bearing inner diameter and crankshaft main

journal diameter to obtain the specified bearing oil clearance. Refer to EM-124, "Inspection". I
• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil J
holes.
• Install main bearing to cylinder block and main bearing cap, and tighten main bearing cap bolts with main
bearing cap to the specified torque. Refer to EM-116, "Disassembly and Assembly" for the tightening proce-
dure. K
CAUTION:
• Remove main bearing cap and bearings, and using the scale on L
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
M
same as that described in the “Method by Calculation”.
JPBIA0231ZZ O
MAIN BEARING CRUSH HEIGHT
P
EM-131
CYLINDER BLOCK
• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-116, "Disassembly and
Assembly" for the tightening procedure.
A : Crush height
Standard : There must be crush height.

• If the standard is not met, replace main bearings.
JPBIA0233ZZ
CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-116, "Disassem-
bly and Assembly" for the tightening procedure.
A : Crush height

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

• Measure the outer diameter of threaded area, “d1” and “d2”, at the
points specified in the figure.
• When the necked point is identified at a point other than where
specified, measure at the point as “d2”.
Limit : 0.13 mm (0.0051 in)

• If it exceeds the limit, replace main bearing cap bolt.
JEM219G
CONNECTING ROD BOLT DEFORMATION

• Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on the
bolt.
• If the nut does not screw in smoothly, measure the outer diameter
of the bolt thread at the point specified in the figure.
• If a necked point is identified, measure at that point.
Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.

Limit : 8.75 mm (0. 3445 in) dia.
• If it exceeds the limit, replace connecting rod bolts and nuts.
JEM220G
OIL JET
EM-132
CYLINDER BLOCK
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs. A
Standard : No deformation and no damage.

• If out of the standard, replace oil jet. EM
JEM221G
D
OIL JET RELIEF VALVE
• Using clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force.
E
Standard:
Valve moves smoothly with proper reaction force.
F
• If out of the standard, replace oil jet relief valve.
JEM222G
DRIVE PLATE H
• Check drive plate and signal plate for deformation or cracks.
CAUTION:
• Never disassemble drive plate.
I
• Never place drive plate with signal plate facing down.
scratch it.
• Handle signal plate in a manner that prevents it from becom- J
ing magnetized.
• If anything is found, replace drive plate.
K
SEM760G
How to Select Piston and Bearing INFOID:0000000013949730

L
DESCRIPTION
Selection points Selection parts Selection items Selection methods M

Determined by match of cylin-
der block bearing housing
Between cylinder block to Main bearing grade (bearing grade (inner diameter of hous- N
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
O
Combining service grades for
connecting rod big end diame-
Between crankshaft to connect- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
ing rod (bearing thickness)
ameter determine connecting P
rod bearing selection.
Piston and piston pin assembly
Between cylinder block to pis- Piston grade (piston outer diam- Piston grade = cylinder bore
The piston is available together
ton eter) grade (inner diameter of bore)
with piston pin as an assembly.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
EM-133
CYLINDER BLOCK
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON WHEN NEW CYLINDER BLOCK IS USED
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade.
• The part No. of piston is specified together with piston pin as
an assembly.
JEM208G
HOW TO SELECT PISTON WHEN CYLINDER BLOCK IS REUSED

1. Measure cylinder bore inner diameter. Refer to EM-133, "How to Select Piston and Bearing".
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
A : Identification code
B : Front mark
C : Piston grade number
3. Select piston of the same grade.
JPBIA3910ZZ
PISTON SELECTION TABLE

Unit: mm (in)
Grade (punched) 1 2 3
Cylinder bore in-
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
ner diameter
Piston outer di-
88.806 - 88.820 (3.4963 - 3.4968) 88.816 - 88.830 (3.4967 - 3.4972) 88.826 - 88.840 (3.4971 - 3.4976)
ameter
NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD WHEN NEW CONNECTING ROD AND CRANKSHAFT
ARE USED
1. Identify the pin diameter grade on front surface of crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.
JEM215G
HOW TO SELECT CONNECTING ROD WHEN CONNECTING ROD AND CRANKSHAFT ARE RE-
EM-134
CYLINDER BLOCK
USED
1. Measure the inner diameter of the big end of connecting rod and check it is within the specified range. A
Refer to EM-124, "Inspection".
2. Measure the outer diameter of the crankshaft pin. Refer to EM-124, "Inspection".
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column EM
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
C
CONNECTING ROD BEARING SELECTION TABLE
JPBIA3907GB
N
UNDERSIZE BEARING USAGE GUIDE
• If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under size
bearings. O
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.
Connecting rod bearing under size : Refer to EM-139, "Standard and Limit". P
CAUTION:
EM-135
CYLINDER BLOCK
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.
Standard dimension R : 1.5 - 1.7 mm (0.059 - 0.067 in)
JEM216G
HOW TO SELECT MAIN BEARING WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE
USED
1. Identify the crank journal grade on LH surface at the rear of the
cylinder block, and locate the applicable grade on the “Grade”
row in the “Main Bearing Grade Table”.
JEM208G
2. Identify the journal grade on the front surface of crankshaft, and

locate the applicable grade under the “Grade” column in the
“Main Bearing Grade Table”.
JEM215G
3. The main bearing to be used can be located in the cell where the row and column cross.
HOW TO SELECT MAIN BEARING WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-124, "Inspection".
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-124, "Inspection".
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used can be located in the cell where the row and column cross.
EM-136
CYLINDER BLOCK
MAIN BEARING SELECTION TABLE
A
EM
L
JPBIA3906GB
MAIN BEARING GRADE TABLE (ALL JOURNALS) M
Main bearing grade table (All journals) : Refer to EM-139, "Standard and
Limit". N
UNDERSIZE BEARING USAGE GUIDE
• If bearing clearance is out of the specifications for main bearings in standard size, use under size bearings.
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank- O
shaft journals to adjust clearance to the specification.
Main bearing under size : Refer to EM-139, "Standard and P

Limit".
CAUTION:
EM-137
CYLINDER BLOCK
When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals)
JEM216G
EM-138
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Standard and Limit INFOID:0000000013949731
GENERAL SPECIFICATIONS EM
Cylinder arrangement In-line 4

Displacement Unit: cm3 (cu in) 2,488 (151.82) C
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Valve arrangement DOHC
D
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 E
Number of main bearings 5
Compression ratio 15
F
Standard 2,800 (28, 28.56, 406)
Compression pressure
Minimum 2,200 (22, 22.44, 319)
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 450 (4.5, 4.59, 65.3) G
Unit: degree
Intake valve open (BTDC) 2
H
Intake valve close (ABDC) 30
Valve timing
Exhaust valve open (BBDC) 46
Exhaust valve close (ATDC) -2 I
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
J
Items Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012) K
DRIVE BELTS
Belt Deflection:
L
Applied belt
A/C compressor, alternator and water M
Auto adjustment by auto-tensioner
pump belt
4.6 - 5.4 7.1 - 7.7
(0.181 - 0.213) (0.280 - 0.303) N
Belt Frequency:
O
Belt frequency (Hertz)
Applied belt
A/C compressor, alternator and water
Auto adjustment by auto-tensioner
P
pump belt
Power steering oil pump belt 290 245 162
CYLINDER HEAD
EM-139
Unit: mm (in)
Items Standard Limit
Cylinder head distortion Less than 0.04 (0.0016) 0.1 (0.004)
JEM204G
VALVE
Valve Dimensions
Unit: mm (in)
SEM188
Intake 28.4 - 28.7 (1.1181 - 1.1299)

Valve head diameter “D”
Exhaust 25.8 - 26.1 (1.0157 - 1.0276)
Intake 105.93 (4.1705)
Valve length “L”
Exhaust 105.48 (4.1527)
Intake 5.965 - 5.98 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “α” Intake and exhaust 45 degrees 15′ - 45 degrees 45′
Intake 1.08 (0.0425)
Valve margin “T”
Exhaust 1.38 (0.0543)
Valve margin “T” limit More than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
Valve Clearance
Unit: mm (in)
Items Cold Hot* (Reference data)

Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
Available Shims
EM-140
Stamped mark (A) Thickness mm (in) A

2.10 2.10 (0.0827)
2.12 2.12 (0.0835)
EM
2.14 2.14 (0.0843)
2.16 2.16 (0.0850)
2.18 2.18 (0.0858) C
2.20 2.20 (0.0866)
2.22 2.22 (0.0874)
2.24 2.24 (0.0882) D
2.26 2.26 (0.0890)
2.28 2.28 (0.0898)
E
2.30 2.30 (0.0906)
2.32 2.32 (0.0913)
2.34 2.34 (0.0921) F
2.36 2.36 (0.0929)
2.38 2.38 (0.0937)
G
2.40 2.40 (0.0945)
2.42 2.42 (0.0953)
2.44 2.44 (0.0961) H
2.46 2.46 (0.0969)
2.48 2.48 (0.0976)
I
2.50 2.50 (0.0984)
2.52 2.52 (0.0992)
2.54 2.54 (0.1000) J
2.56 2.56 (0.1008)
2.58 2.58 (0.1016)
2.60 2.60 (0.1024) K
2.62 2.62 (0.1031)
2.64 2.64 (0.1039)
L
2.66 2.66 (0.1047)
2.68 2.68 (0.1055)
2.70 2.70 (0.1063) M
2.72 2.72 (0.1071)
2.74 2.74 (0.1079)
N
JPBIA3912ZZ
Valve Spring
EM-141
Valve spring square mm (in) 1.9 (0.075)

Intake 43.7 (1.720)
Free height mm (in)
Exhaust 43.7 (1.720)
Pressure N (kg, lb) at height mm (in) 184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
Intake 24.95 (0.9823)
Height during valve open mm (in)
Exhaust 24.66 (0.9709)
Intake 250 - 274 (25.5 - 27.9, 56.2 - 61.6)
Load with valve open N (kg, lb)
Exhaust 308 - 336 (31.4 - 34.3, 69.2 - 75.5)
Valve Lifter
Unit: mm (in)
Items Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)
Valve Guide
Unit: mm (in)
JEM156G
Items Standard Service

Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.10 (0.0039)
Projection length 10.4 - 10.6 (0.409 - 0.417)
Valve Seat
EM-142
Unit: mm (in)
A
EM
E1BIA0294ZZ
JEM253G
M
Items Standard Oversize (Service) [0.5 (0.020)]
Cylinder head seat (1) recess diame- Intake 30.4 - 30.416 (1.1968 - 1.1975) 30.9 - 30.916 (1.2165 - 1.2165)
ter “D” Exhaust 28.200 - 28.216 (1.1102 - 1.1109) 28.7 - 28.716 (1.1299 - 1.1305) N
Intake (A) 30.48 - 30.5 (1.2 - 1.2008) 30.98 - 31.0 (1.2197 - 1.2205)
Valve seat outer diameter “d”
Exhaust (B) 28.28 - 28.296 (1.1134 - 1.1140) 28.78 - 28.796 (1.1331 - 1.1337)
O
Intake (A) 0.064 - 0.100 (0.0025 - 0.0039)
Valve seat interference fit
Exhaust (B) 0.064 - 0.096 (0.0025 - 0.0038)
Intake (A) 27.7 - 28.2 (1.0689 - 1.0886) 27.7 - 28.2 (1.0689 - 1.0886) P
Diameter “d1”
Exhaust (B) 25.1 - 25.6 (0.9882 - 1.0079) 25.1 - 25.6 (0.9882 - 1.0079)
Angle “α” 89.5°±45′
Intake (A) 6.84 - 6.94 (0.269 - 0.273) 6.39 - 6.49 (0.252 - 0.256)
Height “h1”
Exhaust (B) 6.84 - 6.94 (0.264 - 0.268) 6.84 - 6.94 (0.269 - 0.273)
EM-143
Intake (A) 2.25 - 2.45 (0.089 - 0.096) 2.15 - 2.55 (0.085 - 0.1004)
Height “h2”
Exhaust (B) 2.9 - 3.1 (0.1142 - 0.1220) 2.8 - 3.2 (0.1102 - 0.1260)
Intake 8.85 - 9.15 (0.3484 - 0.3602)
Depth “H”
Exhaust 9.29 - 9.59 (0.3657 - 0.3776)
Intake 36.18 - 36.78 (1.4382 - 1.4559)
Projection (L)
Exhaust 36.16 - 36.96 (1.4236 - 1.4551)
CAMSHAFT
Unit: mm (in)

Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034)
No.1 30.500 - 30.521 (1.2008 - 1.2016)
Camshaft bracket inner diameter
No. 2, 3, 4, 5 24.000 - 24.021 (0.9449 - 0.9457) —
No. 1 30.435 - 30.455 (1.1982 - 1.1990)
Camshaft journal outer diameter
No. 2, 3, 4, 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft runout [TIR*] — 0.02 (0.0008)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
SEM671
Intake 39.505 - 39.695 (1.5553 - 1.5628)

Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
*: Total indicator reading
CYLINDER BLOCK
Unit: mm (in)
SEM899G
Standard Less than 0.03 (0.0012)

Top surface distortion
Limit 0.1 (0.004)
EM-144
Grade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
A
Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Cylinder bore Inner diameter
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.07 (0.0028) EM
Out-of-round (Difference between X and Y) 0.015 (0.0006)
Limit
Taper (Difference between A and C) 0.010 (0.0004)
Main bearing housing inner diameter (Without bearing) 66.656 - 66.680 (2.6242 - 2.6252) C
Difference in inner diameter
Limit Less than 0.05 (0.0020)
between cylinders
D
PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in) E
E1BIA0295ZZ
Grade No. 1 88.806 - 88.820 (3.496 - 3.4968) I

Grade No. 2 88.816 - 88.830 (3.4967 - 3.4972)
Piston outer diameter “A” Standard Grade No. 3 88.826 - 88.840 (3.4971 - 3.4976) J
Oversize (Service) [0.25] 89.066 - 89.080 (3.5065 - 3.5071)
Oversize (Service) [0.5] 89.316 - 89.330 (3.5164 - 3.5169)
“a” dimension 43.0 (1.63) K
Piston pin bore diameter 28.008 - 28.013 (1.1027 - 1.1029)
Piston to cylinder bore clearance 0.18 - 0.204 (0.0071 - 0.008)
L
Piston Ring
Unit: mm (in)
Items Standard Limit M

Top 0.04 - 0.06 (0.0016 - 0.0024) 0.17 (0.007)
Side clearance 2nd 0.08 - 0.12 (0.0031 - 0.0047) 0.13 (0.005)
N
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
Top 0.18 - 0.28 (0.0071 - 0.0110)
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039) O
Oil ring 0.30 - 0.55 (0.0118 - 0.0217)
Piston Pin
P
Unit: mm (in)
Piston pin outer diameter 27.995 - 28.000 (1.1022 - 1.1024)

Piston to piston pin clearance 0.008 - 0.018 (0.0003 - 0.0007)
Standard 0.026 - 0.043 (0.0010 - 0.0017)
Connecting rod bushing clearance
Limit 0.057 (0.0022)
CONNECTING ROD
EM-145
Unit: mm (in)
Center distance 154.47 - 154.53 (6.0815 - 6.0838)

Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter* 55.000 - 55.013 (2.1654 - 2.1659)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.40 (0.0157)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
Main journal dia. “Dm” 62.951 - 62.975 (2.4784 - 2.4793)

Pin journal dia. “Dp” 51.956 - 51.974 (2.0455 - 2.0462)
Center distance “r” 49.97 - 50.03 (1.9673 - 1.9697)
Out-of-round (Difference between X Standard 0.003 (0.0001)

and Y) Limit 0.005 (0.0002)
Standard 0.003 (0.0001)
Taper (Difference between A and B)
Limit 0.005 (0.0002)
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.085 - 0.25 (0.0033 - 0.0098)
End play
Limit 0.30 (0.0118)
SEM645 SBIA0535E
AVAILABLE MAIN BEARING

Main bearing
EM-146
Unit: mm (in)
A
EM
D
SEM255G
Grade number Thickness Width Identification color Remarks

E
0 1.812 - 1.809 (0.0713 - 0.0712) Black
1 1.815 - 1.812 (0.0715 - 0.0713) Brown
2 1.818 - 1.815 (0.0716 - 0.0715) Green
F
3 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are the
same for upper and
4 1.824 - 1.821 (0.0718 - 0.0717) Blue lower bearings.
5 1.827 - 1.824 (0.0719 - 0.0718) Pink G
6 1.830 - 1.827 (0.0720 - 0.0719) Purple
7 1.833 - 1.830 (0.0722 - 0.0720 Red
H
UPR 1.812 - 1.809 (0.0715 - 0.0712) Black
01
LWR 1.815 - 1.812 (0.0715 - 0.0713) Brown
UPR 1.815 - 1.812 (0.0715 - 0.0713) 19.9 - 20.1 Brown I
12
LWR 1.818 - 1.815 (0.0716 - 0.0715) (0.783 - 0.791) Green
UPR 1.818 - 1.815 (0.0716 - 0.0715) Green
23 J
LWR 1.821 - 1.818 (0.0717 - 0.0716) Yellow
UPR 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are dif-
34 ferent between upper
LWR 1.824 - 1.821 (0.0718 - 0.0717) Blue and lower bearings. K
UPR 1.824 - 1.821 (0.0718 - 0.0717) Blue
45
LWR 1.827 - 1.824 (0.0719 - 0.0718) Pink
L
UPR 1.827 - 1.824 (0.0719 - 0.0718) Pink
56
LWR 1.830 - 1.827 (0.0720 - 0.0719) Purple
UPR 1.830 - 1.827 (0.0720 - 0.0719) Purple M
67
LWR 1.833 - 1.830 (0.0722 - 0.0720 Red
Undersize
Unit: mm (in) N
Size Thickness Main journal diameter “Dm”
Grind so that bearing clearance is the spec-
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769) O
ified value.
AVAILABLE CONNECTING ROD BEARING

Connecting Rod Bearing P
Grade number Thickness mm (in) Width Identification color Remarks
EM-147
0 1.488 - 1.485 (0.0586 - 0.0585) Green
1 1.491 - 1.488 (0.0585 - 0.0587) Yellow
Grade and color are the same
2 1.494 - 1.491 (0.0588 - 0.0585) Blue
for upper and lower bearings.
3 1.497 - 1.494 (0.0589 - 0.0588) Pink
4 1.500 - 1.497 (0.0591 - 0.0589) Purple
UPR 1.488 - 1.485 (0.0586 - 0.0585) Green
01 22.9 - 23.1
LWR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
(0.902 - 0.909)
UPR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
12
LWR 1.494 - 1.491 (0.0588 - 0.0585) Blue Grade and color are different
between upper and lower
UPR 1.494 - 1.491 (0.0588 - 0.0585) Blue bearings.
23
LWR 1.497 - 1.494 (0.0589 - 0.0588) Pink
UPR 1.497 - 1.494 (0.0589 - 0.0588) Pink
34
LWR 1.500 - 1.497 (0.0591 - 0.0589) Purple
Undersize
Unit: mm (in)
Size Thickness Crank pin journal diameter “Dp”

UPR 1.534 - 1.542 (0.0604 - 0.0607)
0.08 (0.0031)
LWR 1.536 - 1.540 (0.0605 - 0.0606)
UPR 1.554 - 1.562 (0.0612 - 0.0615)
0.12 (0.0047) Grind so that bearing clearance is the specified value.
LWR 1.556 - 1.560 (0.0613 - 0.0614)
UPR 1.619 - 1.627 (0.0637 - 0.0641)
0.25 (0.0098)
LWR 1.621 - 1.625 (0.0638 - 0.0640)
MISCELLANEOUS COMPONENTS
Flywheel
Unit: mm (in)
Flywheel deflection [TIR]* Standard 0.45 (0.0177) or less

Bearing Clearance
Unit: mm (in)
Main bearing oil clearance Standard 0.056 - 0.066 (0.0022 - 0.0026)

Connecting rod bearing oil
Standard 0.051 - 0.061 (0.002 - 0.0024)
clearance
E M -1 4 8
PRECAUTIONS
< SERVICE INFORMATION > [YD25DDTi FOR GENERAL AREAS]
SERVICE INFORMATION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING: D
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the I
battery, and wait at least 3 minutes before performing any service.
J
• Never disconnect battery terminal while engine is running. K
L

D4D engine : 20 minutes YS23DDT : 4 minutes M
M9R engine : 4 minutes ZD30DDTT : 60 seconds N
SEF289H
O
NOTE:
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait P
NOTE:
EM-149
PRECAUTIONS
NOTE:
NOTE:
DISCONNECTING FUEL PIPING



replace if necessary.

• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
in the step.

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
• Replace with new gasket, packing, oil seal or O-ring.
Before assembly, oil sliding surfaces well.
• After disassembling, or exposing any internal engine parts, change engine oil and replace oil filter with a new
one.
• Release air within route when refilling after draining engine coolant.
EM-150
PRECAUTIONS
tightening) A
• The torque value for these parts are for a preliminary step.
EM
REMOVAL OF LIQUID GASKET C

surface using the seal cutter (SST) and remove the old liquid gas-
ket sealing. D
CAUTION:
Be careful not to damage the mating surfaces.
as shown in the figure. E
mer to lightly tap the parts, to remove it.
CAUTION: F
PBIC0275E
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE G
uid gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the H
holes.
2. Wipe the liquid gasket application surface and the mating sur- I
adhering moisture, grease and foreign materials.
J
PBIC0003E
3. Attach the liquid gasket tube to the tube presser (SST). K

4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions. L
liquid gasket to the groove.
M
PBIC2160E N
• As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes. O
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If the liquid gasket protrudes, wipe it off immediately. P
• After 30 minutes or more pass from the installation, fill the
CAUTION:
SEM159F
EM-151
PREPARATION
PREPARATION
Tool number
Description
Tool name
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
NT603
f: 5 (0.20)
Unit: mm (in)
1. KV10116100
S-NT605
KV11103000 Removing crankshaft pulley

Pulley puller
NT676

ZZA1188D
KV101056S0 Preventing crankshaft from rotating

Ring gear stopper a: 3 (0.12)
1. KV10105630 b: 6.4 (0.252)
Adapter c: 2.8 (0.110)
2. KV10105610 d: 6.6 (0.260)
Plate e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
NT617
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0 Changing adjusting shim
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopper
NT041
EM-152
PREPARATION
Tool number
Description
Tool name A
KV10116200 Disassembling and assembling valve mecha-
Valve spring compressor nism
1. KV10115900 Part (1) is a component of KV10116200, but EM
Attachment Part (2) is not so.
2. KV10109220
Adapter
C
PBIC1650E
ST16610001 Removing crankshaft pilot bush

Pilot bushing puller D
NT045
F
KV10111100 Removing oil pan upper, oil pan lower and rear
Seal cutter chain case, etc.
H
NT046

Tube presser
I
NT052
KV10112100 Tightening bolts for bearing cap, cylinder K

Angle wrench head, etc.
NT014 M
N
O
NT044
KV11106010 Removing and installing chain tensioner

Hexagon wrench a: 5 mm (0.20 in) (Face to face) P
b: 20 mm (0.79 in)
NT801
EM-153
PREPARATION
Tool number
Description
Tool name
KV11106020 Removing and installing slack guide
Hexagon wrench a: 6 mm (0.24 in) (Face to face)
b: 20 mm (0.79 in)
NT803
KV11106030 Fixing fuel pump sprocket

Positioning stopper pin a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)
NT804

TORX wrench nut
a: T70
b: 26 mm (1.02 in)
NT805

Hexagonal wrench a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)
SBIA0224E
KV11106060 Holding fuel pump sprocket

Sprocket holder
SBIA0225E
EM-154
PREPARATION
A
EM
C
NT048
NT030
Valve guide reamer Reaming valve guide with (1) or hole for over- F
size valve guide with (2)
Intake and Exhaust:
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia. G
NT016
H
TORX socket Loosening and tightening flywheel and drive
plate
Size: E20
I
J
NT807
Valve guide drift Removing and installing valve guide

Intake and Exhaust: K
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
NT015
TORX socket Loosening and tightening fuel pump mounting M

bolt
Size: E10
N
NT807
O
EM-155
PREPARATION
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with angle wrench [SST:
KV10112100]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583
TORX socket Loosening and tightening main bearing cap

bolt
Size: E14
NT807
EM-156
A
EM
P
PBIC3402E

EM-157
4. Check specified noise source.
Operating condition of engine

up up ing
gine clicking noise
Rocker
cover Camshaft
head noise
Piston to piston pin

— A — B B —
oil clearance
Piston to cylinder bore
Crank- clearance
EM-270
shaft pul- Piston ring side clear-
Slap or Piston EM-270
ley A — — B B A ance
rap slap noise EM-270
Cylinder Piston ring end gap
EM-270
Oil pan ing rod oil clearance EM-270
Knock A B C B B B
noise oil clearance (Big end)
Main bear- EM-270
ing noise EM-270
Crankshaft runout
Timing
Front of Timing chain cracks
chain and EM-221
engine Tapping or and wear
A A — B B B chain ten- EM-228
Timing ticking Timing chain tensioner
sioner EM-227
chain case operation
noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-161
ping)
Front of
Drive belts Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related
EM-158
ENGINE COVERS
ENGINE COVERS
A
EM
MBIB9173E
P
EM-159
ENGINE COVERS
REMOVAL
4. Remove mountings bolts and remove covers.
INSTALLATION
EM-160
DRIVE BELTS
DRIVE BELTS
A
Checking Drive Belts INFOID:0000000013949743
EM
PBIC4038E
E
4. Crankshaft pulley 5. 6. Alternator F
A/C compressor, alternator and wa-
7. Idler pulley 8. Water pump pulley 9.
ter pump belt
• Before inspecting engine, check that engine cools down, wait approximately 30 minutes after engine stops. G
• Visually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
• Measure deflection at the marked point ( ).
CAUTION: H
Then, after turning crankshaft two turns or more, readjust to the specified value to avoid variation
in deflection between pulleys. I
• Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection:
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in) J

Applied belt
New Adjusted Limit for readjusting
A/C compressor, alternator and water 3.3 - 3.6 4.6 - 5.1
8.5 (0.335) K
pump belt (0.130 - 0.142) (0.181 - 0.201)
4.6 - 5.4 7.1 - 7.7
(0.181 - 0.213) (0.280 - 0.303)
*: When engine is cold. L
Belt Deflection:
M
Belt deflection frequency (Hz)
Applied belt
A/C compressor, alternator and water N
308 ± 7 255 ± 7 183
pump belt
Power steering oil pump belt 290 ± 7 560 ± 28 162
*: When engine is cold. O
EM-161
DRIVE BELTS
Deflection Adjustment INFOID:0000000013949744
PBIC4039E
4. Crankshaft pulley 5. 6. Alternator
A/C compressor, alternator and wa-
7. Idler pulley 8. Water pump pulley 9.
ter pump belt
A. Adjusting bolt B. Idler pulley lock nut C. Adjusting nut
D. Idler pulley lock nut
• Adjust belts with the parts shown below.
Applied belt Belt adjustment method

Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
Adjusting nut on idler pulley (C)
water pump belt
CAUTION:
• When a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
• If the belt deflection of the current belt is out of the “Limit for readjusting”, adjust to the “Adjusted”
value.
Then, after turning crankshaft two turns or more, readjust it to the specified value to avoid varia-
tion in deflection between pulleys.
• Check that the belts are fully fitted into the pulley grooves during installation.
• Handle with care to avoid smearing the belts with engine oil or engine coolant.
• Never twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT
1. Remove engine undercover front.
2. Loosen idler pulley lock nut (B).
3. Turn adjusting bolt (A) to adjust. Refer to "Deflection Adjustment".
4. Tighten idler pulley lock nut (B).
Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT

EM-162
DRIVE BELTS
1. Loosen idler pulley lock nut (D).
2. Turn adjusting nut (C) to adjust. Refer to "Deflection Adjustment". A
3. Tighten lock nut (D).
Nut D: EM
: 45.0 N·m (4.6 kg-m, 33 ft-lb)

C
REMOVAL
D
1. Loosen each belt. Refer to EM-162, "Deflection Adjustment".
2. Remove power steering oil pump belt. Refer to EM-162, "Deflection Adjustment".
3. Remove A/C compressor, alternator and water pump belt. Refer to EM-162, "Deflection Adjustment". E
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt deflection. Refer to EM-162, "Deflection Adjustment". F
3. Tighten nuts provided for adjustment to the specified torque.
4. Check again that each belt deflection is as specified.
G
EM-163
MBIB9140E
1. Air duct 2. Air tube 3. Air cleaner case (upper)

4. Air cleaner filter 5. Air cleaner case (lower) 6. Air cleaner bracket
7. Air duct side
A. Air cleaner assembly B. To tube inlet assembly C. Air flow meter
(turbocharger)
D. Arrow mark E. Mating mark F. Mating mark

REMOVAL
1. Disconnect the air flow meter harness connector.
EM-164
3. Add marks as necessary for easier installation.
CAUTION: A
Handle air flow meter with care.
EM
• Do not touch its sensor.
Inspect air duct for crack or tear. C
• If anything found, replace air duct.
INSTALLATION
Note the following, and install in the reverse order of removal. D
Changing Air Cleaner Filter INFOID:0000000013949748 E
REMOVAL
1. Unhook clips, and lift air cleaner case (upper). F
INSTALLATION G
Installation is the reverse order of removal.
EM-165
CHARGE AIR COOLER
CHARGE AIR COOLER
MBIB9079E
1. Clamp 2. Air hose 3. Air hose

4. Inlet tube 5. Tube 6. Air hose
7. Charge air cooler 8. Radiator assembly 9. Bracket
10. Turbocharger 11. Intake manifold 12. Washer
13. Stud
A. View A B. View B C. Rib aligned with paint mark
D. Paint mark E. View E
REMOVAL
1. Remove clamps from air hose between charge air cooler and tubes.
2. Remove bracket from the radiator.
remove air hoses and tube hoses.
CAUTION:
EM-166
CHARGE AIR COOLER
charge air cooler if necessary. A
INSTALLATION
Note the following, and install in the reverse order of removal. EM
• Pay attention to identification mark color and direction when installing air inlet hose.
Tighten bolts and nuts to the specified torques. C
EM-167
INTAKE MANIFOLD
INTAKE MANIFOLD
INTAKE MANIFOLD WITH WATER GALLERY
PBIC4836E
1. Vacuum hose 2. Vacuum hose clamp 3. Vacuum hose

4. Bracket 5. Bracket 6. Gasket
EM-168
INTAKE MANIFOLD
7. Bracket 8. Bracket 9. Intake manifold
10. Water hose 11. Heater feed pipe 12. O-ring A
13. Throttle chamber 14. Gasket 15. Gasket
16. EGR passage 17. Gasket 18. EGR volume control valve
19. Washer 20. Vacuum gallery 21. Bracket EM
22. Bracket 23. Washer 24. Power steering pipe bracket
25. Water hose 26. Water hose 27. Water hose
28. Clip 29. Water hose 30. Water hose C
31. Bracket 32. Gasket 33. EGR cooler
34. Bracket
A. To heater return pipe B. To cylinder head C. To air inlet hose
D
D. To water outlet E. To exhaust manifold
: Vehicle front
E
EM-169
INTAKE MANIFOLD
INTAKE MANIFOLD WITHOUT WATER GALLERY
E1BIA0245GB
1. Vacuum hose 2. Vacuum gallery 3. Vacuum hose

4. Bracket 5. Bracket 6. Gasket
7. Intake manifold 8. Water hose 9. Heater feed pipe
10. O-ring 11. Gasket 12. EGR passage
13. Gasket 14. EGR volume control valve 15. Washer
16. Vacuum gallery 17. Bracket 18. Bracket
EM-170
INTAKE MANIFOLD
19. Washer 20. Power steering pipe bracket 21. Water hose
22. Water hose 23. Clip 24. Water hose A
25. Water hose 26. Bracket 27. Gasket
28. EGR cooler 29. Bracket
A. To heater return pipe B. To cylinder head E. To exhaust manifold EM
: Vehicle front
• Refer to GI-9, "Component" for symbol marks in the figure. C

D
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
E
CAUTION:
Be careful not to damage engine cover surface.
2. Disconnect air inlet hose from throttle chamber. Refer to EM-168 F
4. Remove oil level gauge guide. Refer to EM-185.
G
5. Remove fuel hoses and fuel gallery. Refer to EM-192.
• To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component. H
6. Remove vacuum galleries and vacuum hoses.
• Add marks as necessary for easier installation. I
7. Disconnect EGR volume control valve water hoses and wiring harness.
8. Disconnect heater feed hose, water hoses, and remove heater feed pipe.
J
9. Remove EGR cooler.
10. Remove injection tube center. Refer to EM-192, "Removal and Installation".
CAUTION:
Be careful not to spill fuel in the engine component. K
11. Remove water pipe.
12. Loosen bolts and nuts in the reverse order of that shown in the figure, and remove intake manifold.
CAUTION: L
Cover engine openings to avoid entry of foreign materials.
• INTAKE MANIFOLD with water gallery M
PBIC4837E
P
EM-171
INTAKE MANIFOLD
• INTAKE MANIFOLD without water gallery
E1BIA0246ZZ
13. Remove EGR volume control valve and throttle chamber from intake manifold.
Surface Distortion
• Check distortion on the mounting surface with a straightedge and
feeler gauge.
Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace intake manifold.
PBIC3411E
INSTALLATION
1. Install intake manifold.
• Tighten fixing bolts and nuts in numerical order as shown in the figure.
• If stud bolts were removed, tighten them to the specified torque.
: 10.8 N·m (1.1 kg-m, 8 ft-lb)
• INTAKE MANIFOLD with water gallery
PBIC4837E
EM-172
INTAKE MANIFOLD
• INTAKE MANIFOLD without water gallery
A
EM
E1BIA0246ZZ
D
2. Install EGR cooler or EGR tube. Tighten fixing bolts and nuts in numerical order as shown in the figure.
PBIC4838E J
1. EGR volume control valve 2. Bracket 3. EGR cooler

4. Bracket K
3. Install EGR volume control valve.
• Tighten fixing bolts in numerical order as shown in the figure.
L
1 : EGR volume control valve
2 : Bracket
3 : Bracket M
4 : Power steering pipe bracket
PBIC4839E
EM-173
INTAKE MANIFOLD
4. Install water hoses and heater feed hose.
PBIC4871E
1. Heater return pipe 2. Heater feed pipe 3. EGR volume control valve
4. EGR cooler 5. Water outlet
A. Paint mark B. View B C. View C
: Vehicle front
• Install water hose by referring to paint marks avoiding twisting.

• When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe
is shorter than dimension A, insert hose fully until it reaches the end.
Dimension A : 27 - 32 mm (1.063 - 1.260 in)

• When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
5. Install vacuum hoses.
EM-174
INTAKE MANIFOLD
EM
PBIC4868E F
A. White mark
: Vehicle front G
• Install vacuum hose by referring to paint marks avoiding twisting.
• When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe
is shorter than dimension A, insert hose fully until it reaches the end. H
Dimension A : 15 – 20 mm (0.591 – 0.787 in)

• When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper. I
INSPECTION AFTER INSTALLATION J
Start engine and increase engine speed to check for fuel leakage.
CAUTION:
NOTE: K
EM-175
CATALYST
CATALYST
MBIB9159E
1. Gasket 2. Exhaust outlet 3. Catalyst cover (rear)

4. Bracket 5. Stud 6. Catalyst
7. Catalyst cover (front)
A. to exhaust front tube B. Turbocharger C. Cylinder block
: Vehicle front

REMOVAL
1. Remove engine undercover.
2. Remove catalyst cover, turbocharger insulator.
3. Remove exhaust front tube. Refer to EX-10, "Removal and Installation"
4. Remove air inlet hose and air inlet tube. Refer to EM-166.
5. Remove exhaust manifold cover. Refer to EM-183.
6. Remove catalyst and exhaust outlet.
7. Remove catalyst from exhaust outlet, as necessary.
INSTALLATION
• If stud bolts of turbocharger were removed, tighten them to the specified torque.
EM-176
CATALYST
: 25.5 N·m (2.6 kg-m, 19 ft-lb) A
• If stud bolts of catalyst were removed, tighten them to the specified torque.
EM
: 45.0 N·m (4.6 kg-m, 33 ft-lb)
• Pushing bracket against the cylinder block and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque. C
Exhaust outlet support
D
PBIC4908E
G
EM-177
TURBO CHARGER
TURBO CHARGER
Component (for VIN<VWA***F24**033633) INFOID:0000000013949755
MBIB9161E
1. Exhaust manifold 2. Water hose 3. Water tube outlet

4. Copper washer 5. Eye-bolt 6. Gasket
7. Gasket 8. Gasket 9. Exhaust outlet
10. Air outlet pipe 11. Air inlet pipe 12. Gasket
13. Turbocharger 14. Stud 15. Clamp
16. Oil return tube 17. Washer 18. Connector
19. Oil return hose 20. Tube water inlet 21. Oil feed tube
A. To water outlet B. To cylinder block C. Yellow paint
EM-178
TURBO CHARGER
Component (for VIN>VWA***F24**033633) INFOID:0000000013949756
EM
MBIB9239E
L
1. Exhaust manifold 2. Water hose 3. Water tube outlet
4. Copper washer 5. Eye-bolt 6. Gasket
7. Gasket 8. Gasket 9. Exhaust outlet M
10. Air outlet pipe 11. Air inlet pipe 12. Gasket
13. Turbocharger 14. Stud 15. Clamp
16. Oil return tube 17. Washer 18. Connector N
19. Oil return hose 20. Tube water inlet 21. Oil feed tube
A. To water outlet B. To cylinder block C. Yellow paint
O
P
REMOVAL
• After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and then
loosen the nuts to remove.
1. Drain engine coolant. Refer to CO-10, "Changing Engine Coolant"
2. Remove air inlet hose and air inlet pipe.
3. Remove air duct and air inlet pipes. Refer to EM-164.
EM-179
TURBO CHARGER
4. Remove exhaust manifold cover. Refer to EM-183.
5. Remove exhaust outlet and catalyst. Refer to EM-176.
6. Remove eye bolt and water hose from water tube.
7. Loosen and remove eye-bolts from oil feed tube.
8. Disconnect oil return hose from oil return tube.
9. Remove turbocharger with water tube and oil feed tube and oil return tube.
CAUTION:
Be careful not to deform water tube and oil feed tube and oil return tube.
10. Remove water tube and oil feed tube and oil return tube from turbocharger.
CAUTION:
Water Tube and Oil Tube
• Clean inside of water tube, oil feed tube and oil return tube, and check tubes for clogging.
• Replace water tube, oil feed tube and/or oil return tube if clogging still exists after cleaning.
PBIC4843E
1. Turbocharger boost control actuator 2. Turbine housing 3. Compressor housing

Check for negative air pressure
A. B. Check for exhaust gas leaks C. Check for charge air pressure leaks
leaks
D. Check for engine coolant leaks E. Check for engine oil leaks
CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:
Suction side : Between turbocharger and charge air cooler

Exhaust side : Between turbocharger and catalyst
Rotor Shaft Clearance
EM-180
TURBO CHARGER
tance when it is rotated by your fingertips. A
• Check that the rotor shaft (1) is not loose when it is moved verti-
cally or horizontally.
• Measure looseness with a dial gauge inserting its measuring rod
EM
through oil drain hole of turbocharger.
Standard : 0.086 - 0.111 mm (0.0034 - 0.0043 in)

C
PBIC4844E
D
Rotor Shaft End Play
• Place a dial gauge (A) at the rotor shaft (1) end in the axial direc-
tion to measure the end play.
E
Standard : 0.030 - 0.111 mm (0.0011 - 0.0043 in)
F
G
PBIC4845E
Turbine Wheel H
• Check that there is no engine oil adhesion.
• Check that there is no carbon accumulation.
• Check that blades of turbine wheel (1) are not bent or broken.
• Check that turbine wheel (1) does not interfere with turbine hous- I
ing (2).
K
PBIC4846E
Compressor Wheel
• Check that there is no engine oil adhesion inside the air inlet. L
• Check that compressor wheel (1) does not interfere with compres-
sor housing (2).
• Check that compressor wheel (1) is not bent or broken.
M
PBIC4847E O
Turbocharger Boost Control Actuator
EM-181
TURBO CHARGER
• Connect the handy vacuum pump (B) to the turbocharger boost
control actuator (1), and check that the rod (2) strokes smoothly in
compliance with the following pressure.
A : Dial gauge
• Pressure to be applied at the turbocharger boost control actuator
(1) part to move rod (2) end as per the following items:
Standard (Pressure/rod stroke amount):

:–51.3 to –55.3 kPa (–513 to –553 mbar, –385 to –415
PBIC3421E
mmHg, –15.16 to –16.34 inHg)/0.2 mm (0.0080 in)
: –28.0 to –36.0 kPa (–280 to –360 mbar, –210 to –270
mmHg, –8.27 to –10.63 inHg)/5.0 mm (0.197 in)
TROUBLE DIAGNOSIS OF TURBOCHARGER

Preliminary check:
• Check that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil amount is
more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbocharger is mis-
judged malfunction.)
• Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
table below.
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.
Symptom
Inspection item Inspection result
(when each inspection item meets each inspection result)
Engine oil Insufficient power/accel-
Smoke Noise
leakage eration malfunction
Engine oil leaks C A C C
Carbon is accumulated C A B B
Turbine wheel
Inside the air inlet is seriously contam-
B B — —
inated by engine oil.
Compressor wheel
There is resistance when the rotor
— C C B
shaft is rotated by your fingertips.
After checking both turbine and
compressor, inspect rotor shaft The rotor shaft sometimes does not
— — — A
end play. rotate by your fingertips.
There is too much play in the bearing. C C B C
Carbon or sludge is accumulated in
Oil return port C A C C
the waste oil hole.
A: Large possibility
B: Medium possibility
C: Small possibility
INSTALLATION
• When a stud bolt is pulled out, replace it with a new one and tighten it to the following torque.
: 25.5 N·m (2.6 kg-m, 19 ft-lb)
EM-182
EXHAUST MANIFOLD
EXHAUST MANIFOLD
A
EM
J
MBIB9160E
1. Cylinder head 2. Exhaust manifold cover 3. Exhaust manifold K

4. Gasket 5. Turbocharger 6. Gasket
7. EGR tube 8. Gasket
A. No.1 port B. No.2 port C. No.3 port L
D. No.4 port E. Alignment protrusion
: Vehicle front
M
N
REMOVAL
O
3. Remove turbocharger. Refer to EM-178.
4. Remove EGR tube or EGR cooler. Refer to EM-168. P
EM-183
EXHAUST MANIFOLD
5. Loosen exhaust manifold mounting nuts in the reverse order in
the figure.
: Vehicle front
PBIC4849E
6. Rotate exhaust manifold.

Surface Distortion
• Use a reliable straight edge and feeler gauge to check the flatness
of exhaust manifold fitting surface.
Limit : 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.
PBIC2210E
INSTALLATION
• If stud bolts were removed, replace them with new ones, and tighten them to the specified torque:
: 14.7 N·m (1.5 kg-m, 11 ft-lb)

• Tighten the exhaust manifold mounting nuts in the following procedure:
1. Install gasket so that the alignment protrusion faces the No. 4 port. Refer to "Removal and Installation".
2. Tighten the nuts in order specified in the figure.
: Vehicle front
3. Re-tighten the nuts 1 to 8.

PBIC4849E

Start engine and raise engine speed to check no exhaust gas and engine oil leaks.
EM-184
A
EM
J
PBIC3424E
1. Oil level gauge 2. Oil level gauge guide 3. Oil level sensor K
7. Oil pan upper 8. Crankshaft position sensor 9. O-ring
10. Rear plate 11. Rear plate cover 12. Oil strainer L
13. Oil pan drain plug 14. Drain plug washer 15. Oil pan lower

REMOVAL N
WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
1. Remove engine undercover. O
EM-185
3. Remove oil pan lower bolts. Loosen bolts in the reverse order of
that shown in the figure.
: Vehicle front
PBIC3425E
4. Remove oil pan lower.

a. Insert the seal cutter (SST) between oil pan upper and oil pan
lower.
CAUTION:
• Never insert screwdriver, or oil pan flange deforms.
b. Slide the seal cutter by tapping on the side of the seal cutter with
a hammer.
c. Remove oil pan lower.
SEM365EA
5. Remove oil strainer.

6. Remove power steering oil pump belt. Refer to EM-161.
7. Remove power steering oil pump bracket and move power steering oil pump aside with its piping con-
nected. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to PS-13,
8. Disconnect oil return hose (vacuum pump) from oil pan upper. Refer to EM-190.
9. Remove crankshaft position sensor and oil level sensor.
CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble.
• Keep it away from metal particles.
• Never place the crankshaft position sensor close to magnetic materials.
10. Remove rear plate cover and transmission joint bolts.
11. Loosen bolts in the reverse order of illustration to remove oil pan
upper.
: Vehicle front
PBIC3431E
12. Remove oil pan upper.
EM-186
• Insert the seal cutter (SST) between oil pan upper and cylinder
block. Slide the seal cutter by tapping on the side of the seal A
cutter with a hammer. Remove oil pan upper.
• Never insert screwdriver, or oil pan flange will be deforms.
EM
SEM365EA
D
Clean oil strainer if any object attached.
E
INSTALLATION
• Install oil pan upper with the following procedure.
- Use the scraper (A) to remove old liquid gasket from mating sur- F
face of oil pan upper (1).
• Also remove old liquid gasket from mating surface of cylinder
block and rear chain case. G
• Remove old liquid gasket from the bolt hole and thread.
PBIC3432E
I

[SST: WS39930000] to areas shown in the figure. J
: Vehicle front
K
Use Genuine Liquid Gasket or an equivalent.
CAUTION:
• At the 2 bolt holes marked , liquid gasket should be
applied outside holes. L
• Check that liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that the
PBIC3433E
diameter of the liquid gasket bead is different around the M
front.)
- Install oil pan upper.
CAUTION: N
Install avoiding misalignment of O-ring.
O
: Vehicle front
• Bolt dimensions vary depending on the installation location. Refer

to the following and use appropriate bolts. P
M6 x 30 mm (1.18 in) : Bolt No. 15, 16

M8 x 25 mm (0.98 in) : Bolt No. 2, 4, 5, 8, 9, 10, 14
M8 x 60 mm (2.36 in) : Bolt No. 1, 3, 6, 7, 11, 12, 13, 17
PBIC3431E
• The shank length under the bolt neck above is the length of the
EM-187
• Install oil pan lower with the following procedure.
- Use a scraper (A) to remove old liquid gasket from mating surface
of oil pan lower (1).
CAUTION:
• Also remove old liquid gasket from mating surface of oil pan
upper.
• Remove old liquid gasket from bolt hole and thread.
PBIC3430E

[SST: WS39930000] as shown in the figure.
: Vehicle front

• Check that liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
PBIC3434E
SEM159F
- Install oil pan lower.

: Vehicle front
NOTE:
Pour engine oil or start engine 30 minutes or more after oil pan is
installed.
PBIC3425E

1. Check engine oil level and add engine oil. Refer toLU-7, "Inspection".
2. Check for leakage of engine oil when engine is warmed.
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-7, "Inspection".
EM-188
GLOW PLUG
GLOW PLUG
A
EM
I
PBIC4851E
1. Glow plate 2. Glow harness 3. Glow nut J

4. Cap 5. Glow plug

K
REMOVAL
CAUTION:
L
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Disconnect glow harness from glow plate.
2. Remove glow nut to remove glow plate.
M
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from N
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
O
1. Remove adhered carbon from glow plug installation hole with a reamer.
3. Install remaining parts in the reverse order of removal. P
EM-189
VACUUM PUMP
VACUUM PUMP
PBIC3435E
1. O-ring 2. Vacuum pump 3. Bracket

4. Oil feed tube 5. Cooper washer 6. Eye-bolt
7. Oil return hose
: Vehicle front

INSPECTION BEFORE REMOVAL

1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector.
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-
tor.
2. Start engine and measure generated vacuum at idle speed.
Standard:
–94.0 to –96.1 kPa (–940 to –961 mbar, –705 to –721 mmHg, –27.76 to –28.38 inHg)
• If out of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump.
REMOVAL
1. Drain engine oil. Refer to LU-8, "Changing Engine Oil"
2. Remove primary timing chain. Refer to EM-227.
3. Disconnect vacuum hose from vacuum pump side.
4. Remove oil feed tube and oil return hose.
5. Remove bracket.
EM-190
VACUUM PUMP
6. Remove vacuum pump and O-ring.
A
INSTALLATION
Bracket EM
: Cylinder block side

C
E
PBIC4907E
EM-191
PBIC4046E
1. Eye-bolt 2. Cooper washer 3. Spill tube

4. Nozzle support 5. Pin 6. Fuel injector
7. O-ring 8. Nozzle gasket 9. Rocker cover
10. Nozzle oil seal 11. Washer 12. Injection tube No. 4
13. Injection tube No. 3 14. Injection tube No. 2 15. Injection tube No. 1
16. Insert rubber 17. Clip 18. Injection tube center
19. Spill hose 20. Fuel gallery 21. Spill hose
22. Fuel hose 23. Fuel pump 24. Cylinder head
25. Cooper washer 26. Fuel hose 27. Fuel rail
A. To fuel filter B. To fuel cooler (under floor)
: Vehicle front

REMOVAL
1. Remove engine cover. Refer to EM-168.
CAUTION:
3. Disconnect the fuel injector harness connector.
EM-192
4. Remove spill hose.
5. Following steps below, remove injection tubes. A
b. Remove injection tubes in order of 2-1-4-3 individually. EM
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator C
clear of fuel.
SBIA0203E
E
6. Remove nozzle oil seal.

• Using the flat-bladed screwdriver, pry flange to remove oil F
seal.
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If G
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.
H
PBIC0944E
I
7. Remove rocker cover. Refer to EM-204.
8. Remove spill tube mounting bolts and nut. J

• Loosen bolts and nut to the reverse order in the figure and
remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with span- K
ner.
B : Spill tube retaining bolt L

C : SECT A – A
D : OK
: Engine front M
P
PBIC4898E
EM-193
9. Following steps below, remove fuel injector.
1 : Fuel injector
2 : O-ring
3 : Nozzle gasket
4 : Nozzle support
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to
remove.
CAUTION: PBIC4852E
• Handle fuel injector carefully without giving any impact.
c. If nozzle gasket remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
d. Remove O-ring from fuel injector.
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface when replacing fuel injector.
• Refer to EC-40, "Injector Adjustment Value Registration".
Example: Injector Adjustment value =
D021ABCD1A061234000000000000E6
2. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them
into cylinder head.
b. Tighten injection tubes temporarily in the order of 3-4-1-2.
c. Check that nozzle support and pin are securely fit.
d. Tighten nozzle support bolts.
e. Loosen injection tubes in the order of 2-1-4-3. MBIB9165E
3. Connect spill tube.

• Tighten fixing bolts and nut in numerical order shown in the fig-
ure.
CAUTION:
When tightening nut, fix spill tube retaining bolt with
spanner.
NOTE:
Connection of spill tube gasket may be broken, even if it is
tighten to the specified torque. It does not affect performance.
B : Spill tube retaining bolt

C : SECT A – A
D : OK
: Engine front
PBIC4898E
EM-194
4. Perform air tightness test for spill tube.
• Connect a handy vacuum pump to spill connector. Check that A
vacuum is retained while applying following vacuum.
Standard: EM
–53.3 to –66.7 kPa (–533 to –667 mbar, –400 to –
500 mmHg, –15.75 to –19.69 inHg)
• If outside of standard, reconnect spill tube. (Replace gasket in C
this case.)
5. Install rocker cover. Refer to EM-204, "Removal and Installa- JEF250Z
tion". D
• Insert it straight until its flange fully contacts rocker cover.
CAUTION: E
• Check gutter spring in nozzle oil seal on fuel injector for missing.
7. Connect injection tubes individually to each cylinder in order of
3-4-1-2.
F
SBIA0203E
I
8. Install fuel hoses, spill hose and fuel gallery as shown in the figure.
PBIC4858E
1. Rocker cover 2. Fuel filter 3. Fuel hose

4. Fuel hose 5. Fuel hose 6. Fuel hose
7. Fuel hose 8. Fuel hose 9. Clamp
EM-195
10. Fuel pump 11. Fuel rail 12. Priming pump
13. Fuel hose
A. Align paint mark B. Insert the hose up to 28 mm (1.10 in) C. Insert the hose up to 26 mm (1.02 in)
D. To fuel centralized under-floor piping E. Insert the hose up to 30 mm (1.18 in) F. Insert the hose up to the wall face
: Vehicle front
NOTE:
Intake manifold and other related parts are omitted for explanation.

• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing
to the vehicle when replacing fuel injector. Refer to EC-40, "Injector
Adjustment Value Registration".
Example: Injector Adjustment value =
D021ABCD1A061234000000000000E6
• Start engine and increase engine speed to check for fuel leakage.
CAUTION:
Never touch engine immediately after stopped as engine
becomes extremely hot.
MBIB9165E
EM-196
FUEL PUMP
FUEL PUMP
A
EM
J
PBIC3438E
1. Washer 2. Fuel pump sprocket 3. Seal washer K

4. O-ring 5. Adjusting shim 6. Sprocket nut
7. Coupling 8. Oil seal 9. Spacer
10. Key 11. Fuel pump 12. Fuel hose L
13. Spill hose
: Engine front
M
N
CAUTION:
• Before removing and installing fuel pump, always remove sprocket. Never loosen or remove installa-
tion nut in the center of fuel pump. If loosened or removed, replace fuel pump. O
ton heads.
surfaces with new engine oil. P
• When fuel pump is replaced with new one or another one, perform fuel pump leaning value cleaning
before starting engine. Refer to EC-41, "Fuel Pump Learning Value Clearing".
REMOVAL
1. Remove engine cover, vacuum gallery and heater feed pipe. Refer to EM-168.
2. Remove fuel hose and spill hose from fuel pump. Refer to EM-192.
CAUTION:
EM-197
FUEL PUMP
3. Disconnect harness connectors from fuel pump.
4. Remove injection tube center, clip and insert rubber. Refer to EM-192.
CAUTION:

6. Hold fuel pump sprocket and remove bolt.
a. Insert the positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel pump sprocket.
b. Using the TORX wrench (SST), turn pump shaft little by little to
adjust the position of fuel pump sprocket so that the holes align.
c. Push the positioning stopper pin (SST) through fuel pump
sprocket to fuel pump body to hold fuel pump sprocket.
MBIA0049E
• Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket.
PBIC2535E
7. Using the hexagon wrench (SST) remove tightening bolts of fuel

pump sprocket.
PBIC2404E
MBIA0074E
EM-198
FUEL PUMP
8. Using the sprocket holder (SST), hold fuel pump sprocket to pre-
vent falling. A
• For sprocket holder, use [SST: KV11106060] machined as
shown in the figure, because the previous bore is not fitting.
EM
SBIA0217E
D
• When the sprocket holder is installed, if the positioning stopper
pin (SST) interferes, pull out the positioning stopper pin
approximately 10 mm (0.39 in), then install it. E
• After the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) (commercial service tool) insert into the machined
bore. F
• The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
• Check that the a- and b-faces of the sprocket holder contact G
the bottom side of the sprocket (small diameter side).
PBIC2534E
CAUTION:
Never remove the sprocket holder (SST) until fuel pump is installed. H
• After the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.
K
MBIA0075E
mercial service tool), remove the tightening bolts. L
CAUTION:
Never disassemble or adjust fuel pump.
M
PBIC2405E
O
10. Remove the fuel pump toward the rear of engine.
CAUTION:
For removal, be careful not to drop the seal washer into the engine. P
NOTE:
11. Remove adjusting shim.
12. Attach a suitable tool in the M8 bolt hole on coupling.
EM-199
FUEL PUMP
13. Loosen sprocket nut with the TORX wrench (SST).
MBIA0013E
14. Remove coupling with a suitable puller.
MBIA0014E
15. Remove spacer from fuel pump.

16. Remove oil seal from spacer.
Timing Chain
SEM984C
INSTALLATION
1. Install new oil seal to spacer.
MBIA0045E
2. Install spacer to fuel pump.
EM-200
FUEL PUMP
3. Install coupling to fuel pump of spacer.
• Using the TORX wrench (SST), tighten the sprocket nut to fix A
the coupling.
EM
MBIA0013E
D
4. Install adjusting shim.
• For shim adjustment, measure dimension L [Distance between
front surface of coupling and the fuel pump flange (spacer)] at
E
two opposing points near the coupling bolt center. Use the
average of these two measurements to select the shim grade
that marked on adjusting shim.
F
G
MBIA0077E
• The shim adjustment is required only when the fuel pump is H

replaced.
PBIC3439E K
Part No. of adjusting shim Grade number Measuring dimension L mm (in) Type L
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657) A
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445) B
M
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A+C N
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B+B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C+B
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D+B O
EM-201
FUEL PUMP
5. Before fuel pump is installed, check that spacer and the 6 mm
(0.24 in) dia. hole on coupling are aligned.
MBIA0016E
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION:
Be careful not to drop the seal washer into engine.
PBIC2438E
mercial service tool), tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder (SST).
PBIC2405E
9. Using the TORX wrench (SST), turn the pump shaft gradually to
adjust the position of fuel pump sprocket. Then, insert the posi-
tioning stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the
fuel pump sprocket through the pump body.
10. Remove the TORX wrench (SST).
MBIA0049E
11. Using the hexagon wrench (SST), tighten the sprocket tighten-
ing bolt.
• When the washer of the fuel pump sprocket is removed, install
it with the marking “F” (front) facing the front of the engine.
12. Pull out the positioning stopper pin (SST).
PBIC2404E
EM-202
FUEL PUMP
13. Install secondary timing chain. Refer to EM-221.
A
14. Following steps below, install injection tube center. Refer to EM-192.
a. Pre-set clip and insert rubber to injection tube center.
b. Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
EM
c. Adjust clip dimension and tight bolt for clip to intake manifold by tool.
d. Tight nut of injection tube center to fuel pump by tool.
e. Tight nut of injection tube center to fuel rail by tool. C
15. Connect the harness connector to fuel pump.
16. Install fuel hoses. Refer to EM-192.
17. Hereafter, install in the reverse order of removal. D
CAUTION:
When fuel pump is replaced with new one or another one, perform fuel pump leaning value clean-
ing before starting engine. Refer to EC-41, "Fuel Pump Learning Value Clearing" E
EM-203
ROCKER COVER
ROCKER COVER
PBIC4854E
1. Nozzle oil seal 2. Oil filler cap 3. Rocker cover

4. Gasket 5. Ventilation hose
A. Refer to EM-204 B. To ventilation hose connector

REMOVAL
1. Remove engine cover. Refer to EM-168.
2. Remove vacuum gallery and engine cover bracket on rocker cover and ventilation hose. Refer to EM-168
and EM-164.
3. Disconnect the fuel injector harness connector. Refer to EM-192.
4. Following steps below, remove injection tube. Refer to EM-192.
CAUTION:
5. Remove injection nozzle oil seal.
EM-204
ROCKER COVER
• Using the flat-bladed screwdriver, pry flange to remove nozzle
oil seal. A
EM
PBIC0944E
D
• Loosen holding bolts in the reverse order of that shown in the figure and remove.
E
: Engine front
PBIC4853E H
7. Remove gasket from rocker cover.

INSTALLATION I
1. Install new gasket to rocker cover.
2. Apply liquid gasket with tube presser [SST: WS39930000] on
locations shown in the figure. J
• Use Genuine Liquid Gasket or an equivalent.
1 : Cylinder head K
A : Liquid gasket application area
: Engine front L
PBIC3442E
M
3. Tighten holding bolts.
• Tighten all bolts in numerical order as shown in the figure.
N
: 7.8 N·m (0.8 kg-m, 69 in-lb)
• Retighten to the same torque in the same order as above.
O
: Engine front
PBIC4853E
EM-205
ROCKER COVER

• Insert it straight until flange fully contacts rocker cover.
Start engine and increase engine speed to check for fuel leakage and engine oil leakage.
CAUTION:
EM-206
CAMSHAFT
CAMSHAFT
A
EM
J
MBIB9166E
1. Camshaft bracket 2. Camshaft (right side) 3. Camshaft (left side) K

4. Signal plate 5. Rubber washer 6. Adjusting shim
7. Valve lifter 8. Camshaft sprocket 9. Cylinder head
10. Cylinder head rear cover 11. O-ring 12. Camshaft position sensor L
A. Refer to text

CAUTION:
• This engine has a different valve arrangement from normal
DOHC 4-valve type engines. As both camshafts on this engine
have intake and exhaust camshafts, in this chapter they are N
named as per the following items:
Camshaft (right side) : Intake manifold side O

Camshaft (left side) : Exhaust manifold side
• Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either intake valve or an P
exhaust valve.)
SBIA0178E
REMOVAL
EM-207
CAMSHAFT
3. Remove cylinder head rear cover, camshaft position sensor and rubber washer.
Loosen cylinder head rear cover mounting bolts in the reverse
PBIC3445E
4. Remove fuel injector. Refer to EM-192.

6. Remove camshaft sprockets and signal plate.
• Loosen the camshaft sprocket mounting bolts and signal plate
mounting bolt by fixing the hexagonal portion of camshaft.
JEM159G
7. Remove camshaft.
• Place distinguishing marks on the right and left sides with paint.
• Loosen and remove the camshaft sprocket bolts in the reverse
JEM160G

• Remove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion.
• Check the camshaft for one sided wear or scratches.
• Replace the camshaft if there are abnormalities.
Camshaft Runout
EM-208
CAMSHAFT
2 and No. 5. A
• Set the dial gauge vertically on journal No. 3.
• Rotate camshaft in one direction by hand, then read needle move-
ment on dial gauge. (Total indicator reading)
EM
Limit : 0.02 mm (0.0008 in)
• If it exceeds the limit, replace camshaft. C
JEM161G
D
Height of Cam Nose
• Measure the height of cam nose using the micrometer.
Standard: E
Intake : 39.505 - 39.695 mm (1.5553 - 1.5628 in)
Exhaust : 39.905 - 40.095 mm (1.5711 - 1.5785 in)
F
• If out of the standard, replace camshaft.
G
SEM549A
Camshaft Journal Oil Clearance H

• Measure outer diameter of camshaft journal with micrometer.
I
Standard:
No. 1 : 30.435 - 30.455 mm
(1.1982 - 1.1990 in) J
No. 2, 3, 4, 5 : 23.935 - 23.955 mm
(0.9423 - 0.9431 in)
K
SEM012A
L
• Install camshaft bracket and tighten bolts to the specified torque. Refer to "INSTALLATION" for the tighten-
ing procedure. M
• Measure inner diameter of camshaft bracket using the inside
micrometer.
Standard: N
No. 1 : 30.500 - 30.521 mm
(1.2008 - 1.2016 in)
O
No. 2, 3, 4, 5 : 24.000 - 24.021 mm
(0.9449 - 0.9457 in)
P
JEM162G

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

• If out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head.
EM-209
CAMSHAFT
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the camshaft
bracket.
Camshaft End Play
• Install dial gauge in thrust direction on front end of camshaft. Mea-
sure end play of dial gauge when camshaft is moved forward/back-
ward (in direction to axis).
Standard : 0.070 - 0.148 mm (0.0028 - 0.0058 in)

Limit : 0.24 mm (0.0094 in)
PBIC0366E
• Measure the following parts if out of the standard.

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

- Dimension “B” for cylinder head
Standard : 7.000 - 7.030 mm (0.2755 - 0.2767 in)

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

1. Install camshaft in cylinder head. Refer to "INSTALLATION" for the tightening procedure.
2. Install sprocket on camshaft. Refer to "INSTALLATION".
3. Measure camshaft sprocket runout. (Total indicator reading)
Limit : 0.15 mm (0.0059 in)

• If it exceeds the limit, replace camshaft sprocket.
JEM164G
Visual Inspection of Valve Lifter and Adjusting Shim

Check that surface of valve lifter and adjusting shim does not have
any wear or cracks.
• If anything above is found, replace valve lifter or adjusting shim.
SEM160D
EM-210
CAMSHAFT
• Measure the outer diameter of the valve lifter with the micrometer.
A
Standard : 29.960 - 29.975 mm (1.1795 - 1.1801 in)
EM
SEM961E
D
• Measure the bore diameter of the cylinder head valve lifter with the
inside micrometer. E
Standard : 30.000 - 30.021 mm (1.1811 - 1.1819 in)

F
PBIC0367E
H
Standard : 0.025 - 0.061 mm (0.0010 - 0.0024 in) I
• If out of standard, refer to the outer diameter and bore diameter standard values and replace valve lifter and/
or cylinder head.
J
INSTALLATION
1. Install valve lifter and adjusting shim.
• Check that these are installed in the same position as before the removal process. K
: Engine front L
• Identify camshafts by the paint position and screw hole at the
rear end.
M
Camshaft (right side) Intake manifold side (1):
Paint is at position (C) (Blue) without screw hole (A).
N
Camshaft (left side) Exhaust manifold side (2):
PBIC3444E
No paint with screw hole (B).
O
• Install so that knock pins are positioned in the directions
PBIC2026E
EM-211
CAMSHAFT
3. Install camshaft brackets.
• Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cylin-
der head.
• Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM175G
4. Tighten camshaft bolts in numerical order as shown in the figure

according to the following procedure:
a. Tighten No.13 to 15.
: 1.96 N·m (0.20 kg-m, 17 in-lb)

• Check that camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten No.1 to 12.
JEM160G
: 5.88 N·m (0.60 kg-m, 52 in-lb)
c. Tighten all bolts.
: 5.88 N·m (0.60 kg-m, 52 in-lb)

d. Tighten all bolts.
: 12.8 N·m (1.3 kg-m, 9 ft-lb)

5. Install camshaft sprockets and signal plate.
• Camshaft sprockets are commonly used for right side and left side.
• Align camshaft sprocket and knock pin on camshaft, and install.
• Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprockets and sig-
nal plate.
6. Install rubber washer to cylinder head rear side.
7. Apply liquid gasket to cylinder head rear cover as shown in the
figure.
PBIC3446E
EM-212
CAMSHAFT
8. Install cylinder head rear cover and tighten mounting bolts in
numerical order shown in the figure. A
M6 × 50 mm : Bolt No.1, 2
M6 × 20 mm : Bolt No.3, 4 EM
M8 × 20 mm : Bolt No.5, 6
PBIC3445E
D
9. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to EM-213, "Valve Clearance".
10. Hereafter, install in the reverse order of removal.
E
F
G
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points. H
ing engine oil and engine coolant. I
J
K
Engine oil Level Leakage Level (*2)
Fuel Leakage Leakage Leakage L
*1: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
M
N
INSPECTION
• When the camshaft or parts in connection with valves are removed or replaced, and a malfunction occurrs
(poor starting, idling, or other malfunction) due to the misadjustment of the valve clearance, inspect as per O
the following items.
• Inspect and adjust when the engine is cool (at normal temperature).
P
EM-213
CAMSHAFT
• Be careful of the intake and exhaust valve arrangement. The valve
arrangement is different from that in a normal engine.
NOTE:
The camshafts have, alternately, either intake valve or exhaust
valve. (Refer to figure.)
SBIA0178E

3. Set the No. 1 piston to TDC on its compression stroke.
• Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft left side faces straight above. (No position indicator, etc.
is provided on the crankshaft pulley.)
PBIC2533E
4. Remove undercover, put an alignment mark with paint, etc. on

crankshaft pulley and on oil pump housing as an angle indicator.
1 : Crankshaft pulley
A : Alignment mark
: Vehicle front
PBIC3447E
5. While referring to the figure, measure the valve clearance

No. 1 No. 2 No. 3 No. 4

Measuring point
INT EXH INT EXH INT EXH INT EXH
When the No. 1
cylinder is in the X X X X
TDC
NOTE:
• The injection order is 1-3-4-2. SBIA0180E
EM-214
CAMSHAFT
• Measure the valve clearance using the feeler gauge when
engine is cool (at normal temperature). A
EM
SBIA0181E
Valve clearance:
D
Unit: mm (in)

E
Intake 0.24 - 0.32 (0.0094 - 0.0126) 0.274 - 0.386 (0.0108 - 0.0152)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)
*: Reference data approximately 80°C (176°F) F
6. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)
7. While referring to the figure, measure the valve clearance G
No. 1 No. 2 No. 3 No. 4 H

Measuring point
When the No. 4
cylinder is in the X X X X I
TDC
8. If the valve clearance is outside the specification, adjust as fol-
lows. SBIA0182E J
ADJUSTMENTS
• Remove adjusting shim for parts which are outside the specified valve clearance.
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6). K
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward.
L
N
SBIA0183E
3. Grip camshaft with the camshaft pliers (SST), then using cam- O
shaft as a support point, push adjusting shim downward to com-
press valve spring.
CAUTION: P
Never damage camshaft, cylinder head and the outer cir-
cumference of valve lifter.
PBIC2321E
EM-215
CAMSHAFT
4. With valve spring in a compressed state, remove the camshaft
pliers (SST) by securely setting the outer circumference of the
valve lifter with the end of the lifter stopper (SST).
• Hold the lifter stopper by hand until the shim is removed.
CAUTION:
Never retrieve the camshaft pliers forcefully, as camshaft
is damaged.
PBIC2322E
5. Move the round hole of adjusting shim to the front with the very
thin screwdriver or like that.
• When adjusting shim on valve lifter does not rotate smoothly,
restart from step 3 to release the end of the lifter stopper (SST)
from touching adjusting shim.
6. Remove adjusting shim from valve lifter by blowing air through
the round hole of the adjusting shim with the air gun.
CAUTION:
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles. PBIC2323E
7. Remove adjusting shim by using the magnet hand.
PBIC2324E
8. Measure the thickness of adjusting shim using the micrometer.

• Measure near the center of the shim (the part that touches
camshaft).
FEM032
Calculation method of the adjusting shim thickness:

R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0010 in)]
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
EM-216
CAMSHAFT
• New adjusting shims have the thickness stamped on the rear
side. A
• Shims are available in 33 size from 2.10 mm (0.0827 in) to
2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in). Refer to
EM-281, "Standard and Limit".
EM
JEM184G
D
10. Fit the selected adjusting shim to valve lifter.
CAUTION:
Place the stamped side of adjusting shim to valve lifter. E
G
PBIC2325E
11. Compress valve spring using the camshaft pliers [SST: KV10115110] and remove the lifter stopper (SST). H
12. Rotate crankshaft 2 to 3 turns by hand.
13. Confirm that the valve clearance is within the specification. Refer to "INSPECTION". I
15. Warm up engine, and check for unusual noise and vibration.
J
EM-217
OIL SEAL
OIL SEAL
Removal and Installation of Valve Oil Seal INFOID:0000000013949775
REMOVAL
1. Turn crankshaft until the cylinder requiring new valve oil seals is at TDC. This prevents valve from drop-
ping into cylinder.
2. Remove camshafts. Refer to EM-207.
3. Remove adjusting shims and valve lifters. Refer to EM-207.
4. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This prevents valve from
dropping into cylinder.
• Compress the valve spring with valve spring compressor,
attachment and adapter (SST). Remove valve collet with a
magnet hand.
CAUTION:
When working, be careful not to damage valve lifter holes.
PBIC2388E
6. Remove valve spring retainer and valve spring.

7. Remove valve oil seal with the valve oil seal puller (SST).
JEM153G
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
JEM165G

Removal and Installation of Front Oil Seal INFOID:0000000013949776
REMOVAL
EM-218
OIL SEAL
• Undercover A
• Drive belt: Refer to EM-161.
• Crankshaft pulley: Refer to EM-227.
2. Remove front oil seal with a suitable tool. EM
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
C
PBIC4050E E
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip. F
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
G
I
SEM715A
• Using the suitable drift [60 mm (2.36 in) dia.] (A), press fit the J
oil seal (2) so that the dimension is as specified in the figure.
1 : Oil pump K
CAUTION:
Never touch lips of oil seal. Check that seal surfaces are
free of foreign materials. L
PBIC4051E
EM-219
OIL SEAL
Removal and Installation of Rear Oil Seal INFOID:0000000013949777
REMOVAL
1. Remove transmission and transfer assembly. Refer to EM-207.
2. Remove flywheel. Refer to EM-257.
3. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
SEM715A
• Press in rear oil seal (2) to rear oil seal retainer (1) as shown in
the figure.
• Using the drift [100 mm (3.94 in) dia.] (A), press fit so that the
PBIC4052E
EM-220
A
EM
J
PBIC4855E
1. Gasket 2. Chain tensioner 3. Spring K

4. Plunger 5. Slack guide 6. Front chain case
7. Tension guide 8. Gasket 9. Secondary timing chain
10. Tension guide L
A. Oil pump side B. Tighten twice

CAUTION: N
• After removing timing chain, never turn crankshaft or camshaft separately, or valves strike piston
heads.
surfaces with new engine oil. O
REMOVAL
• For preparative work for removing/installing secondary timing chain to remove/install fuel pump, refer to EM-
P
197.
• To prepare for removing/installing secondary timing chain to remove/install camshaft, refer to EM-207,
1. Remove radiator shroud (upper and lower) and cooling fan (crankshaft driven type). Refer to CO-13,
"Component".
2. Remove EGR cooler and related water hoses.
CAUTION:
EM-221
• Perform this step when engine is cold.
• Never spill engine coolant on drive belts.
3. Remove front chain case.
• Loosen fixing bolts in reverse order of that shown in the figure
and remove them.
CAUTION:
• While front chain case is removed, cover openings to
prevent entry of foreign material into engine.
JEM121G
• Never remove two mass dampers on the back of cover.
SBIA0189E
4. Set the No. 1 piston to TDC on its compression stroke.

• Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
• No position indicator is provided on crankshaft pulley.
• When installing, color coded links on secondary timing
chain can be used as alignment marks. Marking may not
be necessary for removal, however, make alignment
marks as required because the alignment mark on fuel
pump sprocket may not be easy to see.
SEM515G

a. Push the plunger of chain tensioner and keep it pressed with a
push pin.
JEM124G
EM-222
b. Using the hexagon wrench (SST), remove bolts to remove chain
tensioner. A
EM
SBIA0227E
D
• Using the hexagon wrench (SST), remove bolt to remove
slack guide.
E
SBIA0228E
H
7. Remove tension guide.
8. Remove secondary timing chain.
• Timing chain alone can be removed without removing sprock-
ets. I
K
JEM127G

Timing Chain L
M
O
SEM984C
INSTALLATION P
1. Install secondary timing chain.
EM-223
color coded alignment marks (colored links) on the timing
chain.
1 : Secondary timing chain

2 : Chain tensioner
3 : Slack guide
4 : Fuel pump sprocket
5 : Tension guide
6 : Camshaft sprocket
A : Alignment mark (silver link)
B : Alignment mark (punched mark)
C : Alignment mark (yellow link)
2. Install tension guide.
• The upper bolt has a longer shank than the lower bolt.
PBIC4048E
3. Using the hexagon wrench (SST), install slack guide.
SBIA0228E

a. Push the plunger of chain tensioner. While holding it with a push
pin, install chain tensioner.
b. Using the hexagon wrench (SST), tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
• Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.
SBIA0227E
5. Install front chain case.
EM-224
a. Install tension guide on the back surface of front chain case.
• Hold front chain case vertically when installing. Tension guide A
may come off if front chain case is tilted.
EM
SBIA0189E
D
b. Apply a continuous bead of liquid gasket on both ends of arched
area (locations where rear chain case is adjoined) as shown in
the figure.
E
• Use Genuine Liquid Gasket or an equivalent.
G
JEF370Y
c. Install front chain case.

H
• When installing, align dowel pin on oil pump housing with the pin hole.
• Install No. 6, 10 and 11 bolts with the rubber washer to front chain case.
I
e. After tightening all the bolts, retighten in the same order.
JEM121G
L
6. Hereafter, install in the reverse order of removal.
M
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required N
quantity, fill to the specified level. Refer toMA-17, "Fluids and Lubricants" .
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- O
• Warm up engine thoroughly to check that there is no leakage of fuel, exhaust gases, or any oil/fluids includ- P
EM-225
EM-226
A
EM
MBIB9163E
1. Gasket 2. Chain tensioner 3. Spring

4. Slack guide 5. Plunger 6. Camshaft sprocket
7. Washer 8. Fuel pump sprocket 9. O-ring
EM-227
10. Tension guide 11. Tension guide 12. Chain guide
13. Slack guide 14. Spacer 15. Front chain case
16. Gasket 17. Secondary timing chain 18. Chain guide
19. Idler pulley 20. Vacuum pump cover 21. Crankshaft pulley
22. Front oil seal 23. Oil pump housing 24. Crankshaft gear
25. Primary timing chain 26. Crankshaft sprocket 27. Key
28. Fuel pump 29. Vacuum pump 30. Seal washer
34. Rear chain case 35. Idler pulley 36. Tension guide
37. A/C compressor bracket 38. Chain tensioner 39. Plunger
40. Plug 41. Spring
A. Oil pump side B. Tighten twice C. Refer to EM-228
• Refer to GI-9, "Component"for symbol marks in the figure.

CAUTION:
• After removing timing chain, never turn crankshaft or camshaft separately, or valves strike piston
heads.
• When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
REMOVAL
1. Remove power steering oil pump and power steering oil pump bracket. Refer to PS-13, "Removal and
Installation"
2. Remove idler pulleys.
4. Remove oil pan (upper and lower). Refer to EM-185.
6. Remove secondary timing chain and associated parts. Refer to EM-221.
7. When removing rear chain case, remove camshaft sprockets. Refer to EM-207.
a. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).
PBIC3469E
c. Using the pulley puller (SST), remove crankshaft pulley.

• Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.
JEM132G
EM-228
9. Remove oil pump housing.
• Loosen bolts in reverse order of that shown in the figure and A
remove them.
• Use the seal cutter [SST: KV10111100] etc. for removal.
EM
PBIC3470E D
10. Remove crankshaft gear.

11. Remove front oil seal from oil pump housing. E
• Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage oil pump housing.
F
• When removing chain tensioner, push the plunger of chain
tensioner and keep it pressed with a push pin, etc. G
I
JEM134G
14. Hold fuel pump sprocket and remove bolt. J

a. Insert positioning stopper pin (SST) into the hole 6 mm (0.24 in)
in the diameter on fuel pump sprocket.
b. Using the TORX wrench, turn pump shaft little by little to adjust K
the position of fuel pump sprocket so that the holes align.
c. Push positioning stopper pin through fuel pump sprocket to fuel
pump body to hold fuel pump sprocket. L
MBIA0049E M
• Insert the positioning stopper pin until its flange contacts fuel pump
sprocket.
N
PBIC2535E
EM-229
15. Using the hexagon wrench (SST) remove tightening bolts to fuel
pump sprocket.
PBIC2404E
MBIA0074E
16. Remove primary timing chain with fuel pump sprocket and
crankshaft sprocket.
MBIA0079E
17. Remove chain guide and tension guides.
JEM885G
18. Remove fuel pump. Refer to EM-197.

19. Remove vacuum pump. Refer to EM-190.
EM-230
20. Remove rear chain case.
• Loosen fixing bolts in the reverse order of that shown in the A
figure and remove them.
• Use the seal cutter [SST: KV10111100] for removal.
EM
G
SBIA0211E

H
Timing Chain
I
K
SEM984C
INSTALLATION L
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.
M
EM-231
PBIC3473E
1. Chain tensioner 2. Slack guide 3. Fuel pump sprocket

4. Chain guide 5. Primary timing chain 6. Vacuum pump sprocket
7. Slack guide 8. Chain tensioner 9. Crankshaft sprocket
10. Key 11. Tension guide 12. Tension guide
13. Tension guide 14. Camshaft sprocket 15. Secondary timing chain
A. Alignment mark (silver link) B. Alignment mark (punched mark) C. Alignment mark (cut-out area)
D. Alignment mark (yellow link)
CAUTION:
Before starting work, check that No. 1 piston is on its compression stroke.
1. Install rear chain case.
a. Apply a continuous bead of liquid gasket with the tube pressure
[SST: WS39930000] on locations shown in the figure.
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.
PBIC1255E
EM-232
b. Install four O-rings to the grooves of the cylinder block and fuel
pump bracket. A
EM
JEM141G
D
c. Install rear chain case.
d. Tighten bolts in numerical order shown in the figure. E
• Install the following four types of bolts, referring to the figure.
16 mm (0.63 in) : Bolt No. 1, 2, 16, 17, 18, 19, 20, 21, 22
F
20 mm (0.79 in) : Bolt No. 3, 4, 6, 9, 10, 11, 13, 14
25 mm (0.98 in) : Bolt No. 12, 15
35 mm (1.38 in) : Bolt No. 5, 7, 8 G
• The shank length under the bolt neck above is the length of
e. After tightening all the bolts, retighten in the same order. H
K
SBIA0211E
2. Install vacuum pump. Refer to EM-190. L

3. Install fuel pump. Refer to EM-197.
• Before installing, check that spacer and the hole 6 mm (0.24
in) in diameter on coupling are aligned. M
4. Install chain guide and tension guides.
5. Install crankshaft sprocket, aligning it with crankshaft key on the
far side. N
JEM885G O
EM-233
6. Install primary timing chain with fuel pump sprocket.
color coded alignment marks (colored links) on primary timing
chain.
• Install fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine.
7. Install timing chain onto power steering oil pump sprocket and
through chain guide.
MBIA0079E
8. Use the positioning stopper pin (SST) to hold the fuel pump
sprocket and install the bolt.
• Using the TORX wrench (SST), turn the fuel pump shaft little
by little to adjust the position of the fuel pump sprocket. Insert
positioning stopper pin into the hole 6 mm (0.24 in) in diameter
on fuel pump sprocket so that the stopper pin goes through the
fuel pump body. While the stopper pin is in place, install the
bolt.
MBIA0049E
PBIC2404E
9. Install timing chain slack guide.

• Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin, etc., install chain ten-
sioner.
• After installation, pull out the push pin holding the plunger.
CAUTION:
Check again that the alignment marks on sprockets and the
colored alignment marks on timing chain are aligned.
JEM134G
11. Install front oil seal (1) to oil pump housing (2).
• Using the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION:
Never touch lips of oil seal. Check that seal surfaces are
free of foreign materials.
PBIC3448E
EM-234
12. Install vacuum pump cover to oil pump housing.
• Apply a continuous bead of liquid gasket with the tube presser A
• Apply liquid gasket on oil pump-side surface. EM
JEM143G
D
13. Install crankshaft gear.

• Install crankshaft gear. E
14. Install oil pump housing.
[SST: WS39930000] as shown in the figure. F
A: Leave the start and end areas of the bead slightly protruding
from the surface.
B: Apply liquid gasket along upper end surface of oil pump hous-
ing. G
JEM144G
I
b. Install O-ring into the groove of rear chain case.
c. Install oil pump housing.

• When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer. J
e. After tightening all the bolts, retighten in the same order. K
PBIC3470E
N
15. Check gaps on upper oil pan mounting surface.
• Using straightedge and feeler gauge, measure gaps between
the locations of the following parts: O
Oil pump housing and rear chain case:

Standard : –0.09 to 0.09 mm (–0.0035 to 0.0035 in) P
Rear chain case and cylinder block:
Standard : –0.19 to 0.07 mm (–0.0075 to 0.0028 in)
• If the measured value is out of the standard, install again.
JEM146G
16. Install crankshaft pulley.

CAUTION:
EM-235
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
c. Hold crankshaft pulley with the pulley holder (SST).
d. Tighten crankshaft pulley fixing bolt.
: 75.0 N·m (7.7 kg-m, 55 ft-lb)

e. Completely loosen.
: 0 N·m (0 kg-m, 0 in-lb)
f. Tighten crankshaft pulley bolt.

PBIC3469E
: 75.0 N·m (7.7 kg-m, 55 ft-lb)

g. Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt.
h. Tighten fixing bolt another 120 degrees (angle tightening) (turn

by 2 notch).
A : Indicate embossments
B : Alignment mark
PBIC3476E
17. Install secondary timing chain and the associated parts. Refer to EM-221, "Removal and Installation".
EM-236
*2: Check engine oil level 10 minutes after engine stopped. A
EM
EM-237
CYLINDER HEAD
CYLINDER HEAD
CHECKING COMPRESSION PRESSURE

2. Using CONSULT, check that no error codes are indicated for self-diagnosis items. Refer to EC-56, "Basic
Inspection".
• Do not disconnect CONSULT until the end of this operation; it is used to check engine rpm and for error
detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal.
4. Remove the engine cover and bracket. Refer to EM-168
5. To prevent fuel from being injected during inspection, disconnect
all the fuel injector connectors.
A : Injector
B : Connector
PBIC4872E
6. Wind the insulating tape around the electrode of the discon-

nected connectors. Tie them together and fix them on the har-
ness side.
A : Connector
PBIC4772E
7. Remove glow plugs from all the cylinders. Refer to EM-189.

CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs.
8. Install compression gauge adapter (SST) to installation holes of

glow plugs and connect compression gauge for diesel engine.
: 20.0 N·m (2.0 kg-m, 15 ft-lb)

9. Connect the battery cable to the negative terminal.
10. Turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine
rpm. Perform these steps to check each cylinder.
• Always use a fully-charged battery to obtain specified engine
speed. SEM112G
EM-238
CYLINDER HEAD
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard Minimum Difference limit between cylinders

A
3,100 (31, 31.6, 450)/200 2,500 (25, 25.5, 363)/200 490 (4.9, 5.0, 71)/200
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure EM
• If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
C
surfaces) and measure again.
• If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
- If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam- D
aged. Check piston ring for malfunction. If any, replace piston ring.
- If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat. E
• If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be leak-
ing from gasket. In this case, replace cylinder head gasket.
11. Complete this operation as per the following items:
F
a. Turn the ignition switch to “OFF”.
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4. G
d. Connect all the connectors of the fuel injector.
e. Connect the battery cable to the negative terminal.
f. Check DTC. If DTC is detected, erase it. Refer to EC-43, "Introduction". H
PBIC3477E
1. Cylinder head bolt 2. Cylinder head assembly 3. Gasket

4. Dowel pin 5. Cylinder block
A. Refer to EM-240
EM-239
CYLINDER HEAD
REMOVAL
2. Remove the following:
• Rocker cover: Refer to EM-204.
• Spill tube and fuel injector: Refer to EM-192.
• Intake manifold and vacuum gallery: Refer to EM-168.
• Turbocharger: Refer to EM-178.
• Exhaust manifold: Refer to EM-183.
• Secondary timing chain: Refer to EM-221.
• Camshaft: Refer to EM-207.
3. Remove cylinder head assembly.
• Remove bolts between rear chain case and cylinder head. Refer to EM-227.
• Remove cylinder head bolts in the reverse order as shown in
the figure with the cylinder head bolt wrench (commercial ser-
vice tool).
• Lift up cylinder head assembly to avoid interference with dowel
pins located between the cylinder block and cylinder head,
and remove cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder
head, or, place wood blocks beneath both ends of cylin-
der head to keep the cylinder bottom from any contact.
JEM149G
• For glow plug removal, the following shall be noted.
CAUTION:
• To avoid breakage, never remove glow plug unless necessary.
• Never use air impact wrench.
• Using micrometer, measure the outer diameters “d1” and “d2” of
bolt thread as shown in the figure.
• If the necking point can be identified, set it as measuring point “d1”.
Limit : 0.15 mm (0.0059 in)

• If it exceeds the limit, replace cylinder head bolt.
JEM171G

1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow gasket debris to enter passages for oil or water.
EM-240
CYLINDER HEAD
2. At each of several locations on bottom surface of cylinder head,
measure distortion in six directions. A
Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace cylinder head. EM
SEM496G
D
INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts.
E
• Cylinder head gasket to be installed is selected by its thickness through the following procedure.
- When replacing gasket alone:
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of cut-outs on F
the rear RH side.
Gasket thickness* mm (in) Number of grade Number of cut-outs G

0.900 (0.0354) 1 0
0.925 (0.0364) 2 1
H
0.950 (0.0374) 3 2
0.975 (0.0384) 4 3
1.000 (0.0394) 5 4 MBIA0020E I
1.025 (0.0404) 6 5
J
• Gasket (3) thickness can be identified at the location (A)
shown in the figure by the numbers of cut-outs before removal.
K
2 : Oil filter
: Vehicle front L
M
PBIC3478E
• Heater return tube is omitted for explanation. N

NOTE:
- When the following parts are repaired/replaced: O
• With cylinder block upper surface and/or crankshaft pin journal ground.
• With cylinder block, pistons, connecting rods, and/or crankshaft replaced.
a. Set piston at a point close to TDC. P
EM-241
CYLINDER HEAD
b. Set the dial gauge at the location as shown in the figure. Turning
crankshaft gradually, set the gauge scale to “0” where the piston
protrusion is maximized.
c. Move the dial gauge stand so that the tip of dial gauge can con-
tact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.
SEM507G
Identification
Piston protrusion mm (in) Gasket thickness* mm (in)
Number of cut-outs
0.230 - 0.255 (0.0091 - 0.0100) 0.900 (0.0354) 0
0.255 - 0.280 (0.0100 - 0.0110) 0.925 (0.0364) 1
0.280 - 0.305 (0.0110 - 0.0120) 0.950 (0.0374) 2
0.305 - 0.330 (0.0120 - 0.0130) 0.975 (0.0384) 3
0.330 - 0.355 (0.0130 - 0.0140) 1.000 (0.0394) 4
0.355 - 0.400 (0.0140 - 0.0157) 1.025 (0.0404) 5
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the tube presser
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.
PBIC1256E
3. Install cylinder head assembly.

• Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure:
a. Apply engine oil to bolt threads and seat surfaces.
b. Tighten all bolts.
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
JEM149G
EM-242
CYLINDER HEAD
c. Tighten 180 degrees (angle tightening).
d. Loosen completely in the reverse order of that shown in the fig- A
ure.
: 0 N·m (0 kg-m, 0 ft-in) EM

C
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
JEM166G
f. Tighten 90 degrees (angle tightening).
D
g. Tighten another 90 degrees (angular tightening).
CAUTION:
• When the angle wrench (SST) is not used, paint an alignment mark on the head of cylinder head
bolt and cylinder head surface before tightening. Check the angle with a protractor. E
4. Tighten bolts between rear chain case and cylinder head. Refer to EM-227.
5. After installing cylinder head, measure dimension from the front
end surface of cylinder block to that of cylinder head (If rear F
chain case is removed).
Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in) G

• If out of the standard, check fitting of dowel pins and cylinder
head.
H
JEM172G
I
CAUTION:
• To avoid damage, glow plugs should be removed only when required. J
• Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one.
• Before installing, remove carbon depositing on mounting hole of glow plug with a reamer.
K
7. Install engine coolant temperature sensor.
8. Install vacuum gallery.
9. Install in the reverse order of removal. L
M
quantity, fill to the specified level. Refer to MA-17, "Fluids and Lubricants". N
- Start engine. With engine speed increased, check again for fuel leakage at connection points. O
ing engine oil and engine coolant. P
EM-243
CYLINDER HEAD
PBIC2328E
1. Adjusting shim 2. Valve lifter 3. Valve collet

4. Valve spring retainer 5. Valve spring 6. Valve oil seal
7. Valve spring seat 8. Valve guide 9. Cylinder head
10. Valve seat 11. Valve (Exhaust) 12. Valve (Intake)
DISASSEMBLY
• Using the valve spring compressor (SST), compress valve
spring. Using magnet hand, remove valve collets.
PBIC2388E
EM-244
CYLINDER HEAD
A
4. Remove valves as pressing valve stems toward combustion chamber.
• Before removing valve, check the valve guide clearance. Refer to "Valve Guide Clearance".
NOTE:
Refer to the figure for intake and exhaust valve positions. EM
Intake and exhaust valve driving cams are provided alternately
for each camshaft.
C
SBIA0196E E
5. Remove valve oil seals using the valve oil seal puller (SST).
6. Remove valve spring seats. F
7. Before removing valve seats, perform valve seat contact check.
Refer to "Valve Seat Contact".
8. Before removing valve guides, perform valve guide clearance G
check. Refer to "Valve Guide Clearance".
JEM153G
ASSEMBLY I
1. Install valve guides. Refer to "Valve Guide Replacement".
2. Install valve seats. Refer to "Valve Seat Replacement".
J
K
M
JEM165G
5. Install valves.
• Install the valves with bigger outer diameter to intake valve N
side.
• Note that valve layout here is different from that of conven-
tional engine. O
SBIA0196E
6. Install valve spring.

7. Install valve spring retainers.
EM-245
CYLINDER HEAD
8. Using the valve spring compressor (SST), compress valve
springs.
Then install valve collets using magnet hand.
• After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
PBIC2388E
9. Install valve lifters and adjusting shims to the same positions as before.
Valve Dimension
• Check dimensions of each valve. For dimensions, refer to EM-281,
• If dimensions are out of the standard, replace valve.
SEM188A
Valve Stem Diameter

• Measure diameter of valve stem with micrometer.
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.945 - 5.960 mm (0.2341 - 0.2346 in)
SEM938C
Valve Guide Inner Diameter

• Measure inner diameter of valve guide with inside micrometer.
Standard
Intake and Exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Valve guide clearance:

Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.040 - 0.073 mm (0.0016 - 0.0029 in)
Limit
EM-246
CYLINDER HEAD
Intake : 0.08 mm (0.0031 in)
A
Exhaust : 0.10 mm (0.0040 in)
• If it exceeds the limit, replace valve and/or valve guide.
Valve Guide Replacement EM
When removing valve guide, replace it with oversized [0.2 mm (0.0008 in)] valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.
C
SEM008A
F
2. Using the valve guide drift (commercial service tool), tap valve
guides out from the combustion chamber side.
WARNING: G
H
I
SEM931C
3. Ream cylinder head valve guide hole with the valve guide J
reamer (commercial service tool).
Valve guide hole diameter (for service parts):

K
10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
M
P
SEM008A
EM-247
CYLINDER HEAD
5. Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension
Projection “L” : 10.4 - 10.6 mm (0.409 - 0.417 in)

WARNING:
PBIC2497E
6. Using the valve guide reamer (commercial service tool), perform

reaming to the press-fitted valve guides.
Reaming specifications:
Intake and Exhaust
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
Valve Seat Contact

• Before starting this check, confirm that the dimension of valve
guide and valves are as specified.
• Apply red lead primer on contacting surfaces of valves seat and of
valve face to examine the conditions of contacting surfaces.
• Check that the paint on contacting surfaces are continuous along
the entire circumference.
• If there are abnormal indications, grind the valve and check the
contact again. If malfunction indications still persist, replace valve
seat.
SBIA0322E

When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-281, "Standard and Limit".
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]:

Intake : 30.500 - 30.516 mm (1.2008 - 1.2014 in)
Exhaust : 29.500 - 29.516 mm (1.1614 - 1.1620 in)
• Check that technician reams in circles concentric to the valve
guide center.
• This enables valve seat to fit correctly.
SEM795A
EM-248
CYLINDER HEAD
3. Heat cylinder head to approximately 110 to 130°C (230 to
266°F) in oil bath. A
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
WARNING: EM
CAUTION:
C
Never touch the cooled valve seats directly by hand.
SEM008A
D
5. Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
E
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or F
repeatedly, the valve seat surface may be damaged.
G
SEM934C
6. Using compound, perform valve fitting.

H
7. Check again that contacting status is satisfactory.
For details, Refer to "Valve Seat Contact".
8. Use the depth gauge to measure the distance between the I

mounting surface of cylinder head spring seat and the valve
stem end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace valve seat with a new J
one.
Valve seat resurface limit “L”: K

Intake : 36.53 - 36.98 mm (1.4382 - 1.4559 in)
Exhaust : 36.53 - 37.01 mm (1.4382 - 1.4571 in)
L
JEM253G
Valve Spring Square

• Position the try square to valve spring, turn the spring, and mea- M
sure the maximum clearance value between top surface of spring
and the try square.
Limit : 1.9 mm (0.075 in) N
• If it exceeds the limit, replace valve spring.

O
PBIC0080E
P
Valve Spring Dimensions and Valve Spring Pressure Load
EM-249
CYLINDER HEAD
• Using valve spring tester, check the following.
Standard:
Free height : 43.7 mm (1.72 in)
Installation height : 32.82 mm (1.2921 in)
Installation load : 184 - 208 N
(18.77 - 21.22 kg, 41.4 - 46.8 lb)
Height during : 24.82 mm (0.9772 in)
valve open
SEM113
Load with valve : 320 - 360 N
open (32.65 - 36.73 kg, 71.9 - 80.9 lb)
• If out of the standard, replace the valve spring.
EM-250
ENGINE ASSEMBLY
ENGINE ASSEMBLY
A
EM
J
MBIB9169E
1. Engine mounting bracket RH 2. Engine mounting bracket LH 3. Engine mounting insulator RH K

L
WARNING: M
CATALOG. N
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations. O
sections.
• Use either 2-pole lift type or separate type lift as best you can. P
NOTE:
EM-251
ENGINE ASSEMBLY
ing.
REMOVAL
Description of Work
Separate the engine from transmission and hoist the engine upward.
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-24, "Removal and Installation".
a. Drain clutch fluid. Refer to CL-8, "Air Bleeding Procedure"..
b. Remove hydraulic lines.
Engine Room Front
1. For models with A/C, remove drive belts.
2. Disconnect radiator upper and lower hose.
3. Disconnect charge air cooler hoses.
4. Remove radiator, and charge air cooler as assembly. Refer to CO-13, "Removal and Installation" and EM-
Engine Room LH
1. Disconnect alternator harness connector.
2. Remove A/C compressor without disconnecting pipes and temporally secure them on body with a rope to
avoid putting load on them. Refer to MTC-66, "Removal and Installation of A/C Compressor".
3. Disconnect glow plug harness. Refer to EM-189.
4. Remove hose blow-by.
Engine Room RH
1. Remove power steering pump without disconnecting pipes.
2. Injectors and fuel pump harness connectors.
3. Disconnect oil pressure switch harness connector. Refer to EC-56, "Basic Inspection" for location.
5. Disconnect fuel feed and fuel return hoses, and plug them to prevent fuel from draining. Refer to EM-192.
7. Disconnect starter harness connector.
Engine Room Rear
1. Disconnect shift cable. Refer to MT-14, "Removal and Installation".
2. Disconnect crank shaft position sensor. Refer to EM-185.
Vehicle Under Body
2. Remove catalyst. Refer to EM-176.
3. Remove clutch operating cylinder from transmission, and move it aside. Refer to CL-11, "Removal and
Installation"
Removal
EM-252
ENGINE ASSEMBLY
rear left of cylinder head (B). A

2 : Engine slinger (rear) EM
: Engine front
PBIC3480E
D
2. Support engine with a hoist and remove LH and RH engine mounting insulator mounting nuts.
3. Support the transmission with a suitable jack.
4. Remove the starter motor and separate the engine from the gearbox. Refer to SC-41, "Removal and E
Installation" and EM-251, "Component".
CAUTION:
• During the operation, check that no part interferes with body side. F
Engine slinger bolts: G

: 28.0 N·m (2.9 kg-m, 21 ft-lb)
INSTALLATION
H
figure of components. Refer to EM-251. I
is provided at vacuum gallery. J
• Before starting engine, check the levels of engine coolant, lubrications and working oils. If less than required K
quantity, fill to the specified level.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
L
• Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil, fuel M
and exhaust gas.
• Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
• After cooling down engine, again check amounts of engine coolant, lubricants, oil, and fluid. Refill to speci-
N
fied level, if necessary.
• Summary of the inspection items:
Item Before starting engine Engine running After engine stopped O

P
Transmission / transaxle AT & CVT Models Leakage Level / Leakage Leakage
fluid MT Models Level / Leakage Leakage Level / Leakage
Exhaust gas — Leakage —
* Power steering fluid, brake fluid, etc.
EM-253
ENGINE ASSEMBLY
WARNING:
CATALOG.
CAUTION:
sections.
NOTE:
ing.
REMOVAL
Description of Work
Support the engine, then remove engine and transmission from vehicle downward.
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-24, "Removal and Installation".
3. Remove front seats. Refer to SE-14, "Removal and Installation of Driver Seat"
5. Disconnect transmission shift cable from inside cab. Refer to MT-14, "Removal and Installation"
6. Disconnect parking brake cable from inside cab. Refer to PB-11, "Removal and Installation"
7. Remove front and rear floor trim. Refer to EI-29, "Removal and Installation"
8. Remove engine covers. Refer to EM-159.
9. For models equipped with air conditioner system, discharge refrigerant and disconnect refrigerant lines
from the cabin. Refer to MTC-66, "Component".
a. Drain clutch fluid. Refer to CL-8, "Air Bleeding Procedure".
b. Remove hydraulic lines. Refer to CL-13
Engine Room Front
1. Remove radiator reservoir tank.
2. Radiator fan. Refer to CO-16
3. Drive belt. Refer to EM-161.
Engine Room LH
1. Disconnect charge air cooler hoses and tubes. Refer to EM-166
2. Remove radiator upper and lower hose.
3. Remove alternator SC-33
4. Disconnect A/C piping and temporally secure them on body with a rope to avoid putting load on it. Refer to
MTC-68
5. Remove air conditioner compressor and its bracket as assembly.
EM-254
ENGINE ASSEMBLY
7. Remove blow-by hose.
Engine Room RH A
1. Disconnect power steering fluid piping at a point between body and engine. Refer to PS-18.
2. Disconnect injector harness connectors and fuel pump harness connectors. EM
3. Disconnect oil pressure switch harness connector.
5. Disconnect air hose from intake manifold. C
6. Disconnect oil cooler hose from heater pipes.
7. Remove EGR exhaust tube. Refer to EM-168.
8. Remove EGR cooler. Refer to EM-168. D
9. Remove EGR volume control valve. Refer to EM-168.
E
12. Remove oil level tube.
13. Disconnect starter harness connector. F
Engine Room Rear
1. Remove shift cable. Refer to MT-14, "Removal and Installation".
2. Disconnect crank shaft position sensor. Refer to EM-185. G
Vehicle Under Body
1. Disconnect ABS harness connector. H
2. Disconnect wheel sensor harness connector and brake pads limit wear harness connector. Refer to BR-
22, "Removal and Installation of Brake Pad"
3. Remove exhaust front tube. Refer to EX-10, "Removal and Installation". I
5. Remove propeller shaft. Refer to PR-4
6. Remove clutch operating cylinder from transmission, and move it aside. Refer to CL-11. J
8. Remove fender protector LH and RH. Refer to EI-18
9. Remove stabilizer. Refer to FSU-10 K
10. Remove air guide and charge air cooler. Refer to EM-166
11. Remove charge air cooler tubes from the radiator. Refer to EM-166.
L
12. Separate radiator shroud, and remove radiator. Refer to CO-13
Removal
1. Install engine slingers into front right of cylinder head (A) and M
1 : Engine slinger (front) N

: Engine front
O
PBIC3480E P
2. Support the engine by a crane and loosen LH and RH engine mounting insulator mounting nuts.
3. Lower the engine and gearbox with the lifting table while loosening the slings on the crane supporting the
upper part of the engine.
4. Loosen and remove the nuts fixing the gearbox bracket to the chassis.
5. Remove engine and transmission from the vehicle underbody.
EM-255
ENGINE ASSEMBLY
6. Remove the starter motor and separate the engine from the gearbox. Refer to SC-41 and EM-251.
CAUTION:

: 28.0 N·m (2.9 kg-m, 21 ft-lb)
INSTALLATION
• Before starting engine, check the levels of engine coolant, lubrications and working oils. If less than required
• Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil, fuel
and exhaust gas.
Item Before starting engine Engine running After engine stopped


EM-256
CYLINDER BLOCK
CYLINDER BLOCK
A
EM
MBIB9164E
1. Fuel pump bracket 2. Oil pressure switch 3. Cylinder block

4. Rear oil seal retainer 5. Rear oil seal 6. Top ring
7. Second ring 8. Oil ring 9. Piston pin
EM-257
CYLINDER BLOCK
10. Snap ring 11. Piston 12. Connecting rod
13. Connecting rod bearing 14. Connecting rod cap 15. Connecting rod nut
16. A/C compressor bracket 17. Oil jet 18. Copper washer
19. Oil jet relief valve 20. Drain plug 21. Thrust bearing
22. Main bearing upper 23. Key 24. Crankshaft
25. Main bearing lower 26. Main bearing cap bolt 27. Main bearing cap
28. Flywheel 29. Pilot bushing 30. Rear plate
A. Refer to EM-258
• Refer to GI-9 for symbol marks in the figure.

DISASSEMBLY
1. Remove engine from the vehicle. Refer to EM-251.
2. Remove clutch cover and disk. Refer to CL-17.
3. If they need to be replaced, replace pilot bush.
• Using the pilot bushing puller (SST), remove the pilot bush
from rear end of crankshaft.
SEM500G
4. Install engine to engine stand as per the following items:

a. Remove flywheel.
• Secure ring gear with the ring gear stopper (A) (SST), then
loosen mounting bolts with TORX socket (B) (commercial ser-
vice tool) and remove them. As an alternative method hold
crankshaft pulley with the pulley holder (commercial service
tool) to remove flywheel.
1 : Flywheel
A : KV10105630
CAUTION:
• Never disassemble flywheel.
• Never place flywheel with signal plate facing down. PBIC3482E

scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
b. Hoist engine and install it to the engine stand (commercial ser-

vice tool).
NOTE:
The figure shows an example of general-purpose engine stand
that can hold mating surface of transmission with drive plate and
rear plate removed.
PBIC0085E
5. Drain engine oil and engine coolant from inside engine. Refer to CO-10 and LU-8.
EM-258
CYLINDER BLOCK
6. Drain engine coolant by removing drain plug from inside of
engine. A
1 : Cylinder block
2 : Drain plug EM
PBIC3483E
D
7. Remove the following parts and related parts. (Only major parts are listed.)
• Intake manifold: Refer to EM-168.
• Turbocharger: Refer to EM-178. E
• Exhaust manifold: Refer to EM-183.
• Rocker cover: Refer to EM-204.
• Fuel injector: Refer to EM-192.
• Oil pan and oil strainer: Refer to EM-185. F
• Water pump: Refer to CO-17.
• Thermostat and water piping: Refer to CO-20
• Secondary timing chain: Refer to EM-221. G
• Primary timing chain: Refer to EM-227.
• Fuel pump: Refer to EM-197.
• Vacuum pump: Refer to EM-190.
• Camshaft: Refer to EM-207. H
• Cylinder head: Refer to EM-238.
• Oil cooler: Refer to LU-12.
• Accessory, accessory bracket and mount brackets I
8. Remove fuel pump bracket.
9. Remove rear oil seal retainer.
• Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer. J
10. Remove rear oil seal from rear oil seal retainer. Refer to EM-218.
• Punch out with a flat-bladed screwdriver.
CAUTION: K
Be careful not to damage rear oil seal retainer.
• Before removing piston and connecting rod assembly, check L
connecting rod side clearance. Refer to EM-270, "Inspection
After Disassembly".
M
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
CAUTION: N
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod JEM195G
big end. O
EM-259
CYLINDER BLOCK
• When removing piston and connecting rod assembly, pre-
oil jet.
12. Remove connecting rod bearings from connecting rods and
caps.
• Keep them by cylinder to avoid confusion.
FEM086
13. Remove piston rings from pistons using the piston ring expander
(commercial service tool).
CAUTION:
• When removing, prevent pistons from being damaged.
• Never expand piston rings excessively. This may damage
piston rings.
JEM196G
14. Remove pistons from connecting rods.

a. Using the snap ring pliers, remove snap rings.
JEM197G
b. Using the industrial use dryer, heat pistons up to 60 to 70°C (140

to 158°F).
PBIC0089E
c. Using rod with outer diameter of 26 mm (1.02 in), press piston

pins out.
EMM0072D
EM-260
CYLINDER BLOCK
15. Remove main bearing cap bolts.
• With a TORX socket (size: E14, commercial service tool), A
loosen main bearing cap bolts in several stages in the reverse
order of that shown in the figure and remove them.
• Before loosening main bearing cap bolts, measure crankshaft EM
end play. Refer to EM-270, "Inspection After Disassembly".
JEM200G
D
16. Remove main bearing caps.
• Using main bearing cap bolts, remove by rocking bearing cap
back and forth. E
18. Remove main bearings and thrust bearings from cylinder block
and main bearing caps. F
CAUTION:
Check the correct installation locations of removed parts.
Store them so they never get mixed up.
G
19. Remove oil jet.
JEM201G
ASSEMBLY H
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to
remove foreign matter.
CAUTION: I
Use a goggles to protect your eye.
2. Install drain plug to cylinder block.
J
1 : Cylinder block
2 : Drain plug
• Apply liquid gasket to drain plug. K
Use Genuine Liquid Gasket or equivalent
PBIC3483E
M
3. Install oil jet relief valve.
4. Install oil jet.
• Align knock pin on back of oil jet with hole on block when N
installing oil jet.
PBIC0389E
EM-261
CYLINDER BLOCK
a. Remove contamination, dust and engine oil from bearing mount-
ing positions on cylinder block and main bearing caps.
block.
• Install thrust bearings with oil groove facing to crankshaft arm
(outside).
JEM224G
c. Being careful with the direction, install main bearings.

cylinder block side, and those without oil holes and grooves
onto the main cap side.
• While installing bearings, apply engine oil to bearing surfaces
(inside). Do not apply engine oil to rear surfaces, but clean
them completely.
• Align stopper notches on bearings to install them.
with the oil hole positions on the bearings.
6. Install crankshaft to cylinder block. JEM213G
• Check that crankshaft rotates smoothly by hand.
7. Install main bearing caps.
• Identify main bearing caps by the punched mark. Install cor-
rectly matching the journal No. on the bearing cap and the
journal with the front mark facing forward.
• Main bearing caps are commonly processed with the cylinder
block. Therefore, caps and cylinder block should be replaced
as a set.
8. Check the main bearing cap bolts for deformation. Refer to EM-
270, "Inspection After Disassembly".
JEM225G
9. With the TORX socket (size: E14, commercial service tool),

tighten the main bearing cap bolts according to the following
procedure:
a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.
: 27.0 N·m (2.8 kg-m, 20 ft-lb)

c. Put alignment marks (with paint) on each bolt and the main
JEM200G
bearing cap, all in the same direction. (When using a protractor)
d. Then, tighten 90 degrees. (angle tightening)

CAUTION:
Always use either the angle wrench (SST) or protractor dur-
ing angular tightening. Avoid tightening based on visual
checks alone.
• After tightening bolts to specified torque, check that crankshaft
rotates smoothly.
• Check crankshaft end play. Refer to EM-270, "Inspection After
Disassembly".
10. Check the outer diameter of connecting rod bolts. Refer to EM-
270, "Inspection After Disassembly". JEM226G
EM-262
CYLINDER BLOCK
11. Install piston to connecting rod.
a. Using the snap ring pliers, install snap rings to groove on piston rear side. A
b. Install pistons to connecting rods.
• Using the industrial use dryer, heat pistons up to approx. 60 to EM
70°C (140 to 158°F) until piston pin can be pressed down by
finger touch. Then insert piston pin into piston and connecting
rod from front side of piston toward rear.
C
PBIC0089E E

head and cylinder No. stamped on connecting rod being posi- F
c. Install snap ring to front side of piston.
• Refer to above step a for precaution on snap ring installation. G
• After installation, check connecting rods for smooth move-
ment.
H
MBIA0024E
I
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged. J
• Install top ring and second ring with punched mark surfaces
facing upward.
Punched mark: K
Top ring : RTOP
Second ring : R2ND
L
• Install rings so that three closed gap position 120 degrees
apart one another.
• Closed gaps do not need to face in a specific directions, as M
long as each are positioned 120 degrees apart. JEM228G
13. Install connecting rod bearing to connecting rod and cap.

• While installing connecting rod bearing, apply engine oil to N
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
• Align protrusions on connecting rod bearings with connecting O
rod cut-outs to install connecting rod bearings.
JEM229G
EM-263
CYLINDER BLOCK
• Move crankshaft pin to be assembled to BDC.
• Align cylinder position with cylinder No. on connecting rod to
• Using the piston ring compressor (SST) or suitable tool, install
piston and connecting rod assembly with front mark on piston
head facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
oil jet.
PBIC1619E
• Align cylinder No. stamped on connecting rod with that on cap
• Check that the front mark on connecting rod cap faces
towards the front of the engine.
MBIA0024E
16. Tighten connecting rod nuts according to the following procedure:

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

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

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

e. Tighten 120 degrees. (angle tightening)
• Always use either the angle wrench (SST) or protractor
during angular tightening. Avoid tightening based on
visual checks alone.
• After tightening nuts, check that crankshaft rotates smoothly.
• Check connecting rod side clearance. Refer to EM-270,
"Inspection After Disassembly".
JEM231G
EM-264
CYLINDER BLOCK
17. Press fit rear oil seal into rear oil seal retainer.
• Using the drift [105 mm (4.13 in) dia.], press fit so that the A
EM
JEM232G
D
18. Install rear oil seal retainer to cylinder block.
• Apply new engine oil to the oil and dust seal lips.
• Apply liquid gasket to rear oil seal retainer using the tube E
presser [SST: WS39930000] as shown in the figure.
F
G
JEM233G
19. Press fit pilot bushing into crankshaft. H

• Using the drift with outer diameter of 19 mm (0.75 in), press fit
pilot bushing until it stops.
I
JEM234G
K
20. Install fuel pump bracket.

• Align the bracket with the dowel pins on cylinder block to L
install.
• The two bolts used for dowel pins have a longer shanks than
the other two.
M
PBIC2329E
O
21. Install parts to engine in the reverse order of disassembly.
22. Remove engine from engine stand in the reverse order of assembly.
23. Install flywheel. P
• Ensure the dowel pins install in the crankshaft.
EM-265
CYLINDER BLOCK
• When installing flywheel to crankshaft, check that crankshaft
side dowel pin and flywheel side dowel pin hole are correctly
aligned.
CAUTION:
If these are not aligned correctly, engine runs roughly and
“MI” turns on.
PBIC2538E
• There is a mating mark on the clutch cover side of flywheel.

Refer it during installation.
PBIC1112E
• Holding ring gear with ring gear stopper (SST), tighten secur-
ing bolts with TORX socket.
• Tighten bolts uniformly in a crisscross manner.
PBIC3482E
- If these are not aligned correctly, engine runs roughly and “MI” turns on.
How to Select Piston and Bearing INFOID:0000000013949792
DESCRIPTION
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block to Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft to connect- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
ing rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block to pis- Piston grade (piston outer diam- Piston grade = cylinder bore
The piston is available together
ton eter) grade (inner diameter of bore)
EM-266
CYLINDER BLOCK
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts. A
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
EM
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
When Using New Cylinder Block C
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade. D
• The part No. of piston is specified together with piston pin as
an assembly.
E
F
JEM208G
G
When Reusing an Old Cylinder Block
MBIA0025E J
1. Measure cylinder bore inner diameter. Refer to EM-270, "Inspection After Disassembly".
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.
3. Select piston of the same grade. K
Piston Selection Table
Unit: mm (in)
L
Grade (punched) 1 2 3
Cylinder bore in-
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
ner diameter
M
Piston outer di-
88.928 - 88.942 (3.5011 - 3.5016) 88.938 - 88.952 (3.5015 - 3.5020) 88.948 - 88.962 (3.5019 - 3.5024)
ameter
NOTE: N
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD BEARING
O
When Using New Crankshaft and Connecting Rod
EM-267
CYLINDER BLOCK
1. Identify the pin diameter grade (No. 0, 1, or 2) on front surface of
crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.
JEM215G
When Re-using the Removed Crankshaft and Connecting Rod

1. Measure the inner diameter of the big end of connecting rod and check that it is within the specified range.
Refer to EM-270, "Inspection After Disassembly".
2. Measure the outer diameter of the crankshaft pin. Refer to EM-270, "Inspection After Disassembly".
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
Connecting rod bearing selection table
JPBIA3907GB
EM-268
CYLINDER BLOCK
Under Size Bearing Usage
• If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under size A
bearings.
shaft pins to adjust clearance to specification.
EM
Connecting Rod Bearing Under Size List

Unit: mm (in)
C
Size Thickness
US 0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606)
US 0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614) D
US 0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
CAUTION:
E
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.
Standard dimension R : 1.5 - 1.7 mm (0.0591 - 0.0669 in) F
H
JEM216G
HOW TO SELECT MAIN BEARING

When Using New Cylinder Block and Crankshaft I
1. Identify the crank journal grade (No. 0, 1, or 2) on LH surface at
the rear of the cylinder block, and locate the applicable grade on
the “Grade” row in the “Main Bearing Grade Table”. J
JEM208G
2. Identify the journal grade (No. 0, 1, or 2) on the front surface of M

crankshaft, and locate the applicable grade under the “Grade”
column in the “Main Bearing Grade Table”.
N
JEM215G
P
3. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
When Reusing Removed Cylinder Block and Crankshaft
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-270, "Inspection After
Disassembly".
EM-269
CYLINDER BLOCK
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-270, "Inspection After Disassembly".
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used (STD 0 to STD 4) can be located in the cell where the row and column cross.
Main Bearing Grade Table
Unit: mm (in)
66.654 - 66.663 66.663 - 66.672 66.672 - 66.681

Inner diameter of Cylinder block main bearing housing
(2.6242 - 2.6245) (2.6245 - 2.6249) (2.6249 - 2.6252)
Crankshaft journal Grade
0 1 2
outer diameter (punched)
STD 0 STD 1 STD 2
• Bearing grade No. 1.816 - 1.820 1.820 - 1.824 1.824 - 1.828
62.967 - 62.975 • Bearing thickness (0.0715 - 0.0717) (0.0717 - 0.0718) (0.0718 - 0.0720)
0
(2.4790 - 2.4793) • Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
• Identification color (0.0015 - 0.0026) (0.0015 - 0.0026) (0.0015 - 0.0026)
Black Brown Green
STD 1 STD 2 STD 3
• Bearing grade No. 1.820 - 1.824 1.824 - 1.828 1.828 - 1.832
1
(2.4787 - 2.6790) • Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
Brown Green Yellow
STD 2 STD 3 STD 4
• Bearing grade No. 1.824 - 1.828 1.828 - 1.832 1.832 - 1.836
2
(2.4784 - 2.4787) • Oil clearance 0.039 - 0.066 0.039 - 0.066 0.039 - 0.066
Green Yellow Blue
Under Size Bearing Usage

• If bearing clearance is out of the specifications for main bearings in standard size, use under size bearings.
shaft journals to adjust clearance to the specification.
Main Bearing Under Size List
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
CAUTION:
When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals)
JEM216G
Inspection After Disassembly INFOID:0000000013949793
CRANKSHAFT END PLAY
EM-270
CYLINDER BLOCK
• Using dial gauge, measure crankshaft travel amount by moving the
crankshaft forward or backward. A
Standard : 0.10 - 0.25 mm (0.0040 - 0.0098 in)

Limit : 0.30 mm (0.012 in) EM
• If the value exceeds the limit, replace thrust bearings with new
ones and measure again.
If the measurement exceeds the limit again, replace crankshaft C
with a new one.
JEM202G
D
CONNECTING ROD SIDE CLEARANCE
• Using feeler gauge, measure side clearance between connecting
rod and crankshaft arm.
E
Standard : 0.20 - 0.35mm (0.0080 - 0.0138 in)
Limit : 0.40 mm (0.016 in)
F
• If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.
G
JEM203G
PISTON TO PISTON PIN CLEARANCE H

Piston Pin Bore Diameter
Using inside micrometer, measure piston pin bore diameter.
I
Standard : 28.003 - 28.009 mm (1.1025 - 1.1027 in)
PBIC0116E
L
Using micrometer, measure piston pin outer diameter.
M
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Calculation of Piston to Piston Pin Clearance P

(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)
Standard : 0.003 - 0.014 mm (0.0001 - 0.0006 in)

• If out of the standard, replace piston/piston pin assembly.
NOTE:
Piston is available together with piston pin as assembly.
EM-271
CYLINDER BLOCK
PISTON RING SIDE CLEARANCE
• Using feeler gauge, measure the side clearance between piston
ring and piston ring groove.
Unit: mm (in)

Top ring 0.050 - 0.090 (0.0020 - 0.0035) 0.2 (0.008)
2nd ring 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
SEM024AA
• Align top ring and external surface of piston. Measure lower side
groove.
• If side clearance exceeds the limit, replace piston ring.
• Check clearance again. If side clearance still exceeds the limit,
replace piston.
FEM100
PISTON RING END GAP

• Check that cylinder bore diameter is within the specifications.
Refer to "PISTON TO CYLINDER BORE CLEARANCE".
• Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and measure
piston ring end gap with feeler gauge.
Unit: mm (in)

Top ring 0.21 - 0.28 (0.0083 - 0.0110)
2nd ring 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039)
Oil ring 0.30 - 0.55 (0.0118 - 0.0217) FEM101
• If out of the limit, replace piston ring. If gap still exceeds the limit even with a new ring, rebore cylinder and
use oversized piston and piston ring. Refer to "PISTON TO CYLINDER BORE CLEARANCE".
CONNECTING ROD BEND AND TORSION
EM-272
CYLINDER BLOCK
• Use connecting rod aligner to check bend and torsion.
A
Bend limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
Torsion limit : 0.12 mm (0.0047 in)/100 mm (3.94 in)
EM
• If it exceeds the limit, replace connecting rod assembly.
G
PBIC2077E
CONNECTING ROD BIG END INNER DIAMETER

• Install connecting rod caps without connecting rod bearings and H
tighten connecting rod nuts to the specified torque. Refer to EM-
258, "Disassembly and Assembly".
• Using inside micrometer, measure connecting rod big end inner
diameter. I
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)

J
• If out of the standard, replace connecting rod.
PBIC1641E K
CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter L
Use inside micrometer to measure bushing inner diameter.
Standard : 28.026 - 28.038 mm (1.1034 - 1.1039 in)

M
O
PBIC0120E

P
EM-273
CYLINDER BLOCK
Use micrometer to measure piston pin outer diameter.
Standard : 27.995 - 28.000 mm (1.1022 - 1.1024 in)
PBIC0117E
Calculation of Connecting Rod Bushing Clearance

(Connecting rod bushing clearance) = (Connecting rod bushing inner diameter) − (Piston pin outer diameter)
Standard : 0.026 - 0.043 mm (0.0010 - 0.0017 in)

Limit : 0.057 mm (0.0022 in)
• If it exceeds the limit, replace connecting rod and/or piston and piston pin assembly. Refer to EM-266, "How
to Select Piston and Bearing" and/or EM-266, "How to Select Piston and Bearing".
CYLINDER BLOCK TOP SURFACE DISTORTION
• Using scraper, remove gasket installed onto cylinder block surface.
Remove contamination such as engine oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket clear of engine oil and engine
coolant passages.
• Use straightedge and feeler gauge to check block upper surface
for six distortion.
Limit : 0.1 mm (0.004 in)

• If it exceeds the limit, replace cylinder block.
SEM501G
MAIN BEARING HOUSING INNER DIAMETER

• Without installing main bearings, install main bearing caps, and
tighten bolts to the specified torque. Refer to EM-258, "Disassem-
bly and Assembly".
• Measure the inner diameter of main bearing housing with a bore
gauge.
Standard : 66.654 - 66.681 mm (2.6242 - 2.6252 in)

• If the measurement is out of the standard, replace cylinder block
and main bearing caps.
NOTE:
These components cannot be replaced as a single unit, because PBIC1643E
they were processed together.

PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
EM-274
CYLINDER BLOCK
• Using bore gauge, measure cylinder inner diameters at six posi-
tions; top, middle, and bottom (A, B, C) in 2 directions (X, Y). A
Cylinder bore inner diameter

: 89.000 - 89.030 mm (3.5039 - 3.5051 in) EM
Wear limit
: 0.07 mm (0.028 in)
C
Out-of-round limit (Difference between X and Y)
: 0.015 mm (0.0006 in)
SEM899G
Taper limit (Difference between A and C) D
: 0.010 mm (0.0004 in)
• If the measured value exceeds the limit, or if there are scratches E

and/or seizure on the cylinder inner wall, hone or bore the inner
wall.
• Oversize piston is provided. When using oversize piston, hone the
F
cylinder so that the clearance between piston and cylinder satisfies
the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with oversize G
piston rings.
Oversize (O/S) : 0.25 mm (0.0098 in) FEM110 H

: 0.50 mm (0.020 in)
Piston Outer Diameter
Use micrometer to measure piston outer diameter. I
Piston outer diameter

J
Measurement position : 11.0 mm (0.43 in)
Distance from the bottom
Standard : 88.928 - 88.962 mm
K
(3.5011 - 3.5024 in)
0.25 (0.0098) O/S : 89.188 - 89.202
(3.5113 - 3.5119 in) L
0.50 (0.0197) O/S : 89.438 - 89.452 PBIC0125E
(3.5212 - 3.5217 in)

Calculation of Piston to Cylinder Bore Clearance M
• Calculate using piston outer diameter and cylinder bore inner diameter (direction X, position B).
(Clearance) = (Cylinder bore inner diameter) − (Piston outer diameter)
N
Specifications at room temperature [20°C (68°F)]:
Standard : 0.058 - 0.082 mm (0.0023 - 0.0032 in)
• If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-266, "How to Select Piston and O
Bearing".
Reboring Cylinder Bore
P
1. Determine the cylinder bore size by adding piston-to-cylinder bore clearance to piston diameter.
Rebore size calculation:

D=A+B–C
Where,
D: Bored diameter
EM-275
CYLINDER BLOCK
A: Piston outer diameter as measured
B: Piston-to-cylinder bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
2. Install main bearing caps and tighten bolts to the specified torque. Refer to EM-258, "Disassembly and
Assembly". This prevents distortion of cylinder bores.
3. Cut cylinder bore.
NOTE:
• When any cylinder needs boring, all other cylinders must also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so at a time.
4. Hone cylinders to obtain the specified piston-to-cylinder bore clearance.
5. Measure finished cylinder bore for the out-of-round and taper.
NOTE:
• Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
• Use micrometer to measure crankshaft main journal diameter.
Standard : 62.951 - 62.975 mm (2.4784 - 2.4793 in)

• If out of the standard, measure the main bearing oil clearance.
then use the undersize bearing. Refer to "MAIN BEARING OIL
CLEARANCE".
FEM114
CRANKSHAFT PIN JOURNAL DIAMETER

• Use micrometer to measure crankshaft pin journal diameter.
Standard : 51.954 - 51.974 mm (2.0454 - 2.0462 in)

• If out of the standard, measure the connecting rod bearing oil
clearance. then use the undersize bearing. Refer to "CONNECT-
ING ROD BEARING OIL CLEARANCE".
PBIC0127E
CRANKSHAFT OUT-OF-ROUND AND TAPER

• Using micrometer, measure each journal and pin at four points
• Out-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.
• Taper value is indicated by difference in dimensions between
points A and B in directions X and Y.
Out-of-round: (Difference between X and Y)

Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
PBIC2203E
Taper: (Difference between A and B)
Standard : 0.003 mm (0.0001 in)
Limit : 0.005 mm (0.0002 in)
• If the measured value exceeds the limit, correct or replace crankshaft.
EM-276
CYLINDER BLOCK
• If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to "MAIN BEARING OIL CLEARANCE" and/or "CONNECTING A
ROD BEARING OIL CLEARANCE".
CRANKSHAFT RUNOUT
• Place V-block onto surface plate to support journals at both ends of EM
crankshaft.
• Position dial gauge vertically onto No. 3 journal.
• Rotate crankshaft to read needle movement on dial gauge. (Total C
indicator reading)
Standard : 0.05 mm (0.0020 in)

D
Limit : 0.10 mm (0.0040 in)
• If it exceeds the limit, replace crankshaft.
FEM116
E
CONNECTING ROD BEARING OIL CLEARANCE

Method by Measurement F
• Install connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Refer to EM-258,
"Disassembly and Assembly". Use inside micrometer to measure
G
connecting rod bearing inner diameter.
(Bearing clearance) = (Connecting rod bearing inner diameter) −
(Crankshaft pin outer diameter)
H
Standard : 0.039 - 0.070 mm (0.0015 - 0.0028 in)
• If clearance exceeds the standard, select proper connecting rod
bearing according to connecting rod big end diameter and crank- I
shaft pin outer diameter to obtain specified bearing oil clearance. PBIC1642E
Refer to EM-266, "How to Select Piston and Bearing".

Method of Using Plastigage J
• Remove contamination such as engine oil, dust completely from
crankshaft pins and each bearing surface.
• Cut plastigage slightly shorter than bearing width, place it in crank- K
shaft direction, avoiding oil holes.
• Install connecting rod bearings to caps, and tighten connecting rod
nuts to the specified torque. L
CAUTION:
• Remove connecting rod caps and bearings, and measure plasti-
gage width using scale on plastigage bag. M
NOTE:
EM142
If out of specification, take same action mentioned in “Method by
Measurement”. N
MAIN BEARING OIL CLEARANCE
Method by Measurement
• Install main bearings to cylinder block and bearing cap, and tighten O
the bolts to the specified torque. Refer to EM-258, "Disassembly
and Assembly". Then, measure the inner diameter of main bear-
ings. P
(Bearing clearance) = (Bearing inner diameter) − (Crankshaft jour-
nal outer diameter)
Standard : 0.047 - 0.077 mm (0.0019 - 0.0030 in)
PBIC1644E
EM-277
CYLINDER BLOCK
• If out of the standard, check main bearing housing inner diameter and crankshaft journal outer diameter, and
select appropriate main bearing to adjust clearance to specifications. Refer to EM-266, "How to Select Pis-
ton and Bearing".
• Remove contamination such as engine oil and dust completely
from crankshaft journals and each bearing surface.
• Cut plastigage slightly shorter than bearing width. Place it in crank-
shaft turning direction, avoiding oil holes.
• Install main bearings and bearing cap and tighten to the specified
torque. Refer to EM-258, "Disassembly and Assembly" for the
tightening procedure.
CAUTION:
• Remove main bearings and bearing caps, and measure plastigage
width using scale on plastigage bag.
EM142
NOTE:
If out of specification, take same action mentioned in “Method by Measurement”.
CRUSH HEIGHT OF MAIN BEARING
• When bearing cap is removed after being tightened to the specified
torque with main bearings installed, the tip end of bearing must
protrude. Refer to EM-258, "Disassembly and Assembly".

• If out of the standard, replace main bearings.
SEM502G
CRUSH HEIGHT OF CONNECTING ROD BEARING

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-258, "Disassembly
and Assembly".

• If out of the standard, replace connecting rod bearings.
PBIC1646E
MAIN BEARING CAP BOLT DEFORMATION

• Measure the outer diameter of threaded area, “d1” and “d2”, at the
points specified in the figure.
• When the necked point is identified at a point other than where
specified, measure at the point as “d2”.
Limit : 0.13 mm (0.0051 in)

• If it exceeds the limit, replace main bearing cap bolt.
JEM219G
CONNECTING ROD BOLT DEFORMATION
EM-278
CYLINDER BLOCK
• Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on the A
bolt.
• If the nut does not screw in smoothly, measure the outer diameter
of the bolt thread at the point specified in the figure.
EM
• If a necked point is identified, measure at that point.

C
Limit : 8.75 mm (0. 3445 in) dia.
• If it exceeds the limit, replace connecting rod bolts and nuts.
JEM220G
D
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
E
Standard : No deformation and no damage.
• If out of the standard, replace oil jet.
F
JEM221G
OIL JET RELIEF VALVE H

• Using clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force.
I
Standard:
Valve moves smoothly with proper reaction force.
• If out of the standard, replace oil jet relief valve. J
K
JEM222G
FLYWHEEL DEFLECTION
• Measure the deflection of flywheel contact surface to clutch with a L
dial indicator.
• Measure the deflection at 210 mm (8.27 in) dia.
M
Standard : 0.45 mm (0.0177 in) or less.
• If measured value is out of the standard, replace flywheel.
CAUTION: N
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
PBIC2646E
O
MOVEMENT AMOUNT OF FLYWHEEL

CAUTION: P
Never disassemble double mass flywheel.
Movement Amount of Thrust (Fore-and-Aft) Direction
• Measure the movement amount of thrust (fore-and-aft) direction when 100 N (10.2 kg, 22 lb) force is added
at the portion of 125 mm (4.92 in) radius from the center of flywheel.
Standard : 1.3 mm (0.051 in) or less

EM-279
CYLINDER BLOCK
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transmis-
sion side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of the flywheel on the transmission side.
Standard: 32.0 mm (1.620 in) or less.

PBIC1263E

DRIVE PLATE
• Check drive plate and signal plate for deformation or cracks.
CAUTION:
• Never disassemble drive plate.
• Never place drive plate with signal plate facing down.
scratch it.
• Handle signal plate in a manner that prevents it from becom-
ing magnetized.
• If anything is found, replace drive plate.
SEM760G
EM-280
A
GENERAL SPECIFICATIONS EM

Displacement Unit: cm3 (cu in) 2,488 (151.82) C
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
D
Compression 2
Oil 1 E
Compression ratio 16.5
F
Standard 3,100 (31, 31.6, 450)
Minimum 2,500 (25, 25.5, 363)
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 490 (4.9, 5.0, 71) G
Valve timing I
EM120
Unit: degree K
a b c d e f
226 210 2 28 −2 48
L
Unit: mm (in)
Items Limit M
Surface distortion
Exhaust manifold 0.3 (0.012)
N
DRIVE BELTS
Belt Deflection:
O
Applied belt
A/C compressor, alternator and water 2.9 - 3.4 3.9 - 4.4 P
8.5 (0.335)
pump belt (0.114 - 0.134) (0.154 - 0.173)
4.6 - 5.4 7.1 - 7.7
(0.181 - 0.213) (0.280 - 0.303)
CYLINDER HEAD
EM-281
Unit: mm (in)
Cylinder head distortion Less than 0.04 (0.0016) 0.1 (0.004)
JEM204G
VALVE
Valve Dimensions
Unit: mm (in)
SEM188
Intake 28.0 - 28.3 (1.102 - 1.114)

Exhaust 26.0 - 26.3 (1.024 - 1.035)
Intake 106.72 (4.2016)
Valve length “L”
Exhaust 106.36 (4.1874)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)
Valve seat angle “α” Intake and exhaust 45 degrees 15′ - 45 degrees 45′
Intake 1.60 (0.0630)
Valve margin “T”
Exhaust 1.80 (0.0709)
Valve margin “T” limit More than 1.0 (0.039)
Valve stem end surface grinding limit Less than 0.2 (0.008)
Valve Clearance
Unit: mm (in)

Intake 0.24 - 0.32 (0.0094 - 0.0126) 0.274 - 0.386 (0.0108 - 0.0152)
Exhaust 0.26 - 0.34 (0.0102 - 0.0134) 0.308 - 0.432 (0.0121 - 0.0170)
Available Shims
EM-282
Stamped mark Thickness mm (in) A

2.10 2.10 (0.0827)
2.12 2.12 (0.0835)
EM
2.14 2.14 (0.0843)
2.16 2.16 (0.0850)
2.18 2.18 (0.0858) C
2.20 2.20 (0.0866)
2.22 2.22 (0.0874)
2.24 2.24 (0.0882) D
2.26 2.26 (0.0890)
2.28 2.28 (0.0898)
E
2.30 2.30 (0.0906)
2.32 2.32 (0.0913)
2.34 2.34 (0.0921) F
2.36 2.36 (0.0929)
2.38 2.38 (0.0937)
G
2.40 2.40 (0.0954)
2.42 2.42 (0.0953)
2.44 2.44 (0.0961) H
2.46 2.46 (0.0969)
2.48 2.48 (0.0976)
I
2.50 2.50 (0.0984)
2.52 2.52 (0.0992)
2.54 2.54 (0.1000) J
2.56 2.56 (0.1008)
2.58 2.58 (0.1016)
2.60 2.60 (0.1024) K
2.62 2.62 (0.1031)
2.64 2.64 (0.1039)
L
2.66 2.66 (0.1047)
2.68 2.68 (0.1055)
2.70 2.70 (0.1063) M
2.72 2.72 (0.1071)
2.74 2.74 (0.1079)
N
SEM512G
Valve Spring
EM-283
Valve spring square mm (in) 1.9 (0.075)

Free height mm (in) 43.7 (1.72)
Pressure N (kg, lb) at height mm (in) 184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
Height during valve open mm (in) 24.82 (0.9772)
Load with valve open N (kg, lb) 320 - 360 (32.65 - 36.73, 71.9 - 80.9)
Valve Lifter
Unit: mm (in)
Items Standard
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)
Valve Guide
Unit: mm (in)
JEM156G
Items Standard Service

Valve guide Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.10 (0.0040)
Valve Seat
EM-284
Unit: mm (in)
A
EM
PBIC4054E
JEM253G
M
Items Standard Oversize (Service) [0.5 (0.020)]
Cylinder head seat (1) recess diame- Intake 30.000 - 30.016 (1.1811 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)
ter “D” Exhaust 29.000 - 29.016 (1.1417 - 1.1424) 29.500 - 29.516 (1.1614 - 1.1620) N
Intake (A) 30.080 - 30.100 (1.1842 - 1.1850) 30.580 - 30.600 (1.2039 - 1.2047)
Valve seat outer diameter “d”
Exhaust (B) 29.080 - 29.096 (1.1449 - 1.1455) 29.580 - 29.596 (1.1646 - 1.1652)
O
Intake (A) 0.064 - 0.100 (0.0025 - 0.0039)
Exhaust (B) 0.064 - 0.096 (0.0025 - 0.0038)
Intake (A) 27.15 - 27.65 (1.0689 - 1.0886) 26.05 - 26.55 (1.0256 - 1.0453) P
Diameter “d1”
Exhaust (B) 24.95 - 25.45 (0.982 - 1.0020) 24.15 - 24.65 (0.9508 - 0.9705)
Intake (A) 26.00 - 26.50 (1.0236 - 1.0433) —
Diameter “d2”
Exhaust (B) —
Intake (A) 25.3 - 25.7 (0.996 - 1.012)
Diameter “d3”
Exhaust (B) 23.3 - 23.7 (0.917 - 0.933)
EM-285
Angle “α” 43°30′ - 46°30′
Intake (A) 7.0 - 7.1 (0.276 - 0.280) 6.6 - 6.7 (0.260 - 0.264)
Height “h1”
Exhaust (B) 6.7 - 6.8 (0.264 - 0.268) 6.3 - 6.4 (0.248 - 0.252)
Intake (A) 2.23 - 2.43 (0.0878 - 0.0957) 2.13 - 2.53 (0.0839 - 0.0996)
Height “h2”
Exhaust (B) 2.76 - 2.96 (0.1087 - 0.1165) 2.66 - 3.06 (0.1047 - 0.1205)
Intake 8.83 - 9.13 (0.3476 - 0.3594)
Depth “H”
Exhaust 9.06 - 9.36 (0.3567 - 0.3685)
Intake 36.53 - 36.98 (1.4382 - 1.4559)
Projection (L)
Exhaust 36.53 - 37.01 (1.4382 - 1.4571)
CAMSHAFT
Unit: mm (in)

Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034)
No.1 30.500 - 30.521 (1.2008 - 1.2016)
Camshaft bracket inner diameter
No. 2, 3, 4, 5 24.000 - 24.021 (0.9449 - 0.9457) —
No. 1 30.435 - 30.455 (1.1982 - 1.1990)
Camshaft journal outer diameter
No. 2, 3, 4, 5 23.935 - 23.955 (0.9423 - 0.9431)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
Camshaft end play 0.070 - 0.148 (0.0028 - 0.0058) 0.24 (0.0094)
SEM671
Intake 39.505 - 39.695 (1.5553 - 1.5628)

Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
CYLINDER BLOCK
Unit: mm (in)
SEM899G
EM-286
Standard Less than 0.03 (0.0012)
Top surface distortion A
Limit 0.1 (0.004)
Grade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047) EM
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.07 (0.0028)
Out-of-round (Difference between X and Y) 0.015 (0.0006) C
Limit
Taper (Difference between A and C) 0.010 (0.0004)
Main bearing housing inner diameter (Without bearing) 66.654 - 66.681 (2.6242 - 2.6252)
D
between cylinders
PISTON, PISTON RING AND PISTON PIN E

Available Piston
Unit: mm (in)
F
I
MBIA0026E
Grade No. 1 88.928 - 88.942 (3.5011 - 3.5016) J

Grade No. 2 88.938 - 88.952 (3.5015 - 3.5020)
Piston outer diameter “A” Standard Grade No. 3 88.948 - 88.962 (3.5019 - 3.5024)
Oversize (Service) [0.25 (0.0098)] 89.188 - 89.202 (3.5113 - 3.5119) K
Oversize (Service) [0.5 (0.020)] 89.438 - 89.452 (3.5212 - 3.5217)
“a” dimension 11.0 (0.43)
L
Piston to cylinder bore clearance 0.058 - 0.082 (0.0023 - 0.0032)
Piston Ring M
Unit: mm (in)

N
Top 0.050 - 0.090 (0.0020 - 0.0035) 0.2 (0.008)
Side clearance 2nd 0.050 - 0.090 (0.0020 - 0.0035) 0.1 (0.004)
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) — O
Top 0.21 - 0.28 (0.0083 - 0.0110)
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039)
P
Oil ring 0.30 - 0.55 (0.012 - 0.0217)
Piston Pin
Unit: mm (in)

Piston to piston pin clearance 0.003 - 0.014 (0.0001 - 0.0006)
EM-287
Standard 0.026 - 0.043 (0.0010 - 0.0017)
Connecting rod bushing clearance
Limit 0.057 (0.0022)
CONNECTING ROD
Unit: mm (in)
Center distance 154.5 (6.083)

Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter* 55.000 - 55.013 (2.1654 - 2.1659)
Standard 0.20 - 0.35 (0.0080 - 0.0138)
Side clearance
Limit 0.40 (0.016)
CRANKSHAFT
Unit: mm (in)
Main journal dia. “Dm” 62.951 - 62.975 (2.4784 - 2.4793)

Pin journal dia. “Dp” 51.954 - 51.974 (2.0454 - 2.0462)
Out-of-round (Difference between X Standard 0.003 (0.0001)

and Y) Limit 0.005 (0.0002)
Standard 0.003 (0.0001)
Taper (Difference between A and B)
Limit 0.005 (0.0002)
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0040)
Standard 0.10 - 0.25 (0.0040 - 0.0098)
End play
Limit 0.30 (0.012)
SEM645 SBIA0535E

Main bearing
EM-288
Unit: mm (in)
A
EM
D
SEM255G
Grade number Thickness Width Identification color

E
STD 0 1.816 - 1.820 (0.0715 - 0.0717) Black
STD 1 1.820 - 1.824 (0.0717 - 0.0718) Brown
STD 2 1.824 - 1.828 (0.0718 - 0.0720) 19.9 - 20.1 (0.783 - 0.791) Green
F
STD 3 1.828 - 1.832 (0.0720 - 0.0721) Yellow
STD 4 1.832 - 1.836 (0.0721 - 0.0723) Blue
G
Undersize
Unit: mm (in)
Size Thickness Main journal diameter “Dm”

H
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769)
ified value.
AVAILABLE CONNECTING ROD BEARING I

Connecting Rod Bearing
Unit: mm (in)
J
Grade number Thickness Width Identification color (mark)
STD 0 1.492 - 1.496 (0.0587 - 0.0589) Black
22.9 - 23.1
STD 1 1.496 - 1.500 (0.0589 - 0.0591)
(0.902 - 0.909)
Brown K
STD 2 1.500 - 1.504 (0.0591 - 0.0592) Green
Undersize
L
Unit: mm (in)
Size Thickness Crank pin journal diameter “Dp”

0.08 (0.0031) 1.536 - 1.540 (0.0605 - 0.0606) M
0.12 (0.0047) 1.556 - 1.560 (0.0613 - 0.0614)
ified value.
0.25 (0.0098) 1.621 - 1.625 (0.0638 - 0.0640)
N
Flywheel
Unit: mm (in) O
Flywheel deflection [TIR]* Standard 0.45 (0.0177) or less
P
Bearing Clearance
Unit: mm (in)

Connecting rod bearing oil
Standard 0.039 - 0.070 (0.0015 - 0.0028)
clearance
EM-289
PRECAUTIONS
< SERVICE INFORMATION > [ZD30DDTi]
SERVICE INFORMATION
PRECAUTIONS

• Never disconnect battery terminal while engine is running.

D4D engine : 20 minutes YS23DDT : 4 minutes
M9R engine : 4 minutes ZD30DDTT : 60 seconds
SEF289H
NOTE:
• After high-load driving, if the vehicle is equipped with the V9X engine, turn the ignition switch OFF and wait
NOTE:
NOTE:
NOTE:
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
Always observe the following items for preventing accidental activation.
the event of a collision that would result in air bag inflation, it is recommended that all maintenance
and repair be performed by an authorized NISSAN/INFINITI dealer.
• Improper repair, including incorrect removal and installation of the SRS, can lead to personal injury
caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module,
see “SRS AIR BAG”.
• Never use electrical test equipment on any circuit related to the SRS unless instructed to in this Ser-
vice Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness
connectors.
EM-290
PRECAUTIONS
WARNING:
Always observe the following items for preventing accidental activation. A
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, never use air or electric power tools or strike near the sensor(s) with
a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly causing
EM
serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery or batteries, and wait at least 3 minutes before performing any service.
C
DISCONNECTING FUEL PIPING D

E
F
replace if necessary. G

H
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, I
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly. J
in the step.
K
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the L
• Replace with new gasket, packing, oil seal or O-ring. M
Before assembly, oil sliding surfaces well. N
• After disassembling, or exposing any internal engine parts, change engine oil and replace oil filter with a new
one.
• Release air within route when refilling after draining engine coolant. O
P
EM-291
PRECAUTIONS
tightening)
• The torque value for these parts are for a preliminary step.
REMOVAL OF LIQUID GASKET

surface using the seal cutter (SST) and remove the old liquid gas-
ket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
as shown in the figure.
mer to lightly tap the parts, to remove it.
CAUTION:
PBIC0275E
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
uid gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the
holes.
2. Wipe the liquid gasket application surface and the mating sur-
adhering moisture, grease and foreign materials.
PBIC0003E
3. Attach the liquid gasket tube to the tube presser (SST).

4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
liquid gasket to the groove.
PBIC2160E
• As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If the liquid gasket protrudes, wipe it off immediately.
• After 30 minutes or more pass from the installation, fill the
CAUTION:
SEM159F
EM-292
PREPARATION
PREPARATION
A
EM
Tool number
Description
Tool name
KV10111100 Removing parts applied with liquid gasket
C
Seal cutter
S-NT046
E
G
S-NT820
KV10109300 a: 68 mm (2.68 in)

Pulley holder b: 8 mm (0.31 in) dia. H
S-NT628
KV101151S0 Changing adjusting shim J

Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120 K
Lifter stopper
S-NT041 L
KV10112100 Tightening bolts for lower cylinder block, cylin-
Angle wrench der head, etc.
M
N
S-NT014
KV101092S0 Disassembling and assembling valve compo-

Valve spring compressor nents O
1 KV10109210
Compressor
3 KV10109220
P
Adapter (M8)
NT718
EM-293
PREPARATION
Tool number
Description
Tool name
1 KV10116100
S-NT605

a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421)
c: 10.3 (0.406) dia. f: 5 (0.20)
Unit: mm (in)
S-NT603

Tube presser
S-NT052
ST16610001 Removing pilot bearing

Pilot bearing puller
ZZA0046D

S-NT044
EM-294
PREPARATION
Tool number
Description
Tool name A
Deep socket (12 mm) Removing and installing glow plugs
EM
C
NT821

D
S-NT048
F
H
S-NT030
Engine stand When overhauling engine
KBIA2232E
Pulley puller Removing fuel supply pump gear K
ZZB0807D M
EM-295
PBIC2206E

EM-296
4. Check specified noise source. A
Operating condition of engine EM

up up ing C
gine clicking noise
Rocker
cover Camshaft D
head noise
Piston to piston pin E

— A — B B —
clearance
F
Piston-to-bore clear-
Crank- ance
EM-388
shaft pul- Piston ring side clear-
Slap or Piston EM-388
ley A — — B B A ance G
rap slap noise EM-388
Cylinder Piston ring end gap
EM-388
H
Oil pan ing rod clearance (Small end) EM-388
Knock A B C B B B
noise clearance (Big end) I
Main bear- EM-388
ing noise EM-388
Crankshaft runout J
Front of Timing
Timing chain cracks
engine chain and
Tapping or and wear EM-353
Timing A A — B B B chain ten-
ticking Timing chain tensioner EM-353 K
chain cov- sioner
operation
er noise
Other
Squeak- drive belt L
ing or fizz- A B — B — C (Sticking Drive belt deflection
ing or slip-
ping) EM-300
Front of M
Other
engine Pulley bearing opera-
Creaking A B A B A B drive belt
tion
(Slipping)
Water N
Squall
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related O
EM-297
ENGINE COVERS
ENGINE COVERS
MBIB9173E
EM-298
ENGINE COVERS
A
REMOVAL
EM
4. Remove mountings bolts and remove covers. C
INSTALLATION
D
EM-299
DRIVE BELTS
DRIVE BELTS
Checking Drive Belt INFOID:0000000013949806
NOTE:
Adjustment of belt deflection is basically not necessary; however followings points can be checked:
• Check for any damage or crack of belt rib.
• Check that the belt is free of dust, sand, etc.
• Check for oil leakage on the auto-tension damper unit
Tension Adjustment INFOID:0000000013949807
Belt tensioning is not necessary as it is automatically adjusted by the auto-tension damper unit.
REMOVAL
Using a wrench (longer than 500 mm (16.69 in) apply torque to the
nut (A) in the direction shown in the figure.
CAUTION:
Never apply excessive load to the nut and turn slowly.
1. Remove belt from alternator.
CAUTION:
Never put hands within area where they may be caught by
belt if retaining tool slips off.
PBIC2208E
MBIB9069E
NOTE:
EM-300
DRIVE BELTS
Arrow on the auto-tension damper unit must be faced upward.
A
Auto- tension damper unit height “a”:
Installed: 77.5 mm (3.051 in)
EM
Extended to the max: 84.5 (3.327 in)
MBIB9111E
D
INSTALLATION
1. Install the belt on each pulley except alternator pulley).
2. Using a wrench (longer than 500 mm (16.69 in) apply torque to the nut (A) in the direction shown in the E
figure.
CAUTION:
Never apply excessive load to the nut and turn slowly.
3. Install belt on the alternator pulley and release torque. F
CAUTION:
Never put hands within area where they may be caught by belt if retaining tool slips off.
G
Drive Belt Auto Tensioner INFOID:0000000013949808
E1BIA0242GB M
1. Damper unit 2. Pulley

: “TOP” installation in upward direction N
REMOVAL
1. Remove drive belt. Refer to EM-300, "Tension Adjustment". O
• Do not remove auto tensioner holder (Service parts) installed to driver belt auto tensioner damper unit.
2. Remove damper unit and tensioner pulley.
3. Remove idler pulley. P
• Check that pulley has no looseness and rotates smoothly.
• Check damper unit for oil leakage.
INSTALLATION
CAUTION:
EM-301
DRIVE BELTS
Never remove auto tensioner holder (Service parts) until drive belt installation is completed.
EM-302
A
Type 1 EM
MBIB9140E
N
1. Air duct 2. Air tube 3. Air cleaner case (upper)
4. Air cleaner filter 5. Air cleaner case (lower) 6. Air cleaner bracket
7. Air duct side O
A. Air cleaner assembly B. To tube inlet assembly C. Air flow meter
(turbocharger)
D. Arrow mark E. Mating mark F. Mating mark P
EM-303
Type 2
E1BIA0423GB
1. Air pipe 2. Air duct 3. Air flow meter

4. Air cleaner case assembly 5. Air duct side 6. Frame
7. Air tube 8. Cap
A. Air cleaner case (upper) B. Air cleaner filter C. Air cleaner case (lower)
X. Distance from air duct (X=0)

REMOVAL
1. Disconnect air flow meter harness connector from mass air flow sensor.
CAUTION:
Handle mass air flow meter with care.
EM-304
• Do not touch its sensor. A
Inspect air duct for crack or tear.
• If anything found, replace air duct. EM
INSTALLATION
• Align marks. Attach each joint. Screw clamps firmly. C
Changing Air Cleaner Filter INFOID:0000000013949811
D
REMOVAL
1. Unhook clips, and lift air cleaner case (upper). E
INSTALLATION
Installation is the reverse order of removal. F
EM-305
CHARGE AIR COOLER
CHARGE AIR COOLER
E1BIA0243GB
1. Clamp 2. Air hose 3. Air hose

4. Inlet tube 5. Tube 6. Air hose
7. Charge air cooler 8. Radiator assembly 9. Bracket
10. Turbocharger 11. Intake manifold 12. Washer
13. Stud 14. Pressure sensor 15. Pressure sensor mounting bolts
A. View A B. View B C. Rib aligned with paint mark
D. Paint mark E. View E F. View F
REMOVAL
3. Disconnect the pressure sensor.
EM-306
CHARGE AIR COOLER
remove air hoses and tube hoses. A
CAUTION:
EM
charge air cooler if necessary. C
INSTALLATION
Note the following, and install in the reverse order of removal. D
• Pay attention to identification mark color and direction when installing air tubes and hoses.
• Tighten bolts and nuts to the specified torques.
E
EM-307
EGR SYSTEM
EGR SYSTEM
MBIB9070E
1. Water pipe 2. Gasket 3. EGR tube

4. Gasket 5. EGR cooler 6. Water pipe
7. Bracket 8. Gasket 9. EGR volume control valve
10. Water hose 11. Gasket 12. Water hose
A: To water pipe B: To exhaust manifold C: To cylinder block
D: To cylinder block
REMOVAL
1. Remove oil level gauge bracket.
2. Remove EGR bracket.
3. Drain engine coolant.
4. Disconnect EGR cooler from the water pipe.
5. Disconnect EGR connecting hoses to EGR volume control valve.
6. Disconnect EGR volume control valve connecting hose to cylinder block.
7. Disconnect EGR connecting hose to cylinder block.
8. Remove EGR tube.
9. Remove EGR cooler.
10. Remove EGR volume control valve.
INSTALLATION
1. Replace all gaskets by new ones.
2. Finger tighten all mountings bolts.
3. Tighten mountings bolts in few steps.
4. Tighten brackets at the end.
EM-308
EGR SYSTEM
5. Tighten mountings bolts to the specified torques.
A
1. Check engine coolant level.
2. Start engine, and check engine coolant and exhaust gas for leakage. EM
EM-309
CATALYST
CATALYST
EXCEPT RUSSIA / UKRAINE MODELS
E1BIA0247GB
1. Exhaust manifold cover 2. Exhaust outlet cover 3. Exhaust manifold

4. Gasket 5. Turbocharger assembly 6. Gasket
7. Catalyst assembly 8. Bracket 9. Catalyst cover LH
10. Catalyst outlet cover 11. Bracket 12. Stud
13. Bracket 14. Bracket 15. Catalyst cover RH
A. To cylinder block B. To front exhaust tube
RUSSIA / UKRAINE MODELS
EM-310
CATALYST
EM
I
E1BIA0213GB
1. Exhaust outlet bolts 2. Turbocharger nut 3. Turbocharger bolts

J
4. Catalyst cover RH 5. Catalyst cover bolt 6. Cylinder block
7. Bracket bolt 8. Plain washer 9. Bracket
10. Bracket bolt (x2) 11. Bracket 12. Bracket bolt
K
13. Bracket bolt 14. Bracket bolt 15. Plain washer
16. Bracket 17. Nut 18. Stud
19. Catalyst cover center 20. Catalyst cover bolt 21. Catalyst cover bolt
L
22. Catalyst cover bolt 23. Catalyst cover LH 24. Catalyst cover bolt (x2)
25. Bracket bolt 26. Plain washer (x2) 27. Bracket bolt
28. Bracket 29. Exhaust outlet bolt 30. Catalyst converter assembly
M
31. Washer wire mesh 32. Catalyst converter cap 33. Exhaust outlet
34. Turbocharger gasket 35. Turbocharger stud
N

O
REMOVAL
1. Apply penetrating lubricant to bolts and nuts before operation. Loosen bolts and nuts when lubricant has
P
penetrates enough.
3. Remove front tube mountings nuts from catalyst and remove front tube and exhaust muffler.
4. Remove all brackets.
5. Remove mountings bolts and nuts from the turbocharger.
6. Remove the catalyst from down side.
EM-311
CATALYST
7. Remove covers from the catalyst if necessary.
INSTALLATION
• Replace all gasket by new ones and reinstall in the reverse order of removal.
• Install bolts and nuts to the specified torques.
• Start engine and check for exhaust gas leakage.
EM-312
INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
I
MBIB9071E
1. Gasket 2. Intake manifold 3. Throttle chamber J

4. Gasket 5. EGR volume control valve 6. Gasket
7. Solenoid valve bracket 8. Bracket
Refer to GI-9, "Component" for symbol marks in the figure. K
REMOVAL
1. Remove EGR cooler and EGR volume control valve. L
2. Remove spill tube bracket.
3. Disconnect vacuum hose from swirl control actuator (if equipped).
4. Remove bracket securing the intake manifold to the block cylinder. M
5. Remove intake manifold.
• Loosen and remove bolts and nuts in the reverse of the order
shown in the figure. N
6. If necessary remove following parts from the intake manifold.
• Throttle chamber
• Remove solenoid valve and solenoid valve bracket
O
MBIB9063E

Surface Distortion
EM-313
INTAKE MANIFOLD
Inspect surface distortion of intake manifold using straightedge and
feeler gauge.
Limit : 0.2 mm (0.008 in)

• Replace intake manifold if outside the limit.
MBIB9058E
INSTALLATION
Intake Manifold
• Tighten in numerical order as shown in the figure.
• Tighten mountings bolts and nuts to the specified torque.
• Replace all gaskets by new ones.
MBIB9063E
MBIB9055E
1. Stopper thrust 2. Valve screw 3. Control valve

4. Intake manifold body 5. Lip seal 6. Shaft assembly
7. Washer 8. Snap ring 9. Swirl control actuator - models with-
out DPF (Diesel Particulate Filter)
DISASSEMBLY
1. Remove Stopper thrust.
EM-314
INTAKE MANIFOLD
2. Remove swirl control actuator mounting bolts.
3. Remove snap ring from the shaft. A
4. Remove all valve screws.
5. Remove all valves.
EM
6. Remove shaft from the intake manifold body.
ASSEMBLY
Reassemble in reverse order of disassembly, paying attention to the following points: C
• Take precaution to not bend the shaft.
• Replace Stopper thrust, valve screws, lip seal and snap ring by new parts.
• Before inserting the lip seal, spread oil on the seal outer, and press fit into the intake manifold body.
• Install valve with arrow in opposite direction of the swirl control D
actuator.
• After installation of all parts, check for smooth operation.
E
MBIB9059E
G
EM-315
TURBO CHARGER
TURBO CHARGER
MBIB9072E
1. Exhaust manifold cover 2. Exhaust outlet cover 3. Exhaust manifold

4. Copper washer 5. Oil feed tube 6. Eye-bolt
7. Gasket 8. Turbocharger assembly 9. Gasket
10. Air suction pipe 11. Gasket 12. Oil return tube
13. Gasket 14. Catalyst assembly
A. To oil cooler B. To cylinder block
EM-316
TURBO CHARGER
EM
I
E1BIA0214GB
1. Exhaust outlet cover 2. Fixing bolts 3. Exhaust manifold

J
4. Turbocharger assembly 5. Gasket 6. Exhaust outlet
7. Exhaust outlet nut 8. Exhaust outlet bolt 9. Copper washer
10. Eye bolt 11. Intake water tube assembly 12. Eye bolt
K
13. Positioning pin 14. Exhaust water tube assembly 15. Water hose
16. Clamp hose
A. To catalyst converter assembly B. To oil cooler
L
REMOVAL
1. Apply penetrating lubricant to bolts and nuts before operation. Loosen bolts and nuts when lubricant has M
penetrates enough.
2. Remove air suction pipe.
3. Remove oil return tube for turbocharger. N
4. Remove oil feed tube for turbocharger on oil cooler side.
5. Remove exhaust manifold nuts securing turbocharger to the exhaust manifold, and then remove turbo-
O
charger.
CAUTION:
• Never hold VNTC control actuator and actuator rod. P
• Check the following route if compressor wheel, turbine wheel, and/or rotor shaft were broken.
Remove all fragments and other foreign materials in order to avoid secondary contamination.
Intake side: Between turbocharger and intercooler
Exhaust side: Between turbocharger and muffler
6. Remove oil feed tube from turbocharger.
• Put matching marks on oil feed tube and turbocharger before removing to ensure they are installed in
original direction.
EM-317
TURBO CHARGER
CAUTION:
Never disassemble or adjust turbocharger assembly.
MBIB9061E
1. Variable nozzle turbocharger 2. Turbine wheel 3. Compressor wheel

(VNTC) control actuator
A. Check for negative air pressure B. Check for exhaust gas leaks C. Check for charge air pressure leaks
leaks
D. Check for oil leaks
• Refer to the figure for component names and visually check points.
NOTE:
The following figures show the image of the inspection procedure. (Existing parts are not the same shape as
the parts in the figure.)
Oil tubes
• Clean inside of oil feed tube and oil return tube, and check tubes for clogging.
• Replace oil feed tube or oil return tube if clogging still exists after cleaning.
Turbocharger
• Perform the following inspection, and then clean it if there are any deposits.
• Replace turbocharger if it is not functioning normally or outside the standard.
• Clean before checking.
• Clean oil feed/return port.
MBIB9073E
EM-318
TURBO CHARGER
• Dry it using an air gun after cleaning.
• Dry compressor wheel, turbine wheel, compressor housing, and A
turbine housing using an air gun.
EM
MBIB9074E
D
Rotor shaft oil clearance
tance when it is rotated by fingertips.
• Shake rotor shaft vertically and horizontally and check for loose- E
ness.
Standard : 0.056 - 0.127 mm (0.0022 - 0.0050 in) F

• Replace turbocharger assembly if resistance and/or looseness are
noted.
• Check for carbon sludge deposits. G
MBIB9068E
Rotor shaft end play H

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

J
K
MBIB9060E
Turbine wheel
• Check for engine oil stains on turbine wheel. L
• Check for carbon deposits.
• Check that turbine wheel (2) vane is not bent or broken.
• Check for interference with turbine housing (1).
M
MBIB9066E O
Compressor wheel
EM-319
TURBO CHARGER
• Check for engine oil stains inside inlet port.
• Check for interference with compressor housing (2).
• Check that compressor wheel (1) is not bent or broken.
MBIB9065E
VNTC control actuator (EXCEPT RUSSIA / UKRAINE MODELS)

• Disconnect vacuum hose on VNTC control solenoid valve side,
and connect the handy vacuum pump to the VNTC control actua-
tor.
• Check that actuator rod is operated strokes smoothly in compli-
ance with the following pressure.
• First, apply the negative air pressure of about -66.7 kPa (-667
mbar, -500 mmHg, -19.69 inHg).
• Then, measure the values while reducing the negative air pressure
to 0.
SEM311G
Standard (Pressure/rod stroke amount)

: -42.9 to -50.9 kPa (-429 to -509 mbar, -322 to -382 mmHg, -12.68 to -15.04 in-
Hg)/0.2 mm (0.008 in)
-21.0 to -22.4 kPa (-210 to -224 mbar, -158 to -168 mmHg, -6.20 to -6.61 inHg)/
8.3 mm (0.327 in)
CAUTION:
Diaphragm in VNTC control actuator may be damaged if excessive negative air pressure is applied.
Check that vacuum pump pressure is within the standard by using pressure gauge to check before
applying pressure to VNTC control actuator.
VNTC control actuator (RUSSIA / UKRAINE MODELS)
• Disconnect vacuum hose on VNTC control solenoid valve side,
and connect the handy vacuum pump to the VNTC control actua-
tor.
• Check that actuator rod is operated strokes smoothly in compli-
ance with the following pressure.
• Apply air pressure to VNTC control solenoid valve.
• Then, measure the values.
SEM805C
Standard (Pressure/rod stroke amount)

: 157.7 to 170.9 kPa (1577 to 1709 mbar, 1182 to 1281 mmHg, 46.54 to 50.43
inHg)/0.2 mm (0.008 in)
: 176.7 to 190.3 kPa (1767 to 1903 mbar, 1325 to 1427 mmHg, 52.17 to 56.18
inHg)/4 mm (0.157 in)
CAUTION:
EM-320
TURBO CHARGER
Diaphragm in VNTC control actuator may be damaged if excessive air pressure is applied. Check
that air pressure system is within the standard by using pressure gauge to check before applying A
pressure to VNTC control actuator.
Do not keep applying air pressure to the actuator.
Trouble diagnosis of turbocharger EM
Check items before trouble diagnosis
1. Check that the engine oil level is between L (Low level) and H (High level) of the oil level gauge. (When
the engine oil amount is more then H (High level), the engine oil flows into the inlet duct through the blow- C
by gas passage, and the turbocharger is misjudged failure.) Refer to LU-23.
2. Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving. D
table below.
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunc-
tions. Check the other parts again. E
Symptoms likely to occur when the results shown on

the left exist. F
Inspection Location Result Poor pow-
er
Oil leakage Smoke Noise
Poor ac- G
celeration
Wet with oil. C A C C
Carbon deposits observed. C A B B H
Turbine wheel
“Rubs against” housing. C B A B
Vane is bent or broken. A A
I
Inside of intake port is badly stained
B B
with oil.
Compressor wheel
“Rubs against” housing. C B A B
J
Vane is bent or broken. A A
Heavy feel or catching when turned by
C C B
hand.
Check both turbine and compres- K
sor rotor shaft end play. Cannot be turned by hand. A
Excessively loose bearing. C C B C
Rotor shaft, oil return port (Check Carbon or sludge deposits in oil drain L
C A C C
inside using penlight.) port.
• Does not operate smoothly when
negative air pressure is gradually M
VNTC control actuator operation
applied. A
(using a handy vacuum pump)
• Stroke amount is not compliance
with the negative air pressure.
N
A: Highly possible. B: Possible. C: May exist.
INSTALLATION O
Installation of Oil Feed Tube
• Install oil feed tube in the original direction in accordance with the matching marks put on before removing. P

Start engine, and raise engine speed to check that there is no exhaust gas and no engine oil leakage.
EM-321
EXHAUST MANIFOLD
EXHAUST MANIFOLD
MBIB9076E
1. Exhaust manifold cover 2. Exhaust manifold 3. Gasket

4. Gasket 5. Gasket 6. EGR tube
A. To EGR cooler B. To turbocharger assembly
REMOVAL
1. Remove turbocharger. Refer to EM-316.
2. Remove EGR tube. Refer to EM-308
4. Loosen mounting nuts in reverse order shown in the figure, and
remove exhaust manifold.
NOTE:
Disregard No.9 to 16 when loosening.
MBIB9062E

Surface Distortion
EM-322
EXHAUST MANIFOLD
• Use a reliable straightedge and feeler gauge to check the flatness
of exhaust manifold fitting surface. A
Limit : 0.2mm (0.008in)

• If it exceeds the limit, replace exhaust manifold. EM
PBIC2210E
D
INSTALLATION
• Install in the reverse order of removal.
Exhaust Manifold E
• Install exhaust manifold and tighten mounting nuts in order shown
in the figure (Double tightening).
F
: 42.0 N·m (4.3 kg-m, 31 ft-lb)
H
MBIB9062E
EGR tube
• Install EGR tube. Refer to EM-308. I
• Start engine, and raise engine speed to check no exhaust gas leaks.
J
EM-323
MBIB9077E
1. Oil pan upper 2. Oil pan lower 3. Washer

4. Drain plug 5. Oil strainer 6. Gasket
7. Oil level sensor
A. To cylinder block
REMOVAL
WARNING:
Never drain the engine oil when the engine is hot to avoid the danger of being scalded.
1. Remove drain plug, and drain engine oil. Refer to LU-24.
2. Pull out oil level gauge.
3. Remove oil level sensor.
CAUTION:
Handle it carefully and avoid impacts.
4. Remove transmission assembly to access to oil pan rear mount-
ings bolts. Refer to MT-27, "Removal and Installation from Vehi-
cle" (M5-40A), MT-5 (6S380).
5. Remove oil pan with the following procedure:
MBIB9096E
EM-324
a. Loosen and remove oil pan mounting bolts in the reverse order
shown in the figure. A
EM
KBIA0762E
D
b. Separate liquid gasket using a seal cutter (SST), and remove oil
pan.
CAUTION:
E
Exercise care not to damage mating surface.
NOTE:
Temporarily tighten two mounting bolts to the bolt holes of center
position of oil pan LH/RH when removing oil pan, to prevent oil F
pan dropping.
c. Remove the two mounting bolts, and remove oil pan.
6. Remove baffle plate from oil pan if necessary. G
7. Remove oil strainer. PBIC0275E
8. If necessary, separate liquid gasket between the oil pan lower and oil pan upper using a seal cutter.
CAUTION: H
Exercise care not to damage mating surface.
• Make sure that there is no foreign material on the oil strainer. I
• Clean oil strainer if necessary.
INSTALLATION J
1. Install oil strainer.
2. If the lower pan is removed, apply liquid gasket thoroughly as
shown in the illustration. K
3. Tighten mountings bolts to the specified torque.
4. Retighten mountings bolts to the specified torque. L
MBIB9110E
N
5. Apply liquid gasket thoroughly to the oil pan lower as shown in
the illustration.
Use Genuine Liquid Gasket or an equivalent. O
MBIB9108E
EM-325
6. Tighten mounting bolts to specified torque in the numerical
order.
7. Retighten mounting bolts to specified in order shown in the fig-
ure.
• Pour engine oil 30 minutes or more after oil pan is installed.
KBIA0762E

• Inspection engine oil level. Refer to LU-23.
• Start the engine, and check that there is no engine oil leakage. Refer to LU-23.
EM-326
GLOW PLUG
GLOW PLUG
A
EM
J
MBIB9107E
1. Glow harness 2. Washer 3. Connection plate K

4. Glow plug oil seal 5. Glow plug 6. Rocker cover
A. Refer to text B. Matching marks
*: Refer to GI-9, "Component" for symbol marks in the figure. L
REMOVAL
1. Remove glow harness. M
2. Remove glow plug oil seal. Refer to EM-341.
CAUTION: N
• Never use tools that apply an impact, such as an air
impact wrench, when removing or installing.
• Handle it carefully without giving any impact, even after
O
removal. [As a guide, if it drops from height of 10 cm (3.94
in) or higher, always replace it.]
PBIC2092E
INSTALLATION
1. Remove carbon adhering to glow plug installation hole with a reamer.
EM-327
GLOW PLUG
3. Install glow plug oil seal.
EM-328
VACUUM PUMP
VACUUM PUMP
A
EM
J
E1BIA0212GB
1. Eye bolt 2. Oil feed tube 3. Copper washer K

4. O-ring 5. Vacuum pump 6. Packing
7. Vacuum pump connector 8. Vacuum pump connector bolt
A. To vacuum hose L
*: Refer to GI-9, "Component"for symbol marks in the figure.
REMOVAL M
CAUTION:
Never disassemble vacuum pump.
1. Disconnect vacuum hose. N
EM-329
VACUUM PUMP
2. Remove feed oil tubes in the reverse order shown in the figure.
3. Remove vacuum pump.
• Remove mounting bolts, and pull off vacuum pump straight
toward front of engine.
• Tap it with a plastic hammer to remove if it is difficult to be
pulled off due to stuck spline.
4. Remove O-ring.
MBIB9081E
INSTALLATION
1. Install new O-ring to vacuum pump.
2. Install vacuum pump.
CAUTION:
Install O-ring (1) making sure (2) that it is correctly engaged
with the vacuum pump groove.
MBIB9078E
3. Replace copper washers by new ones.

• Tighten vacuum pump connector (upper) in specified torque.
EM-330
VACUUM PUMP
4. Reinstall feed oil tubes in the order shown in the figure.
A
: 18.5 N·m (1.9 kg-m, 14 ft-lb)
EM
G
MBIB9081E

Following the steps below, check vacuum generated by vacuum pump. H
1. Connect a vacuum gauge to any point where vacuum generated by vacuum pump can be measured.
2. Start engine, and measure vacuum generated at idle speed.
I
Standard : -93.3 to -101.3 kPa (-933 to -1,013 mbar, -700 to -760 mmHg, -27.56 to -29.91 inHg)
• If outside of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump. J
EM-331
INJECTION TUBE AND COMMON RAIL ASSEMBLY
MBIB9138E
1. Injector tube No.1 2. Injector tube No.2 3. Injector tube No.3

4. Injector tube No.4 5. Fuel supply tube 6. Fuel injector No.1*
7. Fuel injector No.2* 8. Fuel injector No.3* 9. Fuel injector No.4*
10. Common rail assembly 11. Injection tube clamp (Upper) 12. Injection tube clamp (Lower)
13. Eye connector 14. Fuel hose 15. Check valve**
16. Spill tube 17. Spill tube bracket (Lower) 18. Fuel return tube
19. Fuel feed tube 20. Fuel supply pump feed hose 21. Fuel supply pump return hose
22. Spill hose 23. Rubber 24. Spill tube bracket (Upper)
25. Copper washer 26. Eye bolt
A. From injector B. From Fuel supply pump C. To fuel supply pump
D. Flow of fuel E. To tank F. From tank
G. Refer to text for tightening order
: Flow of fuel
*: Refer to GI-9, "Component" for symbol marks in the figure.
CAUTION:
• Check that no foreign materials attach and enter into the paths when disassembling fuel piping.
• Never disassemble common rail assembly.
• Except eye bolt and eye connector, never remove any part such fuel pressure sensor, plugs, etc from
the common rail assembly.
• Injector tube and fuel supply tube are not reusable. Replace by new ones if removed.
• Handle common rail carefully and avoid impacts.
REMOVAL
EM-332
1. For all injectors 1 to 4 proceed as follow:
a. Disconnect injector harness connectors (1) from injector. A
b. Pull up to release injector cover (2) from injector.
c. Remove each injection tube.
• Loosen injection tubes at fuel injector side retaining inlet con- EM
nector of fuel injector with a spanner to prevent it from loosing.
2. Remove all spill tube, spill hose connector with the following pro-
cedure: C
a. Disconnect spill hose on common rail assembly side.
MBIB9104E
D
b. Push and pull fuel injector fixing clip to release the spill tube con-
nector from the injector. E
CAUTION:
• Never remove the clip
• Replace the clip if it is removed.
• Remove spill tube. F
3. Disconnect spill hose from return tube.
KBIA2319E
H
4. Using two spanners, loose fuel supply tube (1) on fuel supply
pump (2).
5. Loose the fuel supply tube on the common rail assembly. I
K
E1BIA1665ZZ
6. Remove mountings bolts and remove common rail assembly L

from the cylinder head.
MBIB9106E
O
INSTALLATION
CAUTION:
P
While tightening injector tubes or fuel supply tube, prevent partner part to move by meaning of a span-
ner, so as not to stress or loosen the part.
1. Use a new copper washer and install eye connector and eye bolt to the common rail assembly.
EM-333
2. Install common rail to cylinder head and tighten mountings bolts
to the specified torque.
: 29.5 N·m (3.0 kg-m, 22 ft-lb)
MBIB9106E
3. Finger tightens fuel injector connections (1), common rail con-

nections (2) and fuel supply pump connection (3).
4. Finger tightens injection tubes clamp (Lower) bolt.
5. Finger tightens injection tubes clamp (Upper) bolt.
MBIB9134E
6. Tighten connections (1) and (3) to the specified torque.
: 29.5 N·m (3.0 kg-m, 22 ft-lb)
MBIB9136E
7. Tighten connections (2) to the specified torque.
: 29.5 N·m (3.0 kg-m, 22 ft-lb)
8. Tighten injection tubes clamp (Lower) bolt.
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
9. Tighten injection tubes clamp (Lower) bolt.
MBIB9137E
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
10. Install check valve of fuel hose between common rail assembly
and spill tube, then the side of large diameter (in the direction of
the arrow) need to be at the side of common rail.
CAUTION:
Fuel hose is not reusable. Replace by a new one if removed
from the check valve.
11. Apply diesel fuel around O-ring spill tube connector.
PBIC1797E
EM-334
12. Open fuel injector head clip with clip pushed. A

CAUTION:
• Never remove the clip.
• Replace the clip if it is removed.
13. Insert spill tube to fuel injector. EM
14. Release the clip to original position and fix it.
CAUTION:
Replace O-ring of spill tube connector. C
15. Pull up spill tube connector by hand, and check that it does not
disconnect.
16. Connect fuel hose to common rail assembly.
KBIA2320E
D

Start engine, increase the engine speed, and check that there is no fuel leakage. E
EM-335
FUEL INJECTOR
FUEL INJECTOR
KBIA2266E
1. Fuel injector 2. O-ring 3. Nozzle gasket

4. Cylinder head bolt 5. Fuel injector support 6. Washer
CAUTION:
Check that no foreign materials attach and enter into the paths when disassembling fuel piping.
REMOVAL
2. Remove fuel injector support bolt.
3. Remove fuel injector from cylinder head.
• Remove fuel injector support while removing.
CAUTION:
• Handle fuel injector carefully and avoid impacts.
• Identify installation position of fuel injector. Arrange
removed parts to prevent mixing them up.
4. Remove O-ring from fuel injector.
5. Remove nozzle gasket from fuel injector.
• Remove nozzle gasket from cylinder head mounting hole if it is PBIC2214E
not at top of fuel injector.

INSTALLATION
NOTE:
In this section, information about non-reusable parts is shown in the text considering these parts' characteris-
tics. (In other sections, information about non-reusable parts is shown in Component Parts Location.)
EM-336
FUEL INJECTOR
1. Record “IMA DATA (ALPHA NUM CODE)” on the top surface
when replacing fuel injector. A
• Refer to "INSPECTION AFTER INSTALLATION" for use of
“IMA DATA (ALPHA NUM CODE)”.
EM
KBIA2268E
D
2. Assemble O-ring and nozzle gasket to fuel injector.
• Apply grease around the O-ring.
• Install fuel injector in its original position.
E
CAUTION:
Replace O-ring and nozzle gasket.
3. Insert fuel injector to cylinder head.
• Install fuel injector support while inserting. F
• Set one side of fuel injector support to the top of cylinder head
bolt.
4. Tighten fuel injector support bolt. G
• Install washer so that the curved surface side faces downward PBIC2214E
(fuel injector support side).

5. Reinstall removed parts in the reverse order of removal. H
Input “IMA DATA (ALPHA NUM CODE)” to ECM after installing to the
vehicle when replacing fuel injector. I
KBIA2268E
L
EM-337
FUEL SUPPLY PUMP
FUEL SUPPLY PUMP
MBIB9090E
1. Fuel supply pump 2. Fuel supply pump mounting 3. Gasket

4. O-ring 5. Oldham coupling 6. Stud
7. Gear case 8. Rear plate 9. Washer
EM-338
FUEL SUPPLY PUMP
EM
H
E1BIA0208GB
1. Fuel supply pump 2. Fuel supply pump mounting 3. Gasket

4. O-ring 5. Oldham coupling 6. Stud I
7. Gear case 8. Rear plate 9. Washer
Refer to GI-9, "Component" or symbol marks in the figure.
J
REMOVAL
1. Remove fuel supply tube from fuel pump supply and common rail assembly. Refer to EM-332.
2. Disconnect fuel feed and return hoses from the fuel pump supply. K
3. Remove fuel supply pump mounting bolts.
4. Remove fuel supply pump taking care not to drop the Oldham coupling from the fuel pump.
L
5. If removal of fuel supply pump mounting is required, proceed as follow:
• Remove chain cover. Refer to EM-353.
• Remove fuel supply pump sprocket, and fuel supply pump gear.
• Remove oil feed eye bolt. M
• Remove bolts securing the fuel supply pump mounting on the
front plate and remove the fuel supply pump mounting.
N
P
MBIB9098E
INSTALLATION
Install in the reverse order of removal paying attention to the followings points:
EM-339
FUEL SUPPLY PUMP
• Replace fuel supply pump O-ring by a new one.
• Before installation of the fuel supply pump, rotate the engine so,
the thin notches on the inner bearing of fuel supply pump bracket
(3) are in the vertical position.
• In this position, center the position of the Oldham coupling (1) on
the fuel supply pump (2) in the manner to obtain the same gap "a"
on both sides.
• Tighten fuel supply pump and fuel supply mounting to the specified
torque.
• Replace old fuel supply pump tube by a new one. Refer to EM-332
• For assembling order of oil feed tubes, refer to EM-329.
MBIB9057E

Start engine, and increase engine speed to check for fuel leakage.
EM-340
ROCKER COVER
ROCKER COVER
A
EM
I
KBIA2280E
1. Rocker cover 2. Glow plug oil seal 3. Oil filler cap J

4. Gasket
REMOVAL
K
• Injection tube and spill tube; Refer to EM-332.
• Glow harness; Refer to EM-327.
L
2. Remove glow plug oil seal from rocker cover.
• While holding cutout on top of oil seal with pliers, rotate it
counterclockwise to remove.
M
O
KBIA2281E
EM-341
ROCKER COVER
• Loosen and remove mounting bolts in reverse order shown in
the figure.
PBIC2264E
INSTALLATION
1. Apply liquid gasket to points shown in the figure following the
steps below.
• Use genuine liquid gasket or an equivalent.
a. Fill gap between mating faces with sealant using a spatula.
b. Apply additional sealant on a heap.
2. Install rocker cover gasket into mounting groove on rocker
cover.
• Install it with tab of front mark "FR" coming front of engine and
upward.
• Apply liquid gasket slightly onto several points on rocker cover
gasket to prevent missing during installation. Then secure it to KBIA2283E
rocker cover.
CAUTION:
If some traces of fluid gasket that was used in past service work are found, remove them com-
pletely before work.
3. Tighten rocker cover mounting bolts following the steps below.
a. Temporarily tighten mounting bolts in ascending order shown in
the figure.
PBIC2264E
b. Install glow plug oil seal.

• Rotate it clockwise to tighten while holding cutout on top of oil
seal with pliers.
KBIA2281E
EM-342
ROCKER COVER
• Align mating marks on glow plug oil seal and rocker cover.
A
EM
PBIC3064E
D
c. Tighten mounting bolts to the specified torque in numerical order
d. Retighten mounting bolts to the specified torque in numerical E
4. Perform airtightness inspection of fuel injector outer circumfer-
ence seal. Refer to "INSPECTION AFTER INSTALLATION".
F
G
PBIC2264E

Perform airtightness inspection of fuel injector outer circumference H
seal with the following procedure:
1. Completely close with tape all engine openings (except PCV
hose connection of rocker cover) to which blow-by pressure is I
applied.
2. Apply soapy water to fuel injector outer circumference seal of
rocker cover. J
2
3. Apply the pressure [19.6 kPa (196 mbar, 0.2 kg/cm , 2.84 psi)]
from PCV hose connection of rocker cover, and check for air
pressure leakage. K
PBIC2215E
• Replace rocker cover if necessary.
EM-343
CAMSHAFT
CAMSHAFT
PBIC3065E
1. Baffle plate 2. Camshaft bracket 3. Camshaft gear (INT)

4. Camshaft sprocket 5. Washer 6. Camshaft gear (EXH)
7. Idler gear 8. Thrust plate 9. Idler shaft
10. Cylinder head 11. Valve lifter 12. Adjusting shim
13. Camshaft (EXH) 14. Camshaft (INT)
NOTE:
Baffle plate on top surface of No.1 camshaft bracket is omitted in the figure below.
• Arrow represent engine front direction.
• Refer to the figure for intake and exhaust valve arrangement.
MBIB9085E
REMOVAL
EM-344
CAMSHAFT
1. Set the No. 1 cylinder at TDC, and then remove the chain case,
timing chain and other parts in connection. Refer to EM-353. A
3. Remove camshaft gear.
• Loosen the camshaft gear mounting bolt by fixing the hexago- EM
nal portion of the camshaft.
NOTE:
The idler gear cannot be removed at this point as gear case is
C
in the way. (Cylinder head can be removed as a single unit.)
FEM011
D
4. Remove camshaft.
• Place matching marks on the right and left sides with paint.
• Loosen and remove the mounting bolt in the reverse order
E
• Remove by taking notice of the installation position, and place
outside engine in order to prevent confusion. F
G
PBIC0364E

H
• Check the camshaft for one-sided wear or scratches.
• Replace the camshaft if there are malfunctions.
I
Camshaft Runout
1 and No. 5.
J
• Set the dial gauge vertically on journal No. 3.
• Rotate camshaft in one direction by hand, then read needle move-
ment on dial indicator. (Total indicator reading)
K
Limit : 0.02 mm (0.0008 in)
• Replace camshaft if outside the limit.
L
PBIC0365E
Height of Cam Nose M

• Measure by using a micrometer.
Standard: N
Intake
40.468 - 40.508 mm (1.5932 - 1.5948 in)
Exhaust O
40.83 - 40.87 mm (1.6075 - 1.6091 in)
P
Wear limit : 0.15 mm (0.0059 in)
SEM549A
• Replace camshaft if outside the wear limit.

Camshaft Oil Clearance
EM-345
CAMSHAFT
• Measure by using a micrometer.
Standard: 29.931 - 29.955 mm (1.1784 - 1.1793 in) dia.
FEM015

• Install camshaft bracket and tighten bolts to the specified torque.
Refer to "INSTALLATION".
• Measure inner diameter of camshaft bracket using an inside
micrometer.
Standard 30.000 - 30.021 mm (1.1811 - 1.1819 in) dia.
FEM016

Standard 0.045 - 0.090 mm (0.0018 - 0.0035 in) dia.

• Refer to the standard value of each unit if it exceeds the standard value, and then replace camshaft and/or
cylinder head.
NOTE:
It is impossible to replace only camshaft bracket as camshaft bracket is manufactured with cylinder head.
Camshaft End Play
• Set the dial gauge to the front end of the camshaft. Measure the
end play by moving the camshaft in the direction of the axle.
Standard : 0.065 - 0.169 mm (0.0026 - 0.0067 in)

Limit : 0.2 mm (0.008 in)
PBIC0366E
• Replace the following parts if outside the limit.

- Dimension A for camshaft (No. 2 journal)
Standard : 19.455 - 19.507 mm (0.7659 - 0.7680 in)

- Dimension B for No. 2 camshaft bracket
Standard : 19.338 - 19.390 mm (0.7613 - 0.7634 in)

• Replace camshaft and/or cylinder head referring to the standards
above.
NOTE: KBIA2318E
EM-346
CAMSHAFT
It is impossible to replace only the camshaft bracket as the camshaft bracket is manufactured with the cylin-
der head. A
Visual Inspection of Valve Lifter and Adjusting Shim
• Check that surfaces of valve lifter and adjusting shim do not have
any wear or cracks. EM
• Replace valve lifter and adjusting shim if necessary.
• When replacing adjusting shim, refer to EM-348, "Valve Clear-
ance". C
SEM160D
E

• Measure the outer diameter of the valve lifter with a micrometer. F

G
KBIA2286E I

• Measure the bore diameter of the cylinder head valve lifter with an J
inside micrometer.

K
PBIC0367E
M

N
Standard : 0.030 - 0.065 mm (0.0012 - 0.0026 in)
• If it exceeds the standard value, refer to the outer diameter and bore diameter standard values and replace
O
valve lifter and/or cylinder head.
INSTALLATION
1. Install adjusting shim and valve lifter. P
• Check that these are installed in the same position as before the removal process.
• Follow the matching marks that were placed on parts in the removal process.
EM-347
CAMSHAFT
• Face the key in the direction shown in the figure.
FEM020
3. Install camshaft bracket.

• Completely remove any foreign material on back surfaces of
camshaft brackets and top surface of cylinder head.
• Refer to the camshaft bracket upper side journal No. and
install.
• Looking from the exhaust manifold side (left side of engine),
install in the direction that the journal number can be read cor-
rectly.
• Place baffle plate onto upper face of No. 1 camshaft bracket,
and tighten together.
PBIC0368E
4. Tighten the installation bolts in numerical order in the figure.

a. Tighten to 12.3 N·m (1.3 kg-m, 9 ft-lb).
• Check that the thrust portion of the camshaft is fitted normally
in the head installation side.
b. Tighten to 21.6 N·m (2.2 kg-m, 16 ft-lb).
PBIC0364E
5. After tightening camshaft bracket, check and adjust the valve clearance.
6. Install camshaft gear.
• Align the matching marks, and install idler gear and each cam-
shaft gear to the position shown in the figure.
• Tighten the camshaft gear installation bolt by fixing the hexag-
onal portion of camshaft.
PBIC0369E
7. Install timing chain, all other related parts, and chain cover.
Refer to EM-353.
INSPECTION
EM-348
CAMSHAFT
• Inspect as per the following items when camshaft or parts in con-
nection with valves are removed or replaced, and a malfunction A
occurrs (poor starting, idling, or other malfunctions) due to the mal-
adjustment of the valve clearance.
• Inspect and adjust when the engine is cool (at normal tempera-
EM
ture).
NOTE:
Components on the figure are as follows:
I: Intake valve C
E: Exhaust
: Engine front MBIB9085E
1. Remove rocker cover. Refer to EM-341. D

2. Set the No. 1 cylinder at TDC.
a. Rotate crankshaft pulley (1) clockwise, and align the TDC mark
of crankshaft pulley (2) with the timing indicator (3) of gear E
case.
G
MBIB9113E
b. Confirm that the cam nose of the No. 1 cylinder and the knock H
pin of the camshaft sprocket are in the position shown in the fig-
ure.
• Rotate the crankshaft pulley again if it is not in the position
shown in the figure. I
NOTE:
Fuel injector is omitted in the figure
Components: J
1. Knock pin
2. Exhaust cam
3. Intake cam
MBIB9114E K
3. Measure the valve clearance in the checked area of the table

below while referring to the figure.
L
No. 1 No. 2 No. 3 No. 4

Measuring point
INT EXH INT EXH INT EXH INT EXH M
When the No. 1 cylin-
× × × ×
der is in the TDC
• : Engine front N
The injection order is 1-3-4-2.
NOTE: MBIB9115E
Fuel injector is omitted in the figure. O

The figure represents camshaft position when cylinder No.1 is at the top of the stroke.
EM-349
CAMSHAFT
• Measure the valve clearance using a fine feeler gauge when
the engine is cool (Approximately 20°C [68°F]).
Standard:
Intake and exhaust
: 0.30 - 0.40 mm (0.012 - 0.016 in)
4. Set the No. 4 cylinder at TDC by rotating the crankshaft clock-
wise once.
KBIA2290E
5. Measure the valve clearance in the checked area of the table

below while referring to the figure.
No. 1 No. 2 No. 3 No. 4

Measuring point
When the No. 4 cyl-
× × × ×
inder is in the TDC
NOTE:
Fuel injector is omitted in the figure.
MBIB9175E
6. : Engine front
Adjust as per the following items if the valve clearance is outside the specification.
ADJUSTMENTS
NOTE:
• Adjust the valve clearance while engine is cold.
• Remove the adjusting shim for parts which are outside the specified valve clearance.
1. Remove the rocker cover. Refer to EM-341.
2. Rotate the crankshaft to face the cam nose (1) for adjusting
shims that are to be removed upward (direction A in the figure).
3. Thoroughly wipe off the engine oil on the upper side of the cylin-
der head (for the air gun used in step 7).
4. Move the round hole (2) of the adjusting shim to the outside
direction with an extra-fine screwdriver or like that.
CAUTION:
Perform (the above procedure) while camshaft never con-
tact with adjusting shim.
MBIB9116E
5. Grip the camshaft with camshaft pliers (special service tool),

then using the camshaft as a support point, push the adjusting
shim downward to compress the valve spring.
CAUTION:
Never damage the camshaft, cylinder head, and the outer
circumference of the valve lifter.
6. With the valve spring in a compressed state, remove the cam-
shaft pliers (special service tool) by securely setting the outer
circumference of the valve lifter with the end of the lifter stopper
(special service tool).
• Hold the lifter stopper by hand until the shim is removed. FEM029A
CAUTION:
Never retrieve the camshaft pliers forcefully, as the camshaft is damaged.
EM-350
CAMSHAFT
7. Remove the adjusting shim from the valve lifter by blowing air
through the round hole of the shim with an air gun. A
CAUTION:
• When blowing, use goggles to protect your eye.
• To prevent any remaining oil from being blown around,
EM
thoroughly wipe the area clean.
MBIB9117E
D
8. Remove the adjusting shim (1) by using a magnetic hand.
G
MBIB9118E
9. Measure the thickness of the adjusting shim using a micrometer.

H
• Measure near the center of the shim (the part that touches the
camshaft).
I
Calculation method of the adjusting shim thickness:
t = t1 + (C1– C2)
J
t = Thickness of replacement adjusting shim
t1 = Thickness of removed adjusting shim
C1 = Measured valve clearance SEM145D
K
C2 = Specified valve clearance
When engine is cold [approximately 20°C (68°F)]
L
0.35 mm (0.014 in)
• New adjusting shims have the thickness stamped on the rear
side. M
Stamp Shim thickness mm (in)
2.35 2.35 (0.0925)
N
2.40 2.40 (0.0945)
· ·
· ·
· · O
3.05 3.05 (0.1201)
• The thickness of the adjusting shim ranges from 2.35 to 3.05 JEM184G
mm (0.0925 to 0.1201 in), where in the space of 0.05 mm P

(0.0020 in). There are 15 types of shims available.
11. Fit the selected adjusting shim to the valve lifter.
CAUTION:
Place the stamped side of the adjusting shim to the valve lifter.
EM-351
CAMSHAFT
12. Compress the valve spring using the camshaft pliers and
remove the lifter stopper (special service tool).
FEM029A
13. Rotate the crankshaft 2 to 3 times by hand.

14. Confirm that the valve clearance is within the specification. Refer to "INSPECTION".
EM-352
TIMING CHAIN
TIMING CHAIN
A
EM
J
PBIC2106E
1. Chain tensioner 2. Timing chain slack guide 3. Camshaft gear (EXT) K

4. Washer 5. Camshaft gear (INT) 6. Camshaft sprocket
7. Timing chain 8. Timing chain tension guide 9. Segment sensor
10. O-ring 11. Engine coolant temperature sensor 12. O-ring L
13. Water outlet 14. Gasket 15. Chain cover
16. O-ring
M
REMOVAL
• Rocker cover; Refer to EM-341. N
• Power steering oil pump; Refer to PS-13.
• Vacuum pump; Refer to EM-329.
2. Remove segment sensor and water outlet from chain cover. O
CAUTION:
Handle segment sensor carefully and avoid impacts.
EM-353
TIMING CHAIN
3. Remove chain cover.
• Remove the mounting bolts A to C shown in the figure.
CAUTION:
Be careful not to allow entry of dust or foreign objects
while chain cover is removed.
• Using a seal cutter (SST: KV10111100), separate liquid gas-
ket, and remove chain case.
MBIB9091E
4. Set the No. 1 cylinder to the compression TDC.

a. Turn crankshaft pulley (1) clockwise, and align the timing indica-
tor of gear case (3) to the timing mark of crankshaft pulley (2).
MBIB9113E
b. Check that the camshaft sprocket mating mark is in the position

• Turn crankshaft pulley once more and position it correctly if the
mating mark is not in position.
NOTE:
Each sprocket and chain is fitted using the mating marks,
therefore there is no need to apply any mating marks before-
hand when removing at No. 1 cylinder compression TDC.
PBIC1728E
5. Remove chain tensioner with the following procedure:

a. Open stopper tab, and press plunger in tensioner body.
b. Engage stopper tab to groove on the end of plunger.
c. Lever hole is aligned with tensioner body hole position in this
condition. Fix lever using stopper pin.
NOTE:
Stopper pin is made from wires of approximately 0.5 mm (0.020
in) diameter or paperclips.
d. Remove chain tensioner.
KBIA2295E
EM-354
TIMING CHAIN
6. Remove timing chain slack guide.
7. Remove timing chain with camshaft sprocket. A
• Loosen the camshaft sprocket mounting bolt by fixing the hex-
agonal portion of the intake manifold side camshaft with a
spanner, etc. EM
CAUTION:
Never loosen the mounting bolt by using the tension of
the chain.
C
8. Remove timing chain tension guide.
EMT0075D
D
Timing Chain
• Check timing chain for cracks and excessive wear at roller links. E
• Replace timing chain if necessary.
SEM984C H
INSTALLATION
NOTE:
The figure shows the relationship between the matching mark on each timing chain and that on the corre- I
sponding sprocket, with components installed.
1. Camshaft sprocket (INT)
2. Chain tensioner J
3. Timing chain slack guide
4. Timing chain tension guide
5. Fuel supply pump sprocket
a: Mating mark (Dark blue link) K
A: Mating mark
b: Mating mark (Yellow link)
B: Mating mark (Notches) L
1. Install timing chain tension guide.
2. Install camshaft sprocket and timing chain together.
• Install by aligning the sprocket and timing chain mating marks. M
NOTE:
There are also mating marks (notches) on fuel supply pump
sprocket, which is possible to align the position of timing chain.
(Possible to visually confirm them from side view) N
• In cases that positions of camshaft and camshaft sprocket are
not fit, make fine adjustment to the position holding the hexag-
onal part of camshaft with a wrench or an equivalent. O
• Tighten the camshaft sprocket mounting bolt by fixing the hex-
agonal portion of the camshaft.
CAUTION:
Never tighten the mounting bolt using the tension of the P
MBIB9129E
chain.
3. Install timing chain slack guide.
CAUTION:
There is a gap between the guide and bolt when the mounting bolt is tightened to the specified
torque. Never overtighten.
EM-355
TIMING CHAIN
• Pull out stopper pin and release the plunger after installing
chain tensioner.
KBIA2295E
5. Install chain cover.

a. Apply liquid gasket to mating surface as shown before installing
chain cover.
• Use genuine liquid gasket or an equivalent.
MBIB9131E
b. Install chain cover and O-ring.

• The length of the mounting bolt varies depending on the part.
A: 20 mm (0.79 in)
B: 50 mm (1.97 in)
C: 60 mm (2.36 in)
MBIB9091E
6. Install by following all removal procedures in reverse.
EM-356
TIMING GEAR
TIMING GEAR
A
EM
E1BIA1666GB
1. Fuel supply pump 2. Gasket 3. O-ring

4. Oil jet 5. Key 6. O-ring
7. Front plate 8. Gasket 9. Protector
EM-357
TIMING GEAR
10. Fuel supply pump gear 11. Washer 12. Fuel supply pump sprocket
13. Idler shaft 14. Idler gear 15. Thrust plate
16. Plug 17. Dowel pin 18. O-ring
19. O-ring 20. Rubber seal 21. Gasket
22. O-ring 23. Gear case 24. Dowel pin
25. TDC sensor 26. Front oil seal 27. Crankshaft pulley
A. Engraved line B. Refer to Fuel supply pump
: Upper side
Refer to GI-9, "Component"for symbol marks in the figure.
REMOVAL
1. Drain engine coolant and engine oil. Refer to CO-30.
• Drive belt and drive belt auto tensioner; Refer to EM-300.
• Alternator and alternator bracket; Refer to SC-33
• Power steering oil pump, A/C compressor (or dummy pulley) and A/C compressor bracket; Refer to PS-
13 and MTC-66.
• Rocker cover; Refer to EM-341.
• Oil pan and oil strainer; Refer to EM-324.
• Water pump; Refer to CO-38
• Water pipe and water hose; Refer to CO-40
• Vacuum pump; Refer to EM-329.
3. Remove chain cover. Refer to EM-353.
4. Remove chain tensioner, timing chain slack guide, and timing chain. Refer to EM-353.
5. Remove TDC sensor. EM-357, "Removal and Installation"
CAUTION:
• Handle it carefully without giving any impact.
• Never place it where iron chips can adhere.
• Keep it clear of objects affected by magnetic fields.
• Secure crankshaft by inserting hammer handle into gap
around counterweight. Loosen mounting bolts to remove crank
pulley.
CAUTION:
• Be careful not to damage crankshaft.
• Be careful to keep inside of engine clear of foreign mate-
rials.
• Handle crankshaft pulley carefully to avoid damaging or
magnetizing protrusions for signal detection.
KBIA2299E
PBIC2138E
EM-358
TIMING GEAR
7. Remove gear case.
• There are 3 pry grooves (shown by arrows in the figure) on A
gear case. Using grooves and a flat-bladed screwdriver or seal
cutter (SST: KV10111100), remove gear case.
8. Remove front oil seal from gear case. EM
• Remove it using a flat-bladed screwdriver.
CAUTION:
Be careful not to damage gear case.
C
EMT0105D
D
9. Remove each timing gear.
• Check backlash between each two gears before removal.
Refer to "inspection after removal".
E
CAUTION:
• Never loosen inner mechanism fixing bolt of idler gear.
(Idler gear cannot be reused if the inner mechanism is
opened.) F
• Never face rear side downward after removing idler
gears. Idler main shaft drops.
• Refer to EM-338 for removal of fuel supply pump gear (includ-
G
ing fuel supply pump sprocket and sensor plate).
MBIB9126E
10. Remove fuel supply pump. Refer to EM-338.

H
11. Remove front plate.
I
Backlash of Each Gear
Method using a fuse wire
• Tighten the mounting bolts of each gear to specification.
• Place a wire (1) in the biting area (2) of the teeth between the J
gears to be checked, and rotate crankshaft in the operating direc-
tion so that the wire is taken inwards.
• Measure the crushed area (A) of the wire with a micrometer. K
MBIB9119E
M
Method using dial gauge
• Tighten the mounting bolts of each gear to specification.
• Place the dial gauge (1) on the tooth surface area of the gear to be
checked. N
• Measure the dial gauge value with the other gear in a set position
while moving the gear left and right.
O
Standard : 0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit : 0.20 mm (0.0079 in)
• Replace the gear and measure again if it exceeds the limit. P
MBIB9120E
• If it exceeds the limit again, check for the installation condition of
the gear driving parts, wear of shaft and gear, and oil clearance.
Idler Gear End Play
• Tighten the holding bolts to the specification.
• Measure the clearance between the thrust plate and idler gear using a feeler gauge.
EM-359
TIMING GEAR
Unit: mm (in)

Idler gear
0.06 - 0.12 (0.0024 - 0.0047) 0.15 (0.0059)
Idler gear
• Replace the idler gear, idler shaft, and thrust plate if it exceeds the limit.
Idler Gear Oil Clearance
• Measure the inner diameter (d1) of the idler gear shaft hole.
Standard:
Idler gear
43.000 - 43.020 mm (1.6929 - 1.6937 in) dia.
• Measure the outer diameter (d2) of the idler shaft.
Standard:
Idler gear
MBIB9121E
42.959 - 42.975 mm (1.6913 - 1.6919 in) dia.
• Calculate the oil clearance.
Clearance = d1 − d2
Unit: mm (in)

Idler gear 0.025 - 0.061 (0.0010 - 0.0024) 0.2 (0.0079)
• Refer to each standard specification and replace the idler gear and/or idler shaft if it exceeds the limit.
INSTALLATION
1. Install front plate.
a. Install the O-rings and gasket to cylinder block.
b. Install front plate.
• Lightly tap with a plastic hammer if the dowel pin cannot be inserted easily.
CAUTION:
Check that the O-rings do not pop out.
c. Apply liquid gasket with a spreader between the cylinder block
plate under cylinder block (oil pan side) and front plate (1)
(shown by the arrows in the figure).
2. Install fuel supply pump. Refer to EM-338, "Removal and Instal-
lation".
3. Install each timing gear.
• Align the matching marks of timing gears by referring to the
figure below.
• Refer to EM-338 for installation of supply pump gear (including
fuel supply pump sprocket). MBIB9122E
EM-360
TIMING GEAR
EM
MBIB9123E F
NOTE:
The figure shows the relationship between the matching marks on each timing gear, with components
installed.
1: Fuel supply pump gear G
2: Idler gear
3: Crankshaft gear
4: Crankshaft key (Directly above) H
4. Install front oil seal to gear case.
• Apply engine oil to the fitting side.
• Evenly insert front oil seal using a drift [outer dia.: approx. 64 I
mm (2.52 in)] completely.
CAUTION:
Check the oil seal does not spill off the end side of the
gear case. J
K
FEM044
5. Install gear case. L

a. Apply liquid gasket to mating surface as shown before installing
gear case.
Use Genuine Liquid Gasket or an equivalent. M
b. Install the O-rings (1) to the gear case.
c. Install the gasket (2) to the gear case.
d. Install the rubber seal (3) into the gasket. N
e. Install gear case.
• Tap the area around the dowel pin with a plastic hammer if it
cannot be inserted easily. MBIB9086E O
CAUTION:
Never pop out the O-rings.
P
EM-361
TIMING GEAR
f. Install the mounting bolt referring to the figure.
Bolt length:
A: 25 mm (0.98 in)
B: 30 mm (1.18 in)
C: 50 mm (1.97 in)
D: 80 mm (3.15 in)
g. Install the mounting bolts from the rear side of front plate.
MBIB9132E
h. Cut gasket upper end exceeded on rocker cover mounting surface so that it is level.
6. Install crankshaft pulley.
• Insert by aligning the 2 flat faces of oil pump with the 2 flat faces of the shaft on the rear side of crank-
shaft pulley.
CAUTION:
Never damage the oil seal lip when inserting.
7. Install the TDC sensor.
• Align the bracket knock pin with the hole on gear case side
and tighten the mounting bolt.
• Confirm that the clearance between the end of the sensor and
the signal detection protrusion of crankshaft pulley are within
the specification.
Standard : 0.5 - 1.5 mm (0.020 - 0.059 in)
KBIA2308E
8. Install the timing chain, related parts, and the chain cover. Refer to EM-353.
EM-362
CYLINDER HEAD
CYLINDER HEAD
A
CHECKING COMPRESSION PRESSURE EM

2. Disconnect the negative battery cable.
C
3. Disconnect the harnesses from all fuel injectors. Refer to EM-336.
4. Remove glow plugs from all the cylinders. Refer to EM-327.
CAUTION:
• Clean the surrounding area to prevent entry of any foreign materials into the engine before D
removal.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs. E
5. Install adapter (SST) to installation holes of glow plugs.

F
: 17.5 N·m (1.8 kg-m, 13 ft-lb)
MBIB9124E
6. Connect compression gauge for diesel engine. I
: 17.5 N·m (1.8 kg-m, 13 ft-lb)

J
MBIB9125E
L
7. Connect negative battery cable.

8. Set the ignition switch to “START” and crank. When gauge pointer stabilizes, read compression pressure M
and engine rpm. Repeat the above steps for each cylinder.
• Always use a fully charged battery to obtain specified engine speed.
Unit: kPa (bar, kg/cm, psi)/rpm
N
Standard Minimum Difference limit between cylinders
2,844 (28.44, 29.0, 412)/200 2,354 (23.54, 24.0, 341)/200 294 (2.94, 3.0, 43)/200
• Check the specific gravity of battery liquid when engine rpm is outside of the specified range. Measure O
• Check valve clearance and combustion chamber components (valves, valve seats, cylinder head gas-
kets, piston rings, pistons, cylinder bores, cylinder block upper and lower surfaces) if engine rpm P
exceeds the limit. Then measure again.
• Apply engine oil from glow plug installation hole if compression pressure is low in some cylinders. Then
- Piston ring may be worn or damaged if compression pressure becomes normal after applying engine oil.
Check piston ring for malfunction. Replace piston ring if there is any malfunction.
- Valve may be malfunctioning if compression pressure is still low after applying engine oil. Check valve
for malfunction. Replace valve or valve seat if contact malfunction is found.
EM-363
CYLINDER HEAD
• Pressure may be leaking from gasket if compression pressure in adjacent two cylinders is low after
applying engine oil. Replace cylinder head gasket in this case.
9. Complete this operation as per the following items:
a. Turn ignition switch to “OFF”.
b. Disconnect negative battery cable.
c. Remove compression gauge for diesel engine and adapter (SST) installed in step 5 and 6.
d. Install all the parts removed in step 4.
CAUTION:
Replace glow plug oil seals with new ones. Refer to EM-327.
e. Connect the harnesses to all fuel injectors. Refer to EM-336.
f. Connect negative battery cable.
MBIB9133E
1. Rear engine slinger 2. Cylinder head assembly 3. Glow plug

4. Cylinder head bolt 5. Gasket 6. Thrust plate
7. Idler gear (Camshaft) 8. Idler shaft 9. Dowel
10. Gasket 11. Front engine slinger 12. Gasket
13. Water pipe
A. Refer to text B. Matching marks C. To heater
Refer to GI-9 for symbol marks in the figure.
REMOVAL
• Drive belt; Refer to EM-300.
• Alternator and alternator bracket; Refer to SC-33.
• EGR volume control valve and related parts; Refer to EM-308.
• Intake manifold; Refer to EM-313.
• Common rail assembly; Refer to EM-332.
• Turbocharger; Refer to EM-316.
• Exhaust manifold; Refer to EM-322.
EM-364
CYLINDER HEAD
• Camshaft; Refer to EM-344.
2. Remove mounting bolts of the gear case and water pump as A
shown by arrows in the figure.
EM
EMT0125D
D
3. Remove front engine slinger, rear engine slinger and water pipe.
4. Remove cylinder head assembly. E
• Loosen and remove mounting bolts in the reverse order shown
in the figure.
• Lift up the cylinder head assembly to avoid interference with
F
dowel pins located between the block and head, and remove
cylinder head assembly.
CAUTION:
• Remove glow plug in advance to avoid damage as the G
tip of the glow plug projects from the bottom of the cyl-
inder head. Or, place wood blocks beneath both ends of
the cylinder head to keep the cylinder bottom from any H
PBIC0408E
contact.
• The following shall be noted for glow plug removal. Refer to EM-327.
CAUTION:
• Never remove glow plugs unless necessary to avoid breakage. I
• Never use air impact wrench. J
5. Remove idler gear.
CAUTION:
Keep the rear of idler gear facing up to prevent idler shaft from falling while removing idler gear. K
• Measure the outer diameters d1 and d2 of bolt thread as shown in L
the figure using micrometer.
• Set the necking point as measuring point d2 if it can be identified.
• Calculate the difference between d1 and d2. M
Limit : 0.15 mm (0.0059 in)

• Replace cylinder head bolt if out of the limit. N
O
FEM056

P
EM-365
CYLINDER HEAD
Check the bottom of the cylinder head for distortion using straight-
edge and feeler gauge.
Limit : 0.2 mm (0.008 in)

Replace cylinder head if it exceeds the limit.
FEM066
Idler Gear End Play

• Tighten mounting bolts to the specified torque. Refer to "Removal and Installation".
• Measure the clearance between thrust plate and idler gear using feeler gauge.
Standard : 0.07 - 0.14 mm (0.0028 - 0.0055 in)

Limit : 0.2 mm (0.0079 in)
• Replace idler gear, idler shaft, and/or thrust plate if the measured value exceeds the limit value.
• Measure the inner diameter (d1) of idler gear shaft hole.
Standard : 26.000 - 26.020 mm (1.0236 - 1.0244 in)

• Measure the outer diameter (d2) of idler shaft (Camshaft).
Standard : 25.967 - 25.980 mm (1.0223 - 1.0228 in)

• Calculate gear oil clearance.
(Clearance) = (d1) – (d2)
Standard : 0.020 - 0.053 mm (0.0008 - 0.0021 in) EMT0128D
• Replace idler gear (Camshaft) or idler shaft, or both if outside the limit.
INSTALLATION
• Cylinder head gasket to be installed is selected by its thick-
ness through the following procedure.
- When replacing gasket only
• Install gasket with the same thickness as the one removed.
• Gasket thickness is identified by the number of notches
located on center rear side.
• Arrow represent engine front direction.
Grade (A) Gasket thickness* mm (in) No. of notches (B)

MBIB9084E
1 0.65 (0.0256) 1
2 0.70 (0.0276) 2
3 0.75 (0.0295) 3
*: Thickness of gasket tightened with head bolts
EM-366
CYLINDER HEAD
• The number of notches can be checked at the position shown
in the figure before cylinder head is removed. (It is necessary A
to remove exhaust manifold.)
EM
PBIC0410E
D
- When repairing/replacing the following
• When the top of cylinder block or crankshaft pin/journal is repaired
• When cylinder block, piston, connecting rod, or crankshaft is E
replaced
a. Move piston toward TDC.
b. Position dial indicator on cylinder block as shown in the figure, F
and adjust the needle to “0”.
c. Move dial indicator stand aside, and position the dial indicator to
the measuring point as shown in the figure. G
d. Rotate crankshaft slowly, and read the value on dial indicator at
piston's maximum height.
e. Repeat above procedure at 2 positions of each cylinder (8 posi- PBIC2402E H
tions in total for 4 cylinders). Select the appropriate gasket by
comparing the maximum crown depression with the table.
I
Grade Piston crown depression Gasket thickness* No. of notches
1 More than 0.079 mm (0.0031 in) 0.65 mm (0.0256 in) 1
2 Less than 0.079 mm (0.0031 in) 0.70 mm (0.0276 in) 2 J
*: Thickness of gasket tightened with head bolts
2. Install idler gear and idler shaft.
• Check that the counter marks with camshaft gear, “AA” and “BB”, are located on the front side of the K
engine. Refer to Component Parts Illustration.
CAUTION:
Since idler gear cannot be installed or removed with cylinder head assembly mounted on the L
engine because of interference with gear case, check that there are no reverse installations or
uninstalled parts.
3. Install cylinder head assembly. M
a. Attach gasket onto the rear of gear case.
b. Align cylinder head assembly with dowel pin of cylinder block
and install. N
CAUTION:
• Never damage gasket located at the front.
O
PBIC2227E
P
4. Position cylinder head assembly close to the rear of gear case.
a. Install cylinder head bolts to the front and rear of cylinder head respectively, and tighten to the specified
torque.
: 44.1 N·m (4.5 kg-m, 33 ft-lb)
EM-367
CYLINDER HEAD
b. Loosen cylinder head bolts completely.
c. Install gear case mounting bolts to 2 positions shown by arrows
in the figure, and tighten to the specified torque.
: 9.8 N·m (1.0 kg-m, 87 in-lb)
EMT0211D
5. Tighten cylinder head bolts in numerical order shown in the fig-

ure.
a. Apply engine oil to installation bolt threads and washers.
PBIC0408E
b. Insert bolt A (with positioning protrusion for fuel injector support)

into bolt holes 12, 13, 16, and 18 shown in the figure and bolt B
into bolt holes 1 to 11, 14, 15, and 17 shown in the figure.
c. Tighten bolts to 100 N·m (10.0 kg-m, 74 ft-lb).
d. Loosen bolts completely until the torque becomes 0 N·m (0 kg-
m, 0 in-lb).
CAUTION:
For procedure “c”, loosen bolts in the reverse order as indi-
cated in the figure.
e. Tighten bolts to 42 N·m (4.3 kg-m, 31 ft-lb).
PBIC1748E
f. Tighten bolts at the angle of 90°. (Angle tightening)
g. Once again, tighten bolts at the angle of 90°. (Angle tightening)
CAUTION:
Perform the following procedure to check turning angle of angle tightening, and never judge by
visual check.
• Make counter marks on the bolt heads of cylinder head and
cylinder head surface with paint, and check the turning angle.
• Check the turning angle using angle indicator of angle wrench
(SST).
6. Loosen gear case mounting bolts which were tightened in “c” of
procedure 4, and retighten them to the specified torque.
7. Install water pump installation bolt (removed at step 2).
PBIC2228E

• Remove the carbon adhering to the installation hole of glow plug using a reamer, and install glow plug.
EM-368
CYLINDER HEAD
EM
H
FEM081A
DISASSEMBLY I
• Check the installation positions, and keep them to avoid being
confused. J
2. Remove valve collets.
• Compress valve spring using valve spring compressor (SST).
• Remove valve collets using magnetic hand.
K
4. Remove valves as pressing valve stems toward cylinder head
lower surface. L
PBIC1750E
• Check the valve guide clearance before removing the valve. M

Refer to "Valve Guide Clearance".
• Check installation positions, and keep them to avoid being
confused. N
NOTE:
Refer to the figure for intake and exhaust valve positions.
I: Intake valve
E: Exhaust valve O
: Engine front
MBIB9085E P
EM-369
CYLINDER HEAD
5. Remove valve oil seals using valve oil seal puller (SST).
6. Remove valve spring seats.
7. Perform valve seat contact check before removing valve spring
seats. Refer to "Valve Seat Contact".
8. Perform valve guide clearance check before removing valve
guides. Refer to "Valve Guide Clearance".
PBIC1795E
ASSEMBLY
1. Install valve guides. Refer to "Valve Guide Replacement".
2. Install valve seats. Refer to "Valve Seat Replacement".
3. Install valve oil seals using valve oil seal drift (SST) and by refer-
• The figure shows the dimension before valve spring seats are
installed.
5. Install valves.
• Install the valves with bigger openings to intake valve side.
• Note that valve layout here is different from that of the conven-
tional engine.
PBIC0412E
6. Install valve springs.

• For exhaust valve springs check that a narrow pitch side (side
with identification paint mark applied) faces the cylinder head
when installing valve spring.
Identification
: Orange paint mark: Exhaust
: Without paint mark: Intake
A: Narrow pitch
B: Wide pitch SEM085D
MBIB9128E
7. Install valve spring retainers.
EM-370
CYLINDER HEAD
8. Compress valve springs using valve spring compressor (SST).
Then install valve collets using magnetic hand. A
• Tap the stem end using a plastic hammer after installing valve
collets, and check the installation status.
9. Install adjusting shims and valve lifters to the same positions as EM
before.
PBIC1750E
D
Valve Dimension
Measure the dimensions of each part using micrometer. E
Standard:
Intake valve Exhaust valve F
a: 113.5 mm (4.47 in) 113.5 mm (4.47 in)
b: 3.8 - 4.2 mm (0.150 - 3.8 - 4.2 mm (0.150 -
0.165 in) 0.165 in) G
c: 1.5 mm (0.059 in) 1.5 mm (0.059 in)
d: 6.962 - 6.977 mm (0.2741 6.945 - 6.960 mm (0.2734
PBIC0413E H
- 0.2747 in) - 0.2740 in)
D: 31.9 - 32.1 mm (1.256 - 29.9 - 30.1 mm (1.177 -
1.264 in) 1.185 in)
I
α: 45°00 - 45°30′ 45°00 - 45°30′
• Replace valve if out of standard.
Valve Guide Clearance J
• Calculate the clearance by measuring valve stem outer diameter
and valve guide inner diameter.
K
Standard:
Intake : 0.023 - 0.056 mm (0.0009 - 0.0022 in)
Exhaust : 0.040 - 0.073 mm (0.0016 - 0.0029 in) L
Limit:
Intake : 0.18 mm (0.0071 in) M
Exhaust : 0.10 mm (0.0039 in)
SEM938C
• Replace valve guide and/or valve if the measured value exceeds

the limit. Refer to "Valve Guide Replacement". N
Valve Guide Replacement
There is no setup for oversized valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath. O
SEM008A
EM-371
CYLINDER HEAD
2. Tap valve guides out from the combustion chamber side using
valve guide drift.
CAUTION:
Cylinder head contains heat. Wear protective equipment to
avoid getting burned when working.
PBIC2229E

4. Press-fit valve guides from camshaft side using valve guide drift,
referring to the dimension shown in the figure.
CAUTION:
Cylinder head contains heat. Wear protective equipment to
avoid getting burned when working.
PBIC0420E
5. Perform reaming to the press-fitted valve guides using valve

guide reamer.
Reaming specifications:
Intake and exhaust
7.000 - 7.018 mm (0.2756 - 0.2763 in)
PBIC2230E
Valve Seat Contact

Check valve seat for any evidence of pitting at valve contact surface,
and replace if worn out excessively.
• Check valve and valve guide for wear beforehand when repairing
valve seats. Replace them if worn. Then check valve seat.
EMA0487D

1. Cut valve seat to make it thin, and pull it out.
CAUTION:
Cutting valve seat too much may cause damage of cylinder head.
NOTE:
• After removing valve seat, check cylinder head inner area for cracks. If any cracks or deformation,
replace cylinder head with new one.
• Check inner diameter of valve seat mounting area. Refer to EM-398, "Standard and Limit".
2. Heat cylinder head to approximately 110 to 130°C (230 to 266°F) in oil bath.
3. Press-fit valve seats to cylinder head after cooling valve seats sufficiently with dry ice.
CAUTION:
EM-372
CYLINDER HEAD
• Cylinder head contains heat. Wear protective equipment to avoid getting burned when working.
• Never touch the cooled valve seats directly by bare hand. A
4. Check that contacting status is satisfactory.
EM
PBIC1751E
H
Valve Spring Squareness
Position a straightedge to valve spring, turn the spring, and measure
the maximum clearance value between top surface of spring and the I
straightedge.
Limit: 2.3 mm (0.091 in)

J
• Replace valve spring if the measured value exceeds the limit.
PBIC0080E
Valve Spring Dimensions and Valve Spring Pressure Load L

Check the following using valve spring tester.
Refer to EM-398.
• Replace valve spring if outside of standard. M
O
SEM113
EM-373
ENGINE ASSEMBLY
ENGINE ASSEMBLY
MBIB9056E
1. Engine mounting bracket RH 2. Engine mounting bracket LH 3. Engine mounting insulator RH

WARNING:
CATALOG.
CAUTION:
sections.
NOTE:
EM-374
ENGINE ASSEMBLY
ing. A
REMOVAL
Description of work EM
Separate the engine from transmission, and hoist the engine upward.
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-16 C
2. Drain engine coolant. Refer to CO-30 .
Engine Room Front
D
1. Remove radiator and charge air cooler as assembly. Refer to CO-33 and EM-306.
2. Remove drive belt, Refer to EM-300.
Engine Room LH E
1. Disconnect air duct from turbocharger inlet tube.
2. Disconnect hose blow-by.
3. Disconnect vacuum hoses from turbocharger. F
4. Disconnect harness connectors from following:
• Water temperature sensor
• Alternator G
5. Remove A/C compressor without disconnect A/C piping and temporally secure them on body with a rope
to avoid putting load on it. Refer to MTC-66.
H
Engine Room RH
1. Disconnect pipes from power steering pump and remove power steering tank.
2. Disconnect glow plug harness. Refer to EM-327. I
• Camshaft position sensor
• Fuel supply pump
J
• Air inlet housing
• EGR volume control valve
• Common rail pressure sensor
• Oil pressure sensor. Refer to LU-23. K
• Oil level sensor
• EVAP valve
4. Remove clips fixing engine room harness to the engine. L
5. Remove the starter motor. Refer to SC-41
7. Remove clutch operating cylinder from transmission, and move it aside. Refer to CL-11, "Component". M
8. Disconnect vacuum hose from vacuum pump.
Engine Room Rear
N
Vehicle Under Body O
1. Disconnect ABS harness connector.
2. Disconnect wheel sensor and brake pads limit wear. Refer to BRC-187, "Removal and Installation"
P
3. Remove exhaust front tube. Refer to EX-14, "Removal and Installation"
6. Remove fender protector LH and RH. Refer to EI-18.
Removal
EM-375
ENGINE ASSEMBLY
1. Install engine slingers into front left of cylinder head and rear
right of cylinder head.

: Engine front
2. Support the engine by a crane and loosen LH and RH engine

mounting insulator mounting nuts.
Support the transmission by a jack.
3. Separate the engine from the gearbox. Refer toMT-27,
"Removal and Installation from Vehicle" .
CAUTION:
• During the operation, check that no part interferes with body
side.
• Before and during this lifting, always check that harnesses
are not connected.

: 28.0 N·m (2.9 kg-m, 21 ft-lb)
MBIB9100E
INSTALLATION
• Before starting engine, check the levels of engine coolant, lubrications and working oils. If less than required
• Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil, fuel
and exhaust gas.


EM-376
ENGINE ASSEMBLY
A
WARNING:
• Place chocks at front and back of rear wheels. EM
CATALOG.
• Ensure that the engine and transmission are lowered and raised safely. C
CAUTION:
• If items or work required are not covered by the engine main body section, refer to the applicable D
sections.
E
pipes, clutch pipes, etc. F
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill- G
ing.
REMOVAL
Description of Work H
Support the engine, then remove engine and transmission from vehicle under.
Preparation
I
1. Disconnect battery cable from negative terminal. Refer to SC-16, "FOR MAINTENANCE REQUIRED
BATTERY MODELS : How to Handle Battery".
2. Drain engine coolant. Refer to CO-30, "Changing Engine Coolant". J
3. Remove front seats. Refer to SE-12, "Component Parts Drawing".
5. Disconnect transmission shift cable from inside cab. Refer to MT-14, "Removal and Installation". K
6. Disconnect parking brake cable from inside cab. Refer to PB-11, "Removal and Installation".
7. Remove front and rear floor trim. Refer to EI-29, "Removal and Installation".
8. Remove engine covers. Refer to EM-298. L
Engine Room Front

1. Remove radiator reservoir tank. M
2. Drive belt, Refer to EM-300.
Engine Room LH
1. Remove radiator upper hose. N
2. Disconnect air duct from turbocharger inlet tube.
3. Remove charge air cooler hoses and tubes. Refer to EM-306, "Component".
O
4. Remove bolt fixing radiator to the frame.
5. Disconnect hose blow-by.
6. Disconnect vacuum hoses from turbocharger. P
• Water temperature sensor
• Alternator
8. Remove A/C compressor without disconnect A/C piping and temporally secure them on body with a rope
to avoid putting load on it. Refer to MTC-66, "Removal and Installation of A/C Compressor".
Engine Room RH
EM-377
ENGINE ASSEMBLY
1. Remove charge air cooler hoses and tubes. Refer to EM-306, "Component".
2. Disconnect radiator lower hose.
3. Remove power steering pipes from the power steering pump, and remove power steering tank.
• Camshaft position sensor.
• Fuel supply pump.
• Air inlet housing.
• EGR volume control valve.
• Common rail pressure sensor.
• Oil pressure sensor. Refer to LU-23, "Inspection".
• Oil level sensor.
• EVAP valve.
6. Remove clips fixing engine room harness to the engine.
7. Remove the starter motor. Refer to SC-41, "Removal and Installation".
9. Remove clutch operating cylinder from transmission, and move it aside. Refer to CL-11, "Component".
10. Disconnect vacuum hose from vacuum pump.
Engine Room Rear
Vehicle Under Body
1. Disconnect ABS harness connector.
2. Disconnect wheel sensor and brake pads limit wear. Refer to BRC-187, "Removal and Installation".
5. Remove propeller shaft. Refer to PR-4, "Removal and Installation".
7. Remove fender protector LH and RH. Refer to EI-18, "Component".
8. Remove stabilizer. Refer to FSU-5, "Component".
9. Remove air guide and charge air cooler. Refer to EM-306, "Component".
10. Remove charge air cooler tubes from the radiator. Refer to EM-306, "Component".
11. Separate radiator shroud, and remove radiator. Refer to CO-33, "Component".
Removal
EM-378
ENGINE ASSEMBLY
1. Install engine slingers into front left of cylinder head and rear
right of cylinder head. A

2 : Engine slinger (front) EM
: Engine front
2. Support the engine by a crane and loosen LH and RH engine

mounting insulator mounting nuts. C
3. Lower the engine and gearbox with the lifting table while loosen-
ing the slings on the crane supporting the upper part of the
engine. D
4. Loosen and remove the nuts fixing the gearbox bracket to the
chassis.
5. Remove engine and transmission from the vehicle underbody. E
6. Separate the engine from the gearbox. Refer to MT-27,
"Removal and Installation from Vehicle".
CAUTION: F
• During the operation, check that no part interferes with body
side.
• Before and during this lifting, always check that harnesses G
are not connected. MBIB9100E
Engine slinger bolts: H

: 28.0 N·m (2.9 kg-m, 21 ft-lb)
INSTALLATION
Install in the reverse order of removal. I
figure of components. Refer to EM-374, "Component". J
K
• Before starting engine, check the levels of engine coolant, lubrications and working oils. If less than required L
age at connection points. M
• Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil, fuel N
and exhaust gas.
fied level, if necessary. O
Item Before starting engine Engine running After engine stopped P


EM-379
ENGINE ASSEMBLY
EM-380
CYLINDER BLOCK
CYLINDER BLOCK
A
EM
PBIC2141E
1. Rear oil seal and retainer assembly 2. Oil pressure switch 3. Oil jet relief valve
4. Water connector 5. Drain plug 6. Cylinder block
7. Top ring 8. Second ring 9. Oil ring
EM-381
CYLINDER BLOCK
10. Oil jet 11. Eye-bolt 12. Piston pin
13. Snap ring 14. Piston 15. Main bearing
16. Thrust bearing 17. Drain plug 18. Connecting rod
19. Key 20. Connecting rod bearing 21. Connecting rod cap
22. Connecting rod nut 23. Lower cylinder block sub bolt 24. Lower cylinder block main bolt
25. Lower cylinder block sub bolt 26. Gusset 27. Lower cylinder block
28. Gusset 29. Main bearing 30. Crankshaft
31. Rear plate 32. Flywheel 33. Pilot bearing
DISASSEMBLY
1. Drain engine coolant and engine oil. Refer to CO-30, "Changing Engine Coolant" and LU-24, "Changing
Engine Oil".
2. Replace pilot bearing if it needs to be replaced.
• Remove pilot bearing from flywheel using pilot bearing puller
(SST).
PBIC2231E
3. Remove flywheel.
• Secure ring gear with suitable plate and bolts, and then loosen
and remove installation bolt.
PBIC1753E
4. Remove rear plate and gussets.

5. Remove rear oil seal and retainer assembly.
• Insert slotted screwdriver into lower cylinder block and rear oil seal retainer to remove them.
NOTE:
Oil seal alone is not available as a service part.
6. Install engine to engine stand.

7. Remove the following parts and related parts.
• Cylinder head; Refer to EM-363.
• Oil cooler; Refer to LU-27, "Removal and Installation".
• Oil pan; Refer to EM-324.
• Check connecting rod side clearance before removing piston and connecting rod assembly. Refer to
EM-388, "How to Select Piston".
EM-382
CYLINDER BLOCK
c. Press the piston and connecting rod assembly out to cylinder
head side using the grip of a hammer. A
EM
EMT0160D
D
CAUTION:
Prevent the big end of the connecting rod from interfering
with the oil jet when removing the piston and connecting E
rod assembly.
PBIC2232E
H
9. Remove connecting rod bearings from connecting rod and cap.
CAUTION:
When removing them, note the installation position. Keep them in the correct order.
I
10. Remove piston rings from piston using piston ring expander.
CAUTION:
• Prevent piston from being damaged when removing. J
• Never expand piston rings excessively. This may damage
the piston rings.
K
L
PBIC0087E
11. Remove piston from connecting rod. M

a. Remove snap rings using long nose pliers.
P
PBIC0388E
EM-383
CYLINDER BLOCK
b. Heat piston up to 60 to 70°C (140 to 158°F) using industrial
dryer.
PBIC0089E
c. Press piston pin out using rod with outer diameter of 30 mm

(1.18 in).
EMM0072D
12. Remove lower cylinder block.

• Lower cylinder block is the lower part of cylinder block, which works as main bearing cap (beam) and oil
pan mounting face.
a. Remove mounting bolts to engine stand if they are tightened on lower cylinder block.
CAUTION:
Check that safe operation can be performed after removing mounting bolts from lower cylinder
block. If it is impossible to work safely, support cylinder block by the arms of engine stand that
supported lower cylinder block and tighten bolts.
b. Loosen and remove mounting bolts in the reverse order shown
in the figure.
PBIC2233E
c. Insert flat-bladed screwdriver into 5 locations shown by arrows

in the figure. Lift lower cylinder block evenly, and remove liquid
gasket.
CAUTION:
Prevent mating faces from being damaged.
PBIC2234E

14. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
EM-384
CYLINDER BLOCK
Check mounting positions. Keep them to avoid confusion.
15. Remove oil jets. A
ASSEMBLY EM
1. Blow air sufficiently to inside of coolant passage, oil passage,
crankcase, and cylinder bore to remove foreign materials.
2. Install oil jet relief valve. C
3. Install oil jets.
• Align knock pin on back of oil jet with pin on block when install-
ing oil jet. D
E
PBIC0389E

F
a. Remove contamination, dust and oil from bearing mounting positions on cylinder block and lower cylinder
block.
G
block.
• Install thrust bearings with oil groove facing to crankshaft arm
(outside).
H
PBIC2235E
J
c. Install main bearings being careful about the direction.
cylinder block side, and those without oil holes and grooves K
onto the lower cylinder block side.
• Apply engine oil to bearing surfaces (inside) while installing
bearings. Never apply engine oil to back surfaces, but clean L
them completely.
• Align stopper notches on bearings to install them.
with the oil hole positions on the bearings. M
PBIC2236E
5. Install crankshaft to cylinder block. N

• Check for smooth rotation while rotating crankshaft by hand.
6. Install lower cylinder block.
• Apply a continuous bead of liquid gasket to lower cylinder O
block as shown in the figure.
P
FEM128
EM-385
CYLINDER BLOCK
• Install the lower cylinder block to the cylinder block using slots on engine sub-attachment, avoiding inter-
ference of dowel pins.
7. Tighten lower cylinder mounting bolts to the torque shown below

in 3 consecutive steps in numerical order shown in the figure.
Unit: N·m (kg-m, ft-lb)
Items Main bolt (No. 1 - 10) Sub-bolt (No. 11 - 20)

1st 19.6 (2.0, 14) 9.8 (1.0, 7)
2nd 98.0 (10, 72) 19.6 (2.0, 14)
3rd 172 (18, 127) 42.7 (4.4, 31)
• Sub-bolt No. 17 has shorter length than that of other sub-bolts.

PBIC2233E
8. Install mounting bolts from engine stand to lower cylinder block as necessary.
• Check crankshaft for smooth rotation after tightening bolts to the specified torque.
• Check crankshaft side clearance.
Refer to EM-388, "How to Select Piston".
9. Install piston to connecting rod.

a. Install snap ring to grooves on piston rear side using long nose pliers.
b. Install piston to connecting rod.
• Heat piston up to approximately 60 to 70°C (140 to 158°F) using an industrial dryer until piston pin can
be pressed down by touching with a finger. Then insert piston pin into piston and connecting rod from
front side of piston toward rear.
crown and cylinder No. stamped on connecting rod being posi-
c. Install snap ring to front side of pistons.
• Check connecting rod for smooth movement after installation.
PBIC1754E
10. Use piston ring expander to install piston rings.

CAUTION:
Prevent piston from being damaged when installing.
• Install top ring and second ring with stamped surfaces facing
upward.
Identification stamp:
Top ring and second ring: R
PBIC2237E
EM-386
CYLINDER BLOCK
11. Install connecting rod bearings to connecting rod and cap.
• Apply engine oil to bearing surfaces (inside) while installing A
connecting rod bearings. Do not apply oil to back surfaces, but
clean them completely.
• Align lugs on connecting rod bearings with connecting rod lug
EM
recesses to install connecting rod bearings.
PBIC1788E
D
• Move crankshaft pin to be installed to BDC.
• Align cylinder position with cylinder No. on connecting rod to
E
• Install piston and connecting rod assembly with front mark on
piston crown facing toward the front side of engine using pis-
ton ring compressor (SST: EM03470000). F
CAUTION:
Prevent the big end of connecting rod from interfering
with oil jet when installing piston and connecting rod
G
assembly. Replace the oil jet if the big end of connecting
PBIC2238E
rod interferes with the oil jet.
• Align cylinder No. stamped on connecting rod with that on cap H
• Check crankshaft for smooth rotation after tightening nuts.
• Check connecting rod side clearance. I
Refer to EM-388, "How to Select Piston".
PBIC1754E
K
14. Install following parts and related parts in the reverse order of disassembly.
• Oil pan; Refer to EM-324 .
• Oil cooler; Refer to LU-27, "Removal and Installation" . L
• Cylinder head; Refer to EM-363 .
15. Remove engine from engine stand.
16. Install rear oil seal and retainer assembly. M
• Apply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.
Use Genuine LIquid Gasket or an equivalent. N
KBIA2379J P
17. Install rear plate and gussets.

18. Install flywheel.
• Secure crankshaft and tighten mounting bolts using the same method as disassembly.
EM-387
CYLINDER BLOCK
• Tighten mounting bolts for flywheel in numerical order shown
in the figure.
PBIC2240E
19. Press-fit pilot bearing into flywheel.

• Press-fit pilot bearing using drift with outer diameter of 45.0
mm (1.772 in) as shown in the figure.
PBIC0390E
PBIC2239E
20. Refill engine oil and engine coolant. Refer to CO-30, "Changing Engine Coolant" and LU-24, "Changing
Engine Oil".
How to Select Piston INFOID:0000000013949839
DESCRIPTION
Connecting points Connecting parts Selection items Selection methods

Piston and piston pin assembly.
Between cylinder block to pis- Piston grade (piston outer diam-
The piston is available together Refer to selection table.
ton eter)
• The identification grade stamped on each part is the grade for the dimension measured in the new condition.
This grade cannot apply to reused parts.
• Measure the dimension accurately for non-reusable or repaired parts. Determine the grade by comparing
the measurement with the values of each selection table.
• Refer to the text for details of the measurement method of each part, the reuse standards, and the selection
method of the selective fitting parts.
SELECTIVE PISTON COMBINATION
When Using New Cylinder Block
EM-388
CYLINDER BLOCK
• Confirm cylinder bore grade (1, 2, 3) on left upper surface of cylin-
der block, and refer to “Selective combination chart” below to A
select appropriate piston.
• Part No. is given to a piston and piston pin as a set.
EM
PBIC2241E
D
When Reusing an Old Cylinder Block
1. Measure cylinder block bore inner diameter.
2. Select appropriate piston according to cylinder bore grade, E
referring to “Cylinder block bore inner diameter” in “Selective
combination chart”.
PBIC2242E
Selective combination chart H

Unit: mm (in)
Piston grade and piston outer diameter

A: Preferable combination
B: Allowable combination
1 2 I
-: NG combination 95.930 − 95.940 95.940 − 95.950
(3.7768 − 3.7772) (3.7772 − 3.7776)
96.000 − 96.010 J
1 A -
(3.7795 − 3.7799)
Cylinder bore grade and cylin- 96.010 − 96.020
2 B A
der block bore inner diameter (3.7799 − 3.7803) K
96.020 − 96.030
3 B A
(3.7803 − 3.7807)
• The piston is available together with piston pin as an assembly. L
• Piston grade 3 (95.950 - 95.960) is applicable at factory only.
M
Crankshaft Side Clearance
• Measure the crankshaft travel amount using dial indicator by mov-
ing the crankshaft forward or backward.
N
• Or, measure the crankshaft travel amount using feeler gauge with
the lower cylinder block removed.
Standard : 0.055 - 0.140 mm (0.0022 - 0.0055 in) O

Limit : 0.25 mm (0.0098 in)
• Select appropriate thrust bearings if measured value exceeds the
P
limit.
Unit: mm (in)
PBIC2243E
Grade symbol Thickness of thrust bearing

A 2.275 - 2.325 (0.0896 - 0.0915)
B 2.300 - 2.350 (0.0906 - 0.0925)
C 2.325 - 2.375 (0.0915 - 0.0935)
EM-389
CYLINDER BLOCK
Connecting Rod Side Clearance

• Measure the side clearance between connecting rod and crank
arm using feeler gauge.
Standard : 0.10 - 0.22 (0.0039 - 0.0087 in)

Limit : 0.22 mm (0.0087 in)
• Replace connecting rod and measure again if measured value
exceeds the limit.
Replace crankshaft if measured value still exceeds the limit.
FEM096
Piston to Piston Pin Clearance
PISTON PIN HOLE INNER DIAMETER

• Measure piston pin hole inner diameter using inside micrometer.
Standard:
32.997 - 33.005 mm (1.2991 - 1.2994 in) dia.
PBIC0116E
PISTON PIN OUTER DIAMETER

• Measure piston pin outer diameter using micrometer.
Standard:
32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
PBIC0117E
CALCULATION OF PISTON TO PISTON PIN CLEARANCE

• (Piston pin clearance) = (Piston pin hole inner diameter) − (Piston pin outer diameter)
Standard :-0.003 (Tightening clearance) to 0.012 mm (-0.0001 to 0.0005 in)

• Replace piston and piston pin assembly if clearance is exceeds the specification.
Piston Ring Side Clearance
• Measure the clearance between piston ring and piston ring groove
using feeler gauge.
Unit: mm (in)

Top ring 0.05 - 0.07 (0.0020 - 0.0028)
0.1 (0.004)
Second ring 0.04 - 0.08 (0.0016 - 0.0031)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059)
SEM024AA
EM-390
CYLINDER BLOCK
• Align top ring and external surface of piston. Measure lower side A
groove.
• Replace piston ring if side clearance exceeds the limit.
• Check clearance again. Replace piston if side clearance still EM
exceeds the limit.
FEM100
D
Piston Ring End Gap
• Check that cylinder bore diameter is within the specifications.
Refer to "PISTON TO CYLINDER BORE CLEARANCE". E
• Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder head with piston.
• Measure piston ring end gap with feeler gauge.
Unit: mm (in) F

Top ring 0.25 - 0.45 (0.0098 - 0.0177) G
Second ring 0.50 - 0.65 (0.0197 - 0.0256) 1.5 (0.059)
Oil ring 0.25 - 0.45 (0.0098 - 0.0177) FEM101
H
• Replace piston ring if measured value exceeds the limit. Rebore cylinder and use oversized piston and pis-
ton rings if measured value still exceeds the limit.
Connecting Rod Bend and Torsion I
• Use connecting rod aligner to check bend and torsion.
Bend limit:
J
0.05 mm (0.0020 in)/100 mm (3.94 in)
Torsion limit:
0.05 mm (0.0020 in)/100 mm (3.94 in) K
• Replace connecting rod assembly if measured value exceeds the
limit.
L
SEM038F
SEM003F
P
Connecting Rod Big End Inner Diameter
EM-391
CYLINDER BLOCK
• Install connecting rod cap without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Refer to EM-
381, "Disassembly and Assembly". Measure connecting rod big
end inner diameter using inside micrometer.
Standard:
59.987 - 60.000 mm (2.3617 - 2.3622 in) dia.
• Replace connecting rod if out of specifications.
PBIC1641E
Connecting Rod Bushing Oil Clearance (Small End)
CONNECTING ROD SMALL END INNER DIAMETER

• Use inside micrometer to measure small end inner diameter.
Standard:
33.025 - 33.038 mm (1.3002 - 1.3007 in) dia.
PBIC0120E
PISTON PIN OUTER DIAMETER

• Use micrometer to measure piston pin outer diameter.
Standard:
32.993 - 33.000 mm (1.2989 - 1.2992 in) dia.
PBIC0117E
CALCULATION OF CONNCTING ROD BUSHING CLEARANCE

• (Connecting rod small end bushing clearance) = (Connecting rod small end inner diameter) − (Piston pin
outer diameter)
Standard : 0.025 - 0.045 mm (0.0010 - 0.0018 in)

• Replace connecting rod and/or piston and piston pin assembly if out of the specifications.
Cylinder Block Top Surface Distortion
• Remove gasket installed onto cylinder block surface using scraper.
Remove contamination such as oil, scale, and carbon.
CAUTION:
Keep broken pieces of gasket from oil and coolant passages.
• Use straightedge and feeler gauge to check block upper surface
for distortion.
Limit : 0.1 mm (0.004 in)

• If out of the specifications, replace cylinder block and lower cylin-
der block as a unit.
FEM107
EM-392
CYLINDER BLOCK
Main Bearing Housing Inner Diameter
• Install lower cylinder block without main bearings. Tighten mount- A
ing bolts to the specified torque. Refer to EM-381, "Disassembly
and Assembly".
• Use bore gauge to measure main bearing housing inner diameter.
EM
Standard:
74.981 - 75.000 mm (2.9520 - 2.9528 in) dia.
C
• Replace cylinder block and lower cylinder block as a unit if out of
the specification.
PBIC2012E D
Piston to Cylinder Bore Clearance
CYLINDER BORE INNER DIAMETER E

• Measure cylinder inner diameters at 6 positions; top, middle, and
bottom (A, B, C) in 2 directions (X, Y) using bore gauge.
Cylinder inner diameter (Standard): F
96.000 - 96.030 mm (3.7795 - 3.7807 in) dia.

Wear limit: G
0.2 mm (0.008 in)
Out-of-round limit (Difference between X and Y):
0.02 mm (0.0008 in) H
PBIC0391E
Taper limit (Difference between A and C):
0.02 mm (0.0008 in)
I
• Horn or bore the applicable cylinder if clearance exceeds the limit,
or if any flaws or seizures are found on inner surface of cylinder.
J
L
PBIC2246E
PISTON OUTER DIAMETER M

• Use micrometer to measure piston skirt outer diameter.
Measurement position: N
14 mm (0.55 in) upper from the lower end of piston
Standard:
95.930 - 95.960 mm (3.7768 - 3.7779 in) dia. O
P
PBIC0125E
CALCULATION OF PISTON TO BORE CLEARANCE

• Calculate using piston skirt outer diameter and cylinder inner diameter (direction X, position B).
(Clearance) = (Cylinder inner diameter) − (Piston skirt outer diameter)
EM-393
CYLINDER BLOCK
Specifications at room temperature [20°C (68°F)]:

0.060 - 0.080 mm (0.0024 - 0.0031 in)
• Replace piston and piston pin assembly if out of the specification.
Crankshaft Journal Outer Diameter
Use micrometer to measure journal outer diameter.
Standard:
70.907 - 70.920 mm (2.7916 - 2.7921 in) dia.
FEM114
• Calculate the main bearing oil clearance if indicated value is out of standard, then use the undersize bearing.
Refer to "Main Bearing Oil Clearance".
Crankshaft Pin Outer Diameter
Use micrometer to measure pin outer diameter.

Crankshaft Out-of-Round and Taper
• Measure each journal and pin using micrometer at 4 points shown
in the figure.
• Out-of-round value is indicated by difference in dimensions
between directions X and Y at points A and B.
• Taper value is indicated by difference in dimensions between
points A and B in directions X and Y.
Out-of-round limit : 0.01 mm (0.0004 in)

Taper limit : 0.01 mm (0.0004 in)
• Correct or replace crankshaft if the measured value exceeds the
PBIC1685E
limit.
• Measure the main bearing/connecting rod bearing oil clearance of the corrected journal if it is corrected.
Then select the main bearing/connecting rod bearing. Refer to "Main Bearing Oil Clearance" / "Connecting
Rod Bearing Oil Clearance" .
Crankshaft Runout
• Place V-block onto surface plate to support No. 2 and No. 4 jour-
nals at both ends of crankshaft.
• Position dial indicator vertically onto No. 1, No. 3 and No. 5 journal.
• Rotate crankshaft to read needle movement on dial indicator. (Total
indicator reading)
Limit : 0.03 mm (0.0012 in)

• Replace crankshaft if it exceeds the limit.
PBIC1756E
Connecting Rod Bearing Oil Clearance
EM-394
CYLINDER BLOCK
Method by measurement
• Install connecting rod bearings to connecting rod and cap, and A
tighten connecting nuts to the specified torque. Refer to EM-381,
"Disassembly and Assembly". Use inside micrometer to measure
connecting rod bearing inner diameter.
EM
(Oil clearance) = (Connecting rod bearing inner diameter) −
(Crankshaft pin outer diameter)
Standard : 0.035 - 0.077 mm (0.0014 - 0.0030 in) C

• If out of the specifications, check connecting rod big end inner
diameter and crankshaft pin outer diameter, and select appropriate PBIC1642E
connecting rod bearing to adjust clearance to the specifications. D

Refer to “Connecting rod bearing undersize list” on the next page.
Method using plastigauge
• Remove contamination such as oil and dust completely from E
crankshaft pins and each bearing surface.
• Cut plastigauge slightly shorter than bearing width, and place it in
crankshaft direction, avoiding oil holes.
• Install connecting rod bearings to cap, and tighten connecting rod F
nuts to the specified torque.
CAUTION:
Never rotate crankshaft. G
• Remove connecting rod cap and bearings, and measure plasti-
gauge width using scale on plastigauge bag.
PBIC2247E
CAUTION:
H
Take the same action mentioned in “Method by measurement” if out of the specification.
Undersize bearing usage
• Use undersize bearings if bearing clearance is out of the specifications for connecting rod bearings in stan-
dard size. I
• Measure bearing inner diameter with bearing installed when using undersize bearings, and grind pins to
adjust clearance to the specification.
Connecting rod bearing undersize list J
Unit: mm (in)
Size Thickness
US 025 1.630 - 1.638 (0.0642 - 0.0645) K
US 050 1.755 - 1.763 (0.0691 - 0.0694)
US 075 1.880 - 1.888 (0.0740 - 0.0743)
L
US 100 2.005 - 2.013 (0.0789 - 0.0793)
CAUTION:
Keep corner radius of fillet R when grinding crank pins to use M
undersize bearings. PBIC2248E
Corner radius dimension (Standard): N

Pin
3.3 - 3.7 mm (0.130 - 0.146 in)
O
Main Bearing Oil Clearance
Method by measurement
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the
specified torque. Refer to EM-381, "Disassembly and Assembly". Measure main bearing inner diameter. P
(Oil clearance) = (Bearing inner diameter) − (Crankshaft journal outer diameter)
Standard : 0.035 - 0.083 mm (0.0014 - 0.0033 in)

• If out of the specification, check main bearing housing inner diameter and crankshaft journal outer diameter,
and select appropriate main bearing to adjust clearance to the specifications.
Refer to “Main bearing undersize list” on the next page.
EM-395
CYLINDER BLOCK
Method using plastigauge
• Remove contamination such as oil and dust completely from
crankshaft journals and each bearing surface.
• Cut plastigauge slightly shorter than bearing width, and place it in
crankshaft direction, avoiding oil holes.
• Install lower cylinder block, and tighten to the specified torque.
Refer to EM-381, "Disassembly and Assembly".
CAUTION:
• Remove lower cylinder block and bearings, and measure plasti-
gauge width using scale on plastigauge bag.
PBIC0131E
CAUTION:
Take the same action mentioned in “Method by measurement” if out of the specification.
Undersize bearing usage
• Use undersize bearings if bearing clearance is out of the specifications for main bearings in standard size.
• Measure bearing inner diameter with bearing installed when using undersize bearings, and grind crank jour-
nals to adjust clearance to the specification.
Main bearing undersize list
Unit: mm (in)
Size Thickness
US 025 2.130 - 2.138 (0.0839 - 0.0842)
US 050 2.255 - 2.263 (0.0888 - 0.0891)
US 075 2.380 - 2.388 (0.0937 - 0.0940)
US 100 2.505 - 2.513 (0.0986 - 0.0989)
CAUTION:
Keep corner radius of fillet R when grinding crank journals to
use undersize bearings. PBIC2249E
Corner radius dimension (Standard):

Journal
2.8 - 3.2 mm (0.110 - 0.126 in)
Main Bearing Crush Height
• Tighten lower cylinder block to the specified torque with main bear-
ings installed. Refer to EM-381, "Disassembly and Assembly". And
remove lower cylinder block. Refer to EM-381, "Disassembly and
Assembly". The bearing end must then be higher than the flat sur-
face.
Standard : Crush height must exist.

• Replace main bearings if out of the specification.
SEM502G
Connecting Rod Bearing Crush Height

• Tighten connecting rod bearing cap to the specified torque with
connecting rod bearing installed. Refer to EM-381, "Disassembly
and Assembly". And remove connecting rod bearing cap. Refer to
EM-381, "Disassembly and Assembly". The bearing end must then
be higher than the flat surface.
Standard : Crush height must exist.

• Replace connecting rod bearings if out of the specification.
PBIC1646E
EM-396
CYLINDER BLOCK
Oil Jet
• Check nozzle for deformation and damage. A
• Blow compressed air from nozzle, and check for clogs.
Standard : No deformation and no damage. EM

• Replace oil jet if it is out of the standard.
PBIC0392E D
Oil Jet Relief Valve
• Press check valve in oil jet relief valve using a clean plastic stick.
Check that valve moves smoothly with proper reaction force. E
Standard:
Valve moves smoothly with proper reaction force. F
• Replace oil jet relief valve if it is out of the standard.
G
EMT0186D
H
Flywheel Runout
Measurement position is approximately 240 mm (9.45 in) from the
crankshaft center.
I
Runout (Total indicator reading):
Limit: 0.1 mm (0.004 in)
J
• Replace flywheel if it is out of the standard.
PBIC0393E
EM-397
GENERAL SPECIFICATIONS

Displacement cm3(cu in) 2,953 (180.19)
Bore and stroke mm (in) 96 x 102 (3.78 x 4.02)
Compression 2
Oil 1
Compression ratio 16.9
Standard 2,844 (28.44, 29.0, 412)
Compression pressure Unit: kPa (bar, kg/cm2, psi)/ Minimum 2,354 (23.54, 24.0, 341)
200 rpm
Differential limit between cylinders 294 (2.94, 3.0, 43)
Valve timing
PBIC0517E
Unit: degree
a b c d e
232 220 6 34 50

Unit: mm (in)
Items Limit
Surface distortion
Exhaust manifold 0.2 (0.008)
TURBOCHARGER
Rotor Shaft
Unit: mm (in)
Items Standard
Oil clearance 0.056 - 0.127 (0.0022 -0.0050)
End play 0.030 - 0.111 (0.0012 - 0.0044)
VNTC control actuator
EM-398
Unit: kPa (mbar, mmHg, inHg)/mm (in)
Items Standard A
-42.9 to -50.9 kPa (-429 to -509, -322 to -382, -12.68 to -15.04) / 0.2 (0.008)
Pressure/rod stroke amount
-21.0 to -22.4 (-210 to -224, -158 to -168, -6.20 to -6.61) / 8.3 (0.327) EM
DRIVE BELTS
Tension of drive belt Auto adjustment by auto tensioner C
CYLINDER HEAD
Unit: mm (in) D
Head surface distortion Less than 0.05 (0.0020) 0.2 (0.008)
E
SEM368G
H
VALVE I
Valve Dimension
Unit: mm (in)
J
M
PBIC0413E
Intake
Valve length “a” 113.5 (4.47) N
Exhaust
Intake
“b” 3.8 - 4.2 (0.150 - 0.165)
Exhaust O
Intake
Valve margin “c” 1.5 (0.059)
Exhaust
Intake 6.962 - 6.977 (0.2741 - 0.2747)
P
Exhaust 6.945 - 6.960 (0.2734 - 0.2740)
Intake 31.9 - 32.1 (1.256 - 1.264)
Exhaust 29.9 - 30.1 (1.177 - 1.185)
Intake
Valve seat angle “α” 45°00′ - 45°30′
Exhaust
EM-399
Valve Clearance
Unit: mm (in)
Items Cold*
Intake & exhaust 0.30 - 0.40 (0.012 - 0.016)
Available Shim
Stamp Thickness mm (in)

2.35 2.35 (0.0925)
2.40 2.40 (0.0945)
2.45 2.45 (0.0965)
2.50 2.50 (0.0984)
2.55 2.55 (0.1004)
2.60 2.60 (0.1024)
2.65 2.65 (0.1043)
2.70 2.70 (0.1063)
2.75 2.75 (0.1083)
2.80 2.80 (0.1102)
2.85 2.85 (0.1122)
2.90 2.90 (0.1142)
2.95 2.95 (0.1161)
3.00 3.00 (0.1181)
3.05 3.05 (0.1201)
JEM184G
Valve Spring
Intake Exhaust
Identification color No identification Orange
Free height mm (in) 55.51 (2.1854) 55.81 (2.1972)
Installation 180 - 206 (18.4 - 21.0, 40.5 - 46.3) at 40.8 (1.606)
Pressure N (kg, lb) at height mm (in)
Valve open 336 - 372 (34.3 - 37.9, 75.5 - 83.6) at 32.3 (1.272)
Out-of-square mm (in) Less than 2.3 (0.091)
Valve Lifter
Unit: mm (in)
Items Standard
EM-400
Lifter guide inner diameter 34.495 - 34.515 (1.3581 - 1.3589)
A
Clearance between lifter and lifter guide 0.030 - 0.065 (0.0012 - 0.0026)
Valve Guide
Unit: mm (in) EM
PBIC0420E
Items Standard F
Valve guide Outer diameter 11.023 - 11.034 (0.4340 - 0.4344)
Inner diameter (Finished size) 7.000 - 7.018 (0.2756 - 0.2763)
G
Cylinder head valve guide hole diameter 10.975 - 10.996 (0.4321 - 0.4329)
Intake 0.023 - 0.056 (0.0009 - 0.0022) H
Standard
Exhaust 0.040 - 0.073 (0.0016 - 0.0029)
Stem to guide clearance
Intake 0.18 (0.0071)
Limit I
Exhaust 0.10 (0.0039)
Valve Seat J
EM-401
Unit: mm (in)
PBIC1726E
SEM373G
PBIC0421E
Items Standard
Cylinder head seat recess diameter Intake 33.000 - 33.015 (1.2992 - 1.2998)
(D) Exhaust 31.495 - 31.510 (1.2400 - 1.2405)
Intake 0.050 - 0.078 (0.0020 - 0.0031)
Exhaust 0.040 - 0.066 (0.0016 - 0.0026)
Intake 33.065 - 33.078 (1.3018 - 1.3023)
Valve seat outer diameter (d)
Exhaust 31.550 - 31.561 (1.2421 - 1.2426)
EM-402
Intake 6.75 - 6.85 (0.2657 - 0.2697)
Height (h) A
Exhaust 7.35 - 7.45 (0.2894 - 0.2933)
Intake 43.65 - 44.35 (1.7185 - 1.7461)
Depth (L)
Exhaust 43.65 - 44.35 (1.7185 - 1.7461) EM
CAMSHAFT AND CAMSHAFT BEARING
Unit: mm (in)
C
G
SEM671
Intake 40.468 - 40.508 (1.5932 - 1.5948) —

Height of cam nose “A”
Exhaust 40.83 - 40.87 (1.6075 - 1.6091) — H
Wear limit of cam height — 0.15 (0.0059)
Camshaft journal outer diameter 29.931 - 29.955 (1.1784 - 1.1793) —
I
Camshaft bracket inner diameter 30.000 - 30.021 (1.1811 - 1.1819) —
Camshaft oil clearance 0.045 - 0.090 (0.0018 - 0.0035) —
Camshaft end play 0.065 - 0.169 (0.0026 - 0.0067) 0.2 (0.008) J
KBIA2318E
Dimension A for camshaft (No. 2 journal) 19.455 - 19.507 (0.7659 - 0.7680) — N

Dimension B for No. 2 camshaft bracket 19.338 - 19.390 (0.7613 - 0.7634) —
O
CYLINDER BLOCK
EM-403
Unit: mm (in)
SEM370G
Surface distortion Limit 0.1 (0.004)

Grade No. 1 96.000 - 96.010 (3.7795 - 3.7799)
Standard Grade No. 2 96.010 - 96.020 (3.7799 - 3.7803)
Grade No. 3 96.020 - 96.030 (3.7803 - 3.7807)
Wear limit 0.2 (0.008)
Out-of-round (Difference between X and Y) Less than 0.02 (0.0008)
Taper (Difference between A and C) Less than 0.02 (0.0008)
Main bearing housing inner diameter (Without main bearing) 74.981 - 75.000 (2.9520 - 2.9528)
Crankshaft journal bearing inner diameter (With bearing) 70.955 - 70.990 (2.7935 - 2.7949)
between cylinders
PISTON, PISTON RING AND PISTON PIN

Available Piston
Unit: mm (in)
SEM369G
Grade No. 1 95.930 - 95.940 (3.7768 - 3.7772)

Piston skirt diameter “A” Standard Grade No. 2 95.940 - 95.950 (3.7772 - 3.7776)
Grade No. 3* 95.950 - 95.960 (3.7776 - 3.7779)
“a” dimension 14 (0.55)
Piston clearance to cylinder block 0.060 - 0.080 (0.0024 - 0.0031)
*: Grade No. 3 is applicable at factory only.
Piston Ring
Unit: mm (in)
EM-404
Top 0.05 - 0.07 (0.0020 - 0.0028)
0.1 (0.004) A
Side clearance 2nd 0.04 - 0.08 (0.0016 - 0.0031)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15(0.0059)
Top 0.25 - 0.45 (0.0098 - 0.0177) EM
End gap 2nd 0.50 - 0.65 (0.0197 - 0.0256) 1.5 (0.059)
Oil (rail ring) 0.25 - 0.50 (0.0098 - 0.0197)
C
Piston Pin
Unit: mm (in)
Items Standard D
Piston to piston pin clearance −0.003 to 0.012 (−0.0001 to 0.0005)
Connecting rod small end bushing clearance 0.025 - 0.045 (0.0010 - 0.0018) E
*: Values measured at ambient temperature of 20°C (68°F)
CONNECTING ROD F
Unit: mm (in)
Center distance 154.475 - 154.525 (6.082 - 6.084)

Bend [per 100 (3.94)] Limit 0.05 (0.0020) G
Connecting rod small end inner diameter (Without bushing) 35.987 - 36.000 (1.4168 - 1.4173)
H
Piston pin bushing inner diameter* 33.025 - 33.038 (1.3002 - 1.3007)
Connecting rod big end inner diameter (Without bearing) 59.987 - 60.000 (2.3617 - 2.3622)
Standard 0.10 - 0.22 (0.0039 - 0.0087) I
Side clearance
Limit 0.22 (0.0087)
J
CRANKSHAFT
Unit: mm (in)
Main journal outer diameter “Dm” 70.907 - 70.920 (2.7916 - 2.7921) K

Pin outer diameter “Dp” Grade No. 0 56.913 - 56.926 (2.2407 - 2.2412)
L
Out-of-round (Difference be-
tween X and Y)
Taper (Difference between A
Limit Less than 0.01 (0.0004) M
and B)
Runout [TIR*] Limit 0.03 (0.0012)
Standard 0.055 - 0.140 (0.0022 - 0.0055) N
Side clearance
Limit 0.25 (0.0098)
SEM645 PBIC1685E
EM-405

Undersize
Unit: mm (in)
PBIC2236E
Size Thickness “T” mm (in) Main journal diameter “Dm”

Standard 2.005 - 2.013 (0.0789 - 0.0793)
US 025 2.130 - 2.138 (0.0839 - 0.0842)
US 050 2.255 - 2.263 (0.0888 - 0.0891)
ified value.
US 075 2.380 - 2.388 (0.0937 - 0.0940)
US 100 2.505 - 2.513 (0.0986 - 0.0989)
AVAILABLE CONNECTING ROD BEARING

Connecting Rod Bearing
Grade number Thickness “T” mm (in) Width “W” mm (in)

Standard 1.505 - 1.513 (0.0593 - 0.0596)
US 025 1.630 - 1.638 (0.0642 - 0.0645)
US 050 1.755 - 1.763 (0.0691 - 0.0694) 25.9 - 26.1 (1.020 - 1.028)
US 075 1.880 - 1.888 (0.0740 - 0.0743)
US 100 2.005 - 2.013 (0.0789 - 0.0793)
TIMING GEAR
Backlash
Unit: mm (in)

Fuel supply pump gear
0.07 - 0.11 (0.0028 - 0.0043) 0.20 (0.0079)
Idler gear
Idler Gear End Play

Unit: mm (in)

Idler gear 0.06 - 0.12 (0.0024 - 0.0047) 0.15 (0.0059)
Idler gear (Camshaft) 0.07 - 0.14 (0.0028 - 0.0055) 0.2 (0.0079)

Unit: mm (in)

Idler gear 43.000 - 43.020 (1.6929 - 1.6937) —
Idler gear shaft hole inner diameter
Idler gear (Camshaft) 26.000 - 26.020 (1.0236 - 1.0244) —
EM-406
A
Idler gear 42.959 - 42.975 (1.6913 - 1.6919) —
Idler shaft outer diameter
Idler gear (Camshaft) 25.967 - 25.980 (1.0223 - 1.0228) —
Idler gear 0.025 - 0.061 (0.0010 - 0.0024) 0.2 (0.0079) EM
Idler gear oil clearance
Idler gear (Camshaft) 0.020 - 0.053 (0.0008 - 0.0021) 0.1 (0.004)
C
Flywheel
Unit: mm (in)
Runout [TIR]* Less than 0.1 (0.004) D
Bearing Oil Clearance

E
Unit: mm (in)

Connecting rod bearing oil clearance Standard 0.035 - 0.077 (0.0014 - 0.0030) F
EM-407

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ENGINE

OIL SEAL ......................................................... 218 DRIVE BELTS ................................................. 300 C

CYLINDER BLOCK .......................................... 257 TURBO CHARGER ......................................... 316 J

BR08DE : 4 minutes YD25DDTi : 2 minutes

DISCONNECTING FUEL PIPING

DRAINING ENGINE COOLANT

INSPECTION, REPAIR AND REPLACEMENT

REMOVAL AND DISASSEMBLY

ASSEMBLY AND INSTALLATION

Parts Requiring Angle Tightening INFOID:0000000013949666

KV11103000 Removing crankshaft pulley

ED19600610 Checking compression pressure

KV101056S0 Preventing crankshaft from rotating

ST16610001 Removing crankshaft pilot bush

WS39930000 Pressing the tube of liquid gasket

KV10112100 Tightening bolts for bearing cap, cylinder K

KV11106010 Removing and installing chain tensioner

KV11106030 Fixing fuel pump sprocket

KV11106040 Removing and installing fuel pump sprocket

KV11106050 Removing and installing fuel pump sprocket

KV11106060 Holding fuel pump sprocket

Commercial Service Tool INFOID:0000000013949669

Piston ring expander Removing and installing piston ring

TORX socket Loosening and tightening fuel pump mounting

TORX socket Loosening and tightening drive plate and fly- M

TORX socket Loosening and tightening main bearing cap

Operating condition of engine

Piston to piston pin

Belt frequency (Hertz)

• Adjust belts with the parts shown below.

Applied belt Belt adjustment method

A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT

2. Remove drive belt.

• Refer to GI-9, "Component" for symbol marks in the figure. P

Removal and Installation INFOID:0000000013949678

1. Clamp 2. Intake manifold 3. Bolt K

Removal and Installation INFOID:0000000013949681 O

• Refer to GI-9, "Component" for symbol marks in the figure.

13. Remove throttle chamber from intake manifold.

Limit : 0.1 mm (0.004 in)

: 10.8 N·m (1.1 kg-m, 8 ft-lb) C

1. Cylinder block 2. Yoke washers 3. Bolts

• Refer to GI-9, "Component" for symbol marks in the figure.

: 25.5 N·m (2.6 kg-m, 19 ft-lb)

: 45.0 N·m (4.6 kg-m, 33 ft-lb)

1. Turbocharger 2. Exhaust manifold 3. Nut M

• Refer to GI-9, "Component" for symbol marks in the figure.

1. Compressor housing 2. Turbocharger boost control actuator 3. Turbine housing

Suction side : Between turbocharger and charge air cooler

Standard : 0.086 - 0.111 mm (0.0034 - 0.0044 in)

: 25.5 N·m (2.6 kg-m, 19 ft-lb)

1. Turbocharger 2. Exhaust manifold cover RH 3. Exhaust manifold cover LH J

• Refer to GI-9, "Component" for symbol marks in the figure.

6. Remove exhaust temperature sensor.

Limit : 0.3 mm (0.012 in)

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

INSPECTION AFTER INSTALLATION

• Refer to GI-9, "Component" for symbol marks in the figure. M