EM Teana

ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
MR20DE SPARK PLUG ................................................... 19 F
Exploded View .........................................................19
SYMPTOM DIAGNOSIS ............................... 5 Removal and Installation .........................................19
Inspection ................................................................20 G
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................. 5 CAMSHAFT VALVE CLEARANCE .................. 21
NVH troubleshooting Chart ....................................... 5 Inspection and Adjustment ......................................21
H
PRECAUTION ............................................... 7 COMPRESSION PRESSURE ........................... 24
Inspection ................................................................24
PRECAUTIONS ................................................... 7 I
Precaution for Procedure without Cowl Top Cover...... 7 ON-VEHICLE REPAIR ................................. 25
Precaution Necessary for Steering Wheel Rota-
tion after Battery Disconnect ..................................... 7 ENGINE COVER ............................................... 25
Precaution for Supplemental Restraint System Exploded View .........................................................25 J
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation .........................................25
SIONER" ................................................................... 7
DRIVE BELT AUTO-TENSIONER .................... 26
Draining Engine Coolant ........................................... 8 K
Exploded View .........................................................26
Disconnecting Fuel Piping ......................................... 8
Removal and Installation .........................................26
Removal and Disassembly ........................................ 8
Inspection, Repair and Replacement ........................ 8 AIR CLEANER AND AIR DUCT ....................... 27 L
Assembly and Installation ......................................... 8 Exploded View .........................................................27
Parts Requiring Angle Tightening ............................. 8 Removal and Installation .........................................27
Liquid Gasket ............................................................ 9 Inspection ................................................................28 M
PREPARATION ........................................... 11 INTAKE MANIFOLD ......................................... 29
Exploded View .........................................................29
PREPARATION ..................................................11 Removal and Installation .........................................29 N
Special Service Tools .............................................. 11
Commercial Service Tools ...................................... 12 EXHAUST MANIFOLD ...................................... 32
Exploded View .........................................................32
ON-VEHICLE MAINTENANCE .................... 15 Removal and Installation .........................................32
O
DRIVE BELTS ....................................................15 Inspection ................................................................33

Exploded View ........................................................ 15 OIL PAN (LOWER) ........................................... 35 P
Checking ................................................................. 15 Exploded View .........................................................35
Tension Adjustment ................................................ 15 Removal and Installation .........................................35
Removal and Installation ......................................... 16 Inspection ................................................................37
AIR CLEANER FILTER ......................................18 FUEL INJECTOR AND FUEL TUBE ................ 38
Removal and Installation ......................................... 18 Exploded View .........................................................38
Removal and Installation .........................................38
Revision: 2008 December EM-1 J32

Inspection ............................................................... 41 Connecting Rod Bearing ..................................... 110
Main Bearing ........................................................ 112
IGNITION COIL, SPARK PLUG AND ROCK-
ER COVER ......................................................... 43 SERVICE DATA AND SPECIFICATIONS
Exploded View ........................................................ 43 (SDS) ......................................................... 116
Removal and Installation ........................................ 43
SERVICE DATA AND SPECIFICATIONS
TIMING CHAIN .................................................. 45 (SDS) ................................................................ 116
Exploded View ........................................................ 45 General Specification ............................................ 116
Removal and Installation ........................................ 46 Drive Belt .............................................................. 116
Inspection ............................................................... 54 Spark Plug ............................................................ 116
Exhaust Manifold .................................................. 117
CAMSHAFT ....................................................... 56
Camshaft ............................................................... 117
Exploded View ........................................................ 56
Cylinder Head ....................................................... 119
Removal and Installation ........................................ 56
Cylinder Block ....................................................... 121
Inspection ............................................................... 60
Connecting Rod Bearing ....................................... 124
OIL SEAL ........................................................... 65 Main Bearing ......................................................... 125
VQ25DE, VQ35DE
VALVE OIL SEAL ..................................................... 65
VALVE OIL SEAL : Removal and Installation ......... 65 SYMPTOM DIAGNOSIS ........................... 126
FRONT OIL SEAL ..................................................... 65 NOISE, VIBRATION AND HARSHNESS
FRONT OIL SEAL : Removal and Installation ........ 66 (NVH) TROUBLESHOOTING ........................... 126
NVH Troubleshooting - Engine Noise ................... 126
REAR OIL SEAL ....................................................... 66
Use the Chart Below to Help You Find the Cause
REAR OIL SEAL : Removal and Installation .......... 66
of the Symptom ..................................................... 127
CYLINDER HEAD .............................................. 68
Exploded View ........................................................ 68 PRECAUTION ........................................... 128
Removal and Installation ........................................ 69 PRECAUTIONS ................................................ 128
Disassembly and Assembly .................................... 70
Precaution for Procedure without Cowl Top Cover. 128
Inspection ............................................................... 74
Precaution for Supplemental Restraint System
REMOVAL AND INSTALLATION ............... 77 (SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ............................................................... 128
ENGINE ASSEMBLY ......................................... 77 Precaution Necessary for Steering Wheel Rota-
Exploded View ........................................................ 77 tion after Battery Disconnect ................................. 128
Removal and Installation ........................................ 77 Precaution for Drain Engine Coolant and Engine
Inspection ............................................................... 81 Oil .......................................................................... 129
Precaution for Disconnecting Fuel Piping ............. 129
DISASSEMBLY AND ASSEMBLY ............. 83 Precaution for Removal and Disassembly ............ 129
Precaution for Inspection, Repair and Replace-
ENGINE STAND SETTING ................................ 83 ment ...................................................................... 129
Setting .................................................................... 83 Precaution for Assembly and Installation .............. 129
Precaution for Angle Tightening ............................ 129
ENGINE UNIT .................................................... 85
Precaution for Liquid Gasket ................................. 130
Disassembly ........................................................... 85
Definitions of Bank Names .................................... 131
Assembly ................................................................ 85
OIL PAN (UPPER) ............................................. 86 PREPARATION ......................................... 132

Exploded View ........................................................ 86 PREPARATION ................................................ 132
Removal and Installation ........................................ 86 Special Service Tool ............................................. 132
Inspection ............................................................... 89 Commercial Service Tool ...................................... 133
CYLINDER BLOCK ........................................... 90 ON-VEHICLE MAINTENANCE ................. 136
Exploded View ........................................................ 90
Disassembly and Assembly .................................... 91 DRIVE BELT ..................................................... 136
Inspection ............................................................... 99 Exploded View ...................................................... 136
Checking ............................................................... 136
HOW TO SELECT PISTON AND BEARING ... 109 Tension Adjustment ............................................. 136
Description .............................................................109
Removal and Installation ....................................... 136
Piston .....................................................................109

AIR CLEANER FILTER .................................... 138 Removal and Installation ....................................... 178
Removal and Installation ....................................... 138 Inspection .............................................................. 190 A
SPARK PLUG .................................................. 139 REMOVAL AND INSTALLATION ............. 192

Exploded View ...................................................... 139
Removal and Installation ....................................... 139 ENGINE ASSEMBLY ...................................... 192 EM
Inspection .............................................................. 140 Exploded View ....................................................... 192
CAMSHAFT VALVE CLEARANCE ................. 141 Inspection .............................................................. 200 C
Inspection and Adjustment .................................... 141
DISASSEMBLY AND ASSEMBLY ............ 201
COMPRESSION PRESSURE .......................... 146
Inspection .............................................................. 146 ENGINE STAND SETTING ............................. 201 D
Setting ................................................................... 201
ON-VEHICLE REPAIR ............................... 148
ENGINE UNIT .................................................. 203 E
ENGINE COVER .............................................. 148 Disassembly .......................................................... 203
Exploded View ...................................................... 148 Assembly ............................................................... 203
REAR TIMING CHAIN CASE .......................... 204 F
DRIVE BELT AUTO TENSIONER AND IDLER Exploded View ....................................................... 204
PULLEY ............................................................ 149 Disassembly and Assembly ................................... 205
Exploded View ...................................................... 149 G
Removal and Installation ....................................... 149 CAMSHAFT ..................................................... 209
Exploded View ....................................................... 209
AIR CLEANER AND AIR DUCT ...................... 150 Removal and Installation ....................................... 209
Exploded View ...................................................... 150 Inspection .............................................................. 213 H
Inspection .............................................................. 151 OIL SEAL ........................................................ 218
VALVE OIL SEAL .................................................... 218 I
INTAKE MANIFOLD COLLECTOR ................. 152
VALVE OIL SEAL : Removal and Installation ........ 218
Exploded View ...................................................... 152
Removal and Installation ....................................... 153 FRONT OIL SEAL .................................................... 218 J
FRONT OIL SEAL : Removal and Installation ....... 218
INTAKE MANIFOLD ......................................... 156
Exploded View ...................................................... 156 REAR OIL SEAL ...................................................... 219
Removal and Installation ....................................... 156 REAR OIL SEAL : Removal and Installation ......... 219 K
Inspection .............................................................. 157
CYLINDER HEAD ........................................... 221
EXHAUST MANIFOLD AND THREE WAY Exploded View ....................................................... 221
CATALYST ....................................................... 158 L
Exploded View ...................................................... 158 Disassembly and Assembly ................................... 225
Removal and Installation ....................................... 158 Inspection .............................................................. 229
Inspection .............................................................. 162 M
CYLINDER BLOCK ......................................... 232
OIL PAN AND OIL STRAINER ........................ 163 Exploded View ....................................................... 232
Exploded View ...................................................... 163 Disassembly and Assembly ................................... 235
N
Removal and Installation ....................................... 163 Inspection .............................................................. 244
Inspection .............................................................. 167
HOW TO SELECT PISTON AND BEARING .. 254
FUEL INJECTOR AND FUEL TUBE ............... 169 Description ............................................................. 254 O
Exploded View ...................................................... 169 Piston ..................................................................... 254
Removal and Installation ....................................... 169 Connecting Rod Bearing ...................................... 255
Inspection .............................................................. 173 Main Bearing ......................................................... 257 P
IGNITION COIL, SPARK PLUG AND ROCK- SERVICE DATA AND SPECIFICATIONS
ER COVER ....................................................... 174 (SDS) .......................................................... 260
Exploded View ...................................................... 174
Removal and Installation ....................................... 174 SERVICE DATA AND SPECIFICATIONS
(SDS) ............................................................... 260
TIMING CHAIN ................................................. 177 General Specification ............................................ 260
Exploded View ...................................................... 177

Drive Belt ...............................................................261 Cylinder Head ...................................................... 264
Spark Plug .............................................................261 Cylinder Block ...................................................... 268
Intake Manifold ......................................................261 Main Bearing ........................................................ 271
Exhaust Manifold ..................................................261 Connecting Rod Bearing ..................................... 272
Camshaft ...............................................................261

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [MR20DE]
SYMPTOM DIAGNOSIS A
NVH troubleshooting Chart INFOID:0000000003802136
EM
JPBIA2251GB
1. Locate the area where noise occurs.

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

< SYMPTOM DIAGNOSIS > [MR20DE]
4. Check specified noise source.
If necessary, repair or replace these parts.
Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-21
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
Cylinder Rattle C A — A B C bearing clearance EM-117
head noise Camshaft runout
Piston to piston pin oil

Slap or Piston pin clearance
— A — B B — EM-121
knock noise Connecting rod bushing
oil clearance
Piston to cylinder bore
Crank- clearance
shaft pul- Piston ring side clear-
Slap or Piston
ley A — — B B A ance EM-121
rap slap noise
Cylinder Piston ring end gap
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-121
Knock A B C B B B
bearing Connecting rod bearing EM-124
noise oil clearance
Main bearing oil clear-
Main bear- EM-125
Knock A B — A B C ance
ing noise EM-121
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-54
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-45
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-15
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water CO-18,
Squall
A B — B A B pump Water pump operation "Exploded
Creak
noise View"
A: Closely related B: Related C: Sometimes related —: Not related

PRECAUTIONS
< PRECAUTION > [MR20DE]
PRECAUTION A
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000004221784
EM
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
C
PIIB3706J
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect F

INFOID:0000000004221783
NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi- G
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables. H
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned. I
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure
below before starting the repair operation.
OPERATION PROCEDURE J
1. Connect both battery cables.

NOTE:
Supply power using jumper cables if battery is discharged. K
2. Turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.)
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon- L
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
M
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III. N
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000004221782 O
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and P
“SEAT BELT” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.

PRECAUTIONS
• 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 “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Draining Engine Coolant INFOID:0000000003802140
Drain engine coolant and engine oil when the engine is cooled.
Disconnecting Fuel Piping INFOID:0000000003802141
• 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.
Removal and Disassembly INFOID:0000000003802142
• 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.
• Cover openings of engine system with a tape or equivalent, if necessary, 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.
Inspection, Repair and Replacement INFOID:0000000003802143
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Assembly and Installation INFOID:0000000003802144
• 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.
• 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:0000000003802145
• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Camshaft sprocket (INT) bolt

PRECAUTIONS
- Cylinder head bolts
- Main bearing cap bolts A
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening)
EM
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
C
Liquid Gasket INFOID:0000000003802146
REMOVAL OF LIQUID GASKET SEALING D

• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter [SST: KV10111100] (A) and remove old
liquid gasket sealing.
CAUTION: E
Be careful not to damage the mating surfaces.
• Tap the seal cutter [SST: KV10111100] to insert it (B), and then
slide it (C) by tapping on the side as shown in the figure. F
• In areas where the seal cutter [SST: KV10111100] is difficult to use,
use a plastic hammer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as a screwdriver is G
JPBIA0052ZZ
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
H
1. Using a scraper (A), remove old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes. I
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. J
K
JPBIA0053ZZ
3. Attach liquid gasket tube to the tube presser (commercial ser-

vice tool). L
Use Genuine Liquid Gasket or equivalent.
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions. M
• If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
N
EMA0622D
O

PRECAUTIONS
• As for bolt holes, normally apply liquid gasket inside the holes.
Occasionally, it should be applied outside the holes. Check to
read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
SEM159F
them.

PREPARATION
< PREPARATION > [MR20DE]
PREPARATION A
PREPARATION
Special Service Tools INFOID:0000000003802147
EM
Tool number
Description C
Tool name
KV10111100 Removing oil pan (upper and lower) etc.
Seal cutter
D
E
S-NT046
KV10116200 Disassembling and assembling valve mecha-

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

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

Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter
N
S-NT605 O
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia. P
b: 13 (0.51) dia. e: 10.7 (0.421)
c: 10.3 (0.406) dia. f: 5 (0.20)
Unit: mm (in)
S-NT603

PREPARATION
Tool number
Description
Tool name
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
S-NT044
ST1661001 Removing pilot converter

Pilot bushing puller
S-NT045
KV11103000 Removing crankshaft pulley

Pulley puller
NT676
KV11105210 Fixing drive plate

Stopper plate
ZZA0009D
Commercial Service Tools INFOID:0000000003802148
Tool name Description

Quick connector release Removing fuel tube quick connectors in en-
gine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
PBIC0198E
Spark plug wrench Removing and installing spark plug

a: 14 mm (0.55 in)
JPBIA0399ZZ

PREPARATION
A
Pulley holder Crankshaft pulley removing and installing
EM
C
ZZA1010D
Valve seat cutter set Finishing valve seat dimensions
S-NT048
Piston ring expander Removing and installing piston ring F
S-NT030
H
Valve guide drift Removing and installing valve guide
J
PBIC4012E
Valve guide reamer 1: Reaming valve guide inner hole

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

before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
a: 18 mm (0.71 in) dia. for zirconia heated
N
oxygen sensor
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor
AEM488
O
Anti-seize lubricant (Permatex 133AR Lubricating oxygen sensor thread cleaning
or equivalent meeting MIL specifica- tool when reconditioning exhaust system
tion MIL-A-907) threads P
AEM489

PREPARATION
Manual lift table caddy Removing and installing engine
ZZA1210D
Tube presser Pressing the tube of liquid gasket
S-NT052

DRIVE BELTS
< ON-VEHICLE MAINTENANCE > [MR20DE]
ON-VEHICLE MAINTENANCE A
DRIVE BELTS
Exploded View INFOID:0000000003802149
EM
JPBIA2205ZZ J
Alternator, water pump and A/C compressor

1. Alternator 2. 3. Power steering oil pump belt
belt auto-tensioner
4. Power steering oil pump 5. Power steering oil pump belt auto-tensioner 6. Crankshaft pulley
K
Alternator, water pump and A/C com-
7. A/C compressor 8. Water pump 9.
pressor belt
A. View A B. View B C. Indicator L
D Possible use range E. Range when new drive belt is installed
Checking INFOID:0000000003802150
M
WARNING:
Perform this step when engine is stopped.
N
• Check that the indicator (C) (notch on fixed side) of each auto-tensioner is within the possible use range (D)
in the figure.
NOTE:
• Check the each auto-tensioner indication when the engine is cold. O
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (E) in the fig-
ure.
• Visually check entire drive belts for wear, damage or cracks. P
• If the indicator (notch on fixed side) is out of the possible use range or belts is damaged, replace belts.
Tension Adjustment INFOID:0000000003802151
Refer to : EM-116, "Drive Belt".

DRIVE BELTS
Removal and Installation INFOID:0000000003802152
REMOVAL
1. Remove front wheel and tire (RH).
2. Remove front splash guard (RH). Refer to EXT-24, "FENDER PROTECTOR : Exploded View".
3. Hold the hexagonal part (B) of power steering oil pump belt
auto-tensioner (1) with a wrench securely. Then move the
wrench handle in the direction of arrow (loosening direction of
tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole (A) of the retaining boss to
fix power steering oil pump belt auto-tensioner.
• Keep power steering oil pump belt auto-tensioner pulley arm JPBIA2252ZZ
locked power steering oil pump belt is removed.
5. Remove power steering oil pump belt.
6. Hold the hexagonal part (A) of alternator, water pump and A/C
compressor belt auto-tensioner (1) with a wrench securely. Then
move the wrench handle in the direction of arrow (loosening
direction of tensioner).
CAUTION:
Avoid placing hand in a location where pinching may occur
if the holding tool accidentally comes off.
7. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole (B) of the retaining boss to
fix alternator, water pump and A/C compressor belt auto-ten-
sioner. PBIC3936E
• Keep alternator, water pump and A/C compressor belt auto-
tensioner pulley arm locked after drive belt is removed.
8. Remove alternator, water pump and A/C compressor belt.
INSTALLATION
CAUTION:
• Confirm each belts is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to each belts and each pulley
groove.
Alternator, Water pump and A/C compressor belt
1. Hook alternator, water pump and A/C compressor belt on to all pulleys except for alternator, water pump
and A/C compressor belt auto-tensioner pulley, and then on to alternator, water pump and A/C compres-
sor belt auto-tensioner pulley finally.
CAUTION:
• Conform alternator, water pump and A/C compressor belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhere to alternator water pump
and A/C compressor belt and each pulley groove.
2. Release alternator, water pump and A/C compressor belt auto-tensioner, and apply tension to alternator
water pump A/C compressor belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-15, "Exploded View".
Power Steering Oil Pump belt
1. Hook power steering oil pump belt on to all pulleys except for power steering oil pump belt auto-tensioner
pulley, and then on to power steering oil pump belt auto-tensioner pulley finally.
CAUTION:
• Conform power steering oil pump belt is completely set to pulleys.

DRIVE BELTS
• Check for engine oil, working fluid and engine coolant are not adhere to power steering oil pump
belt and each pulley groove. A
2. Release power steering oil pump belt auto-tensioner, and apply tension to power steering oil pump belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to EM

AIR CLEANER FILTER
AIR CLEANER FILTER
REMOVAL
1. Unhook air cleaner case (lower) side clips and lift up air cleaner case (upper).
2. Remove air cleaner filter from air cleaner case (lower).
PBIC1165E
INSTALLATION
Note the following, and install in the reverse order of removal.
• Install the air cleaner filter by aligning the seal with the notch of air cleaner case.

SPARK PLUG
SPARK PLUG
A
EM
J
PBIC4366J
1. PCV hose 2. Rocker cover 3. Spark plug K

4. Ignition coil 5. PCV hose 6. PCV valve
7. O-ring 8. Rocker cover gasket
A. To air duct assembly B. Refer to EM-43 C. To intake manifold L
Refer to GI-4, "Components" for symbols in the figure.
Removal and Installation INFOID:0000000003802155 M
REMOVAL
1. Remove ignition coil. Refer to EM-43, "Exploded View". N
2. Remove spark plug with a spark plug wrench (commercial ser-
vice tool).
O
a : 14 mm (0.55 in)
CAUTION:
Never drop or shock spark plug. P
JPBIA0030ZZ
INSTALLATION
Install in the reverse order of removal.

SPARK PLUG
Inspection INFOID:0000000003802156
INSPECTION AFTER REMOVAL

Use the standard type spark plug for normal condition.
Spark plug (Standard type) : Refer to EM-116, "Spark Plug".

CAUTION:
• Never drop or shock spark plug.
• Never use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used.
Cleaner air pressure : Less than 588 kPa (5.88 bar, 6

kg/cm2, 85 psi)
Cleaning time : Less than 20 seconds
SMA773C
• Checking and adjusting plug gap is not required between

replacement intervals.
• Measure spark plug gap. when it exceeds the limit, replace
spark plug even if it is with in the specified replacement mile-
age. Refer to EM-116, "Spark Plug".
JPBIA0031ZZ

CAMSHAFT VALVE CLEARANCE
A
Inspection and Adjustment INFOID:0000000003802157
INSPECTION EM
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-43, "Exploded View". C
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no D
paint) (B) to timing indicator (A) on front cover.
C : White paint mark (Not use for service)

E
PBIC3960E G
• At the same time, check that both intake and exhaust cam
noses of No. 1 cylinder face inside ( ) as shown in the figure. H
1 : Camshaft (INT)
2 : Camshaft (EXH)
I
: Engine front
• If they do not face inside, rotate crankshaft pulley once more

(360 degrees) and align as shown in the figure. J
PBIC3359J
K
b. Use a feeler gauge, measure the clearance between valve lifter
and camshaft.
L
Valve clearance : Refer to EM-117, "Camshaft".
N
PBIC3192J
• By referring to the figure, measure the valve clearances at

O
locations marked “×” as shown in the table below [locations
indicated with black arrow ( ) in the figure] with a feeler
gauge.
P
A : Exhaust side
B : No. 1 cylinder
C : No. 2 cylinder
D : No. 3 cylinder
E : No. 4 cylinder
PBIC3193J

F : Intake side
: Engine front
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
EXH × ×
No. 1 cylinder at compression TDC
INT × ×
c. Set No. 4 cylinder at TDC of its compression stroke.

• Rotate crankshaft pulley (1) one revolution (360 degrees) and
align TDC mark (no paint) (B) to timing indicator (A) on front
cover.
PBIC3960E
• By referring to the figure, measure the valve clearance at loca-

tions marked “×” as shown in the table below [locations indi-
cated with black arrow ( ) in the figure] with a feeler gauge.
A : Exhaust side
B : No. 1 cylinder
C : No. 2 cylinder
D : No. 3 cylinder
E : No. 4 cylinder
F : Intake side
PBIC3194J
: Engine front
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
EXH × ×
No. 4 cylinder at compression TDC
INT × ×
3. If out of standard, perform adjustment. Refer to “ADJUSTMENT”.

ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-56, "Exploded View".
2. Remove valve lifters at the locations that are out of the standard.
3. Measure the center thickness of the removed valve lifters with a
micrometer (A).
PBIC3195J
4. Use the equation below to calculate valve lifter thickness for replacement.

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

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
EM
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in) C
Exhaust : 0.33 mm (0.013 in)
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder). D
• Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.
PBIC3196J
G
NOTE:
Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.1181 to 0.1378 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-117, "Camshaft". H
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-56, "Exploded View".
7. Install timing chain and related parts. Refer to EM-45, "Exploded View". I
8. Manually rotate crankshaft pulley a few rotations.
9. Check that the valve clearances is within the standard. Refer to “INSPECTION”.
J
10. Install remaining parts in the reverse order of removal.
11. Warm up the engine, and check for unusual noise and vibration.
K

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

2. Release fuel pressure. Refer to EC-356, "Inspection" (TYPE 1) or EC-648, "Inspection" (TYPE 2).
3. Remove ignition coil and spark plug from each cylinder. Refer to EM-43, "Exploded View".
4. Connect engine tachometer (not required in use of CONSULT-III).
5. Install compression gauge (B) with an adapter (A) (commercial
service tool) onto spark plug hole.
PBIC3541J
• Use the adapter whose picking up end inserted to spark plug

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
a : 20 mm (0.79 in)
JPBIA0171ZZ
6. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each
cylinder.
Compression pressure : Refer to EM-116, "General Specification".

CAUTION:
Always use a fully charged battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the
engine speed again with normal battery gravity.
• If compression pressure is below minimum value, check valve clearances, and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to recheck it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
7. After inspection is completed, install removed parts.
8. Start the engine, and check that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-103, "Description" (TYPE 1) or EC-442,
"Description" (TYPE2).

ENGINE COVER
< ON-VEHICLE REPAIR > [MR20DE]
ON-VEHICLE REPAIR A
ENGINE COVER
EM
JPBIA2354GB
H
1. Engine cover
I
REMOVAL J
Remove engine cover.
CAUTION:
Never damage or scratch engine cover when installing or removing.
K
INSTALLATION
L

DRIVE BELT AUTO-TENSIONER
DRIVE BELT AUTO-TENSIONER
JPBIA2206GB
Power steering oil pump belt auto- Alternator, water pump and A/C compressor
1. Power steering oil pump bracket 2. 3.
tensioner belt auto-tensioner
4. Front cover
Removal
1. Remove drive belts. Refer to EM-16, "Removal and Installation".
• Keep each auto-tensioner pulley arm locked after drive belts are removed.
2. Remove power steering oil pump belt auto-tensioner.
3. Remove exhaust front tube. Refer to EX-5, "Exploded View".
4. Remove rear torque rod mounting bolt to the engine side. Refer to EM-77, "Exploded View".
5. Remove engine cover. Refer to EM-25, "Exploded View".
6. Remove reservoir tank of power steering oil pump, and then move it to aside. Refer to ST-37, "Exploded
View".
7. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and the engine mounting insulator (RH). Refer to EM-77, "Exploded View".
CAUTION:
Never damage or scratch oil pan (lower) when supporting.
8. Loosen mounting bolt and remove alternator, water pump and A/C compressor belt auto-tensioner.
• Lift the front side of the engine with a jack sustaining engine base to remove mounting bolt.
Installation
CAUTION:
When installing each auto-tensioner, be careful not to interfere with water pump pulley or power steer-
ing oil pump pulley.

AIR CLEANER AND AIR DUCT
A
EM
J
JPBIA2207GB
1. Mass air flow sensor 2. Air cleaner case (upper) 3. Air cleaner filter K
4. Clamp 5. Air duct assembly 6. Clamp
7. PCV hose 8. Air duct (inlet) 9. Grommet
10. Collar 11. Air cleaner case (lower) 12. Grommet L
13. Bracket 14. Bracket
A. To electric throttle control actuator B. To rocker cover
Refer to GI-4, "Components" for symbols in the figure. M
N
REMOVAL
NOTE:
Mass air flow sensor is removable under the car-mounted condition. O
1. Remove air duct (inlet).
3. Disconnect mass air flow sensor harness connector. P
4. Disconnect PCV hose.
5. Remove air cleaner cases (upper and lower) and mass air flow sensor assembly and air duct assembly
disconnecting their joints.
• Add mating marks if necessary for easier installation.
6. Remove mass air flow sensor from air cleaner case (upper), if necessary.
CAUTION:
Handle the mass air flow sensor with following cares.

• Never shock the mass air flow sensor.
• Never disassemble the mass air flow sensor.
• Never touch the sensor of the mass air flow sensor.
INSTALLATION
• Align marks. Attach each joint. Screw clamps firmly.

Inspect air duct assembly for crack or tear.
• If anything found, replace air duct assembly.

INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
J
JPBIA2494GB
1. Clamp 2. Harness bracket 3. Clamp K

4. PCV hose 5. Gasket 6. Vacuum hose
7. Clamp 8. Intake manifold 9. Bracket
EVAP canister purge volume L
10. EVAP hose 11. Clamp 12.
control solenoid valve
13. O-ring 14. Clamp 15. Water hose
16. Water hose 17. Electric throttle control actuator 18. Gasket M
A. To brake booster B. To centralized under-floor piping C. To water outlet
D. For China
Refer to GI-4, "Components" for symbols in the figure. N
O
REMOVAL
2. Pull out oil level gauge. P
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
3. Disconnect PCV hose from intake manifold and rocker cover.
4. Remove air duct assembly. Refer to EM-27, "Exploded View".
5. Disconnect vacuum hose from intake manifold.
6. Disconnect water hoses from electric throttle control actuator as follows (for China):

INTAKE MANIFOLD
• Drain engine coolant from radiator or attach plug to prevent engine coolant leakage when engine cool-
ant is not drained. Refer to CO-9, "Draining".
CAUTION:
Perform this step when the engine is cold.
7. Remove electric throttle control actuator.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble electric throttle control actuator.
8. Remove intake manifold (1) with the following procedure:
: Engine front
a. Loosen and remove intake manifold mounting bolts (A) and (B).
b. Remove harness clip from intake manifold side.
c. Disconnect EVAP hose from intake manifold.
d. Disconnect harness connector from EVAP canister purge vol-
ume control valve.
PBIC3939E
e. Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
CAUTION:
Cover engine openings to avoid entry of foreign materials.
PBIC3527J
9. Remove brackets from intake manifold, if necessary.

10. Remove engine cover bracket, if necessary.
11. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary.
INSTALLATION
Intake Manifold
1. Check if gasket is not dropped from the installation groove of intake manifold.
2. Install intake manifold with the following procedure:

INTAKE MANIFOLD
a. Tighten in numerical order as shown in the figure.
A
: Engine front
EM
b. Tighten No. 1 bolt again.
PBIC3527J
D
c. Tighten intake manifold mounting bolt (A). Then tighten intake
manifold mounting bolt (B).
E
1 : Intake manifold
: Engine front
PBIC3939E
K
Electric Throttle Control Actuator
• Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec- L
tric throttle control actuator. Refer to EC-30, "THROTTLE VALVE CLOSED POSITION LEARNING : Special
Repair Requirement" (TYPE 1) or EC-370, "THROTTLE VALVE CLOSED POSITION LEARNING : Special
Repair Requirement" (TYPE2). M
• Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing
electric throttle control actuator. Refer to EC-30, "IDLE AIR VOLUME LEARNING : Special Repair Require-
ment" (TYPE1) or EC-370, "IDLE AIR VOLUME LEARNING : Special Repair Requirement" (TYPE 2).
N

EXHAUST MANIFOLD
EXHAUST MANIFOLD
PBIC4735E
1. Exhaust manifold cover 2. Exhaust manifold 3. Gasket

4. Stud bolt 5. Harness bracket 6. Heated oxygen sensor 1
7. Exhaust manifold stay
REMOVAL
2. Remove exhaust manifold cover.
3. Remove the heated oxygen sensor 1.
• Using heated oxygen sensor wrench [SST: KV10117100], remove heated oxygen sensor 1.
CAUTION:
Handle heated oxygen sensor 1 carefully and avoid impacts.
NOTE:
The exhaust manifold can be removed and installed without removing the heated oxygen sensor 1 (Disas-
sembly of harness connector is necessary).
4. Remove exhaust manifold stay.
5. Remove exhaust manifold.

EXHAUST MANIFOLD
• Loosen nuts in reverse order as shown in the figure.
A
: Engine front
NOTE:
Disregard No. 6 to 8 when loosening. EM
JPBIA2356ZZ
D
6. Remove gasket.
CAUTION:
E
INSTALLATION
1. Install gasket to cylinder head as shown in the figure.
F
: Engine front
PBIC3943E
I
2. Install exhaust manifold with the following procedure:
a. Tighten nuts in numerical order as shown in the figure.
J
: Engine front
NOTE:
No. 6 to 8 mean double of nuts No. 1 to 3. K
JPBIA2356ZZ
M
b. Install exhaust manifold stay (2) in the direction as shown in the
figure.
1 : Exhaust manifold
N
3 : Drive shaft support bearing bracket
A : Upper mark
O
: Engine front
P
PBIC3255J


EXHAUST MANIFOLD
Surface Distortion
• Using feeler gauge (A) and straightedge (B), check the surface dis-
tortion of exhaust manifold mating surface in each exhaust port
and entire part.
Limit : Refer to EM-117, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.
PBIC3530J

OIL PAN (LOWER)
OIL PAN (LOWER)
A
EM
J
JPBIA1889GB
1. Rear oil seal 2. O-ring 3. Oil pan (upper) K

4. Balancer unit timing chain tensioner 5. Balancer unit timing chain 6. Crankshaft sprocket
7. Balancer unit sprocket 8. Drain plug 9. Drain plug washer
10. Oil pan (lower) 11. Oil filter 12. Oil filter stud bolt L
13. O-ring 14. Oil level gauge 15. Oil level gauge guide
A. Refer to LU-9 B. Oil pan (lower) side
N
REMOVAL
1. Remove engine undercover.
2. Drain engine oil. Refer to LU-7, "Draining". O
3. Remove oil pan (lower) with the following procedure:

OIL PAN (LOWER)
a. Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
PBIC3146J
b. Insert seal cutter (SST) between oil pan (upper) and oil pan
(lower).
CAUTION:
Be careful not to damage the mating surface.
SEM365EA
INSTALLATION
1. Install oil pan (lower) with the following procedure:
a. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Also remove old liquid gasket from mating surface of oil pan
(upper).
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Never scratch or damage the mating surface when cleaning
off old liquid gasket.
PBIC3953E

OIL PAN (LOWER)
b. Apply a continuous bead of liquid gasket (A) with a tube presser
(commercial service tool) as shown in the figure. A
1 : Oil pan (lower)

: Engine front EM
: Engine outside

CAUTION: C
Attaching should be done within 5 minutes after liquid gas-
ket application.
D
G
JPBIA0289ZZ
c. Tighten bolts in numerical order as shown in the figure.

H
: Engine front
PBIC3146J
K
L
Clean oil strainer portion [part of the oil pan (upper)] if any object attached.
M
INSPECTION AFTER INSTALLATION
1. Check the engine oil level and adjust engine oil. Refer to LU-6, "Inspection".
2. Start engine, and check there is no leakage of engine oil. N
3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-6, "Inspection".
O

FUEL INJECTOR AND FUEL TUBE
JPBIA2357GB
1. Quick connector cap (vehicle side) 2. Fuel feed tube 3. Clip

4. Injector 5. O-ring (green) 6. O-ring (black)
7. Fuel tube 8. Quick connector cap (engine side) 9. Bracket
CAUTION:
Never remove or disassemble parts unless instructed in the figure.
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
REMOVAL
1. Release the fuel pressure. Refer to EC-356, "Inspection" (TYPE1) or EC-648, "Inspection" (TYPE 2).
2. Remove intake manifold. Refer to EM-29, "Exploded View".

3. Disconnect quick connector with the following procedure. Dis-
connect fuel feed tube (1) from fuel tube (3). A
NOTE:
There is no fuel return path.
a. Remove quick connector cap (engine side) (2) from quick con- EM
nector connection.
PBIC3157J
D
b. With the sleeve side of quick connector release facing quick connector, install quick connector release
(commercial service tool) onto fuel tube.
c. Insert quick connector release (A) into quick connector (2) until E
sleeve (B) contacts and goes no further. Hold quick connector
release on that position.
D : Insert and retain F

CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it G
contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube (1).
CAUTION: JPBIA2255ZZ H
• Pull quick connector (E) holding position (C) in the figure.
• Never pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leakage out. I
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Never expose parts to battery electrolyte or other acids. J
• Never bend or twist connection between quick connector and fuel feed tube during installation/
removal.
• To keep clean the connecting portion and to avoid dam- K
age and foreign materials, cover them completely with
plastic bags, etc. (A) or something similar.
L
JPBIA0035ZZ N
4. Disconnect harness connector from fuel injector.

5. Remove fuel tube and fuel injector assembly. O
• Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
P
CAUTION:
• When removing, be careful to avoid any interference with fuel
injector.
• Use a shop cloth to absorb any fuel leakage from fuel tube.
PBIC3154J

6. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip (2).
b. Remove fuel injector (3) from fuel tube (1) by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube.
• Be careful not to damage fuel injector nozzle during
removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector.
JPBIA0290ZZ
INSTALLATION
1. Note the following, and install O-rings to fuel injector.
CAUTION:
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Black

Nozzle side : Green
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring is stretched while installing, never insert it quickly into fuel tube.
• Insert O-ring straight into fuel tube. Never decenter or twist it.
2. Install fuel injector to fuel tube with the following procedure:
a. Insert clip (2) into clip mounting groove (F) on fuel injector (4).
3 : O-ring (black)
5 : O-ring (green)
• Insert clip so that protrusion (G) of fuel injector matches cut-
out (D) of clip.
CAUTION:
• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (B) of fuel tube matches
cut-out (C) of clip.
• Check that fuel tube flange (A) is securely fixed in flange fixing
groove (E) on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
PBIC3155J
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.
CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.
4. Install fuel tube and injector assembly onto cylinder.

• Tighten mounting bolts in numerical order as shown in the fig-
ure. A
: Engine front
EM
PBIC3154J
D
5. Connect harness connector to fuel injector.
6. Connect fuel feed tube with the following procedure.
a. Check for damage or foreign material on the fuel tube and quick connector. E
b. Apply new engine oil lightly to area around the top of fuel tube.
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector (1) to fuel tube until the top spool (C) on F
fuel tube is inserted completely and the 2nd level spool (D) is
positioned slightly below quick connector bottom end.
G
B : Upright insertion
E : Fitted condition
CAUTION: H
• Hold (A) position in the figure when inserting fuel tube
into quick connector.
• Carefully align center to avoid inclined insertion to pre-
I
vent damage to O-ring inside quick connector. JPBIA2256ZZ
• Insert until you hear a “click” sound and actually feel

the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next J
step.
d. Pull quick connector hard by hand holding position. Check it is completely engaged (connected) so that it
does not come out from fuel tube. K
e. Install quick connector cap (engine side) (2) to quick connector
connection.
L
1. Fuel feed hose
3. Fuel tube
• Install quick connector cap (engine side) with the side arrow M
facing quick connector side (fuel feed tube side).
CAUTION:
• Check that the quick connector and fuel tube are
N
securely engaged with the quick connector cap (engine
side) mounting groove. PBIC3157J
• Quick connector may not be connected correctly if

quick connector cap (engine side) cannot be installed easily. Remove the quick connector cap O
(engine side), and then check the connection of quick connector again.
f. Install fuel feed hose to hose clamp.

P

Check on Fuel Leakage

1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leakage at connection
points.
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.

IGNITION COIL, SPARK PLUG AND ROCKER COVER
A
EM
J
PBIC4366J
1. PCV hose 2. Rocker cover 3. Spark plug K

4. Ignition coil 5. PCV hose 6. PCV valve
7. O-ring 8. Rocker cover gasket
A. To air duct assembly B. Refer to EM-43 C. To intake manifold L
Removal and Installation INFOID:0000000003802176 M
REMOVAL
1. Remove intake manifold. Refer to EM-29, "Exploded View". N
2. Remove ignition coil.
CAUTION:
• Never drop or shock ignition coil. O
• Never disassemble ignition coil.
3. Remove rocker cover.
P

• Loosen bolts in reverse order shown in the figure.
: Engine front
PBIC3151J
4. Remove PCV valve and PCV hose, if necessary.

5. Remove rocker cover gasket from rocker cover.
6. Use scraper to remove all traces of liquid gasket from cylinder head and front cover.
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket.
INSTALLATION
1. Install the rocker cover gasket to rocker cover.
CAUTION:
Check the gasket is not dropped.
2. Install rocker cover.
• Tighten bolts in two steps separately in numerical order as
shown in the figure.
: Engine front
1st step : 1.96 N·m (0.20 kg-m, 17 in-lb)

2nd step : 8.33 N·m (0.85 kg-m, 74 in-lb)
3. Install in the reverse order of removal, for the rest of parts.
PBIC3151J

TIMING CHAIN
TIMING CHAIN
A
EM
JPBIA2208GB
P
1. Slack guide 2. Timing chain tensioner 3. Camshaft sprocket (EXH)
4. Timing chain 5. Tension guide (front cover side) 6. Oil filler cap
Intake valve timing control solenoid
7. Front cover 8. O-ring 9.
valve
10. Power steering oil pump bracket 11. Power steering oil pump bracket 12. Crankshaft pulley bolt
13. Crankshaft pulley 14. Front oil seal 15. Crankshaft sprocket
16. Balancer unit sprocket 17. Balancer unit timing chain 18. Balancer unit timing chain tensioner

TIMING CHAIN
19. O-ring 20. Tension guide 21. Camshaft sprocket (INT)
A. Refer to EM-56
REMOVAL
CAUTION:
The rotating direction in the text indicates all directions seen from the engine front.
1. Remove rocker cover. Refer to EM-43, "Exploded View".
2. Drain engine oil. Refer to LU-7, "Draining".
CAUTION:
Perform this step when engine is cold.
3. Remove drive belts. Refer to EM-16, "Removal and Installation".
4. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
PBIC3960E
b. At the same time, check that the cam noses of the No. 1 cylinder
are located ( ) as shown in the figure.
1 : Camshaft (INT)
2 : Camshaft (EXH)
: Engine front
• If not, rotate crankshaft pulley one revolution (360 degrees)

and align as shown in the figure.
PBIC3359J
5. Remove crankshaft pulley with the following procedure:

a. Fix crankshaft pulley (1) with a pulley holder (A) (commercial
service tool), loosen crankshaft pulley bolt, and locate bolt seat-
ing surface at 10 mm (0.39 in) from its original position.
CAUTION:
Never remove the crankshaft pulley bolt as they will be
used as a supporting point for the pulley puller [SST:
KV11103000].
PBIC3961E

TIMING CHAIN
b. Attach a pulley puller [SST: KV11103000] (A) in the M6 thread
hole on crankshaft pulley (1), and remove crankshaft pulley. A
EM
PBIC3962E
D
6. Remove power steering oil pump belt auto-tensioner. Refer to EM-26, "Exploded View".
7. Remove power steering oil pump and power steering oil pump brackets. Refer to ST-30, "Exploded View".
8. Remove exhaust front tube. Refer to EX-5, "Exploded View". E
9. Remove rear torque rod. Refer to EM-77, "Exploded View".
10. Remove oil pan (lower). Refer to EM-35, "Exploded View".
NOTE: F
If crankshaft sprocket and balancer unit component are not removed, this step is unnecessary.
11. Remove reservoir tank of power steering oil pump, and then move it to aside. Refer to ST-37, "Exploded
View". G
12. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and the engine mounting insulator (RH). Refer to EM-77, "Exploded View".
13. Remove intake valve timing control solenoid valve. H
14. Remove alternator, water pump and A/C compressor belt auto-tensioner. Refer to EM-26, "Exploded
View".
15. Remove front cover with the following procedure: I
b. Remove power steering oil pump brackets.
J
PBIC3164J
P

TIMING CHAIN
c. Cut liquid gasket by prying the position ( ) shown in the figure,
and then remove the front cover.
CAUTION:
• Be careful not to damage the mating surface.
• A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off
the position not specified.
PBIC3357J
16. Remove front oil seal from front cover.

CAUTION:
Be careful not to damage front cover.
• Lift up front oil seal using a screwdriver.
17. Remove timing chain tensioner with the following procedure:
a. Push in timing chain tensioner plunger.
b. Insert a stopper pin (A) into the body hole, and then fix it with the
plunger pushed in.
NOTE:
Use approximately 1.5 mm (0.059 in) diameter. hard metal pin
as a stopper pin.
c. Remove timing chain tensioner (1).
PBIC3165J
18. Remove slack guide (2), tension guide (3) and timing chain (1).
CAUTION:
Never rotate each crankshaft and camshaft individually
while timing chain is removed. It causes interference
between valve and piston.
JPBIA0830ZZ
19. Remove crankshaft sprocket and balancer unit drive component with the following procedure:

TIMING CHAIN
a. Press stopper tab (A) in the direction shown in the figure to push
the balancer unit timing chain slack guide (B) toward balancer A
unit timing chain tensioner (1).
• The balancer unit timing chain slack guide is released by
pressing the stopper tab. As the result, the balancer unit timing
EM
chain slack guide can be moved.
b. Insert a stopper pin (D) into tensioner body hole (C) to secure
the balancer unit timing chain slack guide.
NOTE: C
Use a hard metal pin with the diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
c. Remove balancer unit timing chain tensioner. D
• When the holes on lever and tensioner body cannot be
aligned, align these holes by slightly moving the balancer unit
timing chain slack guide. E
G
PBIC5314E
d. Hold the WAF part of balancer shaft [WAF: 19 mm (0.75 in)] (A),
and then loosen the balancer unit sprocket bolt. H
1 : Oil pan (upper)

: Engine front I
CAUTION:
• Secure the balancer unit shaft with the WAF part.
• Never loosen the balancer unit sprocket bolt by tightening J
the balancer unit drive chain.
e. Remove crankshaft sprocket, balancer unit sprocket and bal-
ancer unit timing chain as a set. K
N
PBIC3168J
20. Remove tension guide (front cover side) from front cover, if necessary. O
INSTALLATION
NOTE:
P

TIMING CHAIN
The figure shows the relationship between the matching mark on
each timing chain and that on the corresponding sprocket, with the
components installed.
1 : Timing chain
2 : Camshaft sprocket (EXH)
3 : Slack guide
4 : Timing chain tensioner
5 : Balancer unit sprocket
6 : Balancer unit timing chain
7 : Balancer unit timing chain tensioner
8 : Crankshaft sprocket
9 : Tension guide
10 : Camshaft sprocket (INT)
A : Matching mark (dark blue link)
B : Matching mark (stamping)
C : Crankshaft key position (straight up)
D : Matching mark (stamping)
E : Matching mark (orange link)
F : Matching mark (outer groove*)
JPBIA0831ZZ
*: There are two outer grooves in camshaft sprocket (INT). The wider one is a match-
ing mark.
1. Check that crankshaft key points straight up.
2. If the tension guide (front cover side) is removed, install it to the front cover.
CAUTION:
Check the joint condition by sound or feeling.
3. Install crankshaft sprocket (2), balancer unit sprocket (3) and
balancer unit timing chain (1).
A : Matching mark (stamping)

B : Matching mark (orange link)
C : Matching mark (dark blue link)
• Install it by aligning matching marks on each sprocket and bal-
ancer unit timing chain.
• If these matching marks are not aligned, rotate the balancer
shaft slightly to correct the position.
CAUTION: PBIC3171J
Check matching mark position of each sprocket after

installing the balancer unit timing chain.

TIMING CHAIN
4. Hold the WAF part of balancer unit shaft [WAF: 19 mm (0.75 in)]
(A), and then tighten the balancer shaft sprocket bolt. A
1 : Oil pan (upper)

: Engine front EM
CAUTION:
• Secure the balancer unit shaft with the WAF part.
• Never loosen the balancer shaft sprocket bolt by tighten- C
ing the balancer unit timing chain.
G
PBIC3168J
H
5. Install balancer unit timing chain tensioner (1).
• Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
• Securely pull out ( ) the stopper pin after installing the bal- I
ancer unit timing chain tensioner.
• Check matching mark position of balancer unit timing chain
and each sprocket again. J
K
PBIC5315E

TIMING CHAIN
6. Align the matching marks of each sprocket with the matching
marks of timing chain.
1 : Camshaft sprocket (EXH)

3 : Timing chain
A : Matching mark (dark blue link)
B : Matching mark (stamping)
C : Matching mark (outer groove*)
D : Matching mark (orange link)
E : Matching mark (stamping)
*: There are 2 outer grooves in camshaft sprocket (INT). The wider one is a
matching mark.
• If these matching marks are not aligned, rotate the camshaft
slightly by holding the hexagonal portion to correct the posi-
tion.
CAUTION:
Check matching mark position of each sprocket and timing
chain again after installing the timing chain.
PBIC3172J
7. Install the tension guide (3) and the slack guide (2).
1 : Timing chain
JPBIA0830ZZ
8. Install timing chain tensioner (1).

• Fix the plunger at the most compressed position using a stop-
per pin (A), and then install it.
• Securely pull out the stopper pin after installing the timing
chain tensioner.
PBIC3165J

TIMING CHAIN
9. Check matching mark position of timing chain and each sprocket again.
10. Install front oil seal. Refer to EM-66, "FRONT OIL SEAL : Removal and Installation". A
11. Install front cover with the following procedure:
a. Install new O-ring to cylinder block.
CAUTION: EM
Never misalign O-ring.
b. Apply a continuous bead of liquid gasket (B) with a tube presser
(commercial service tool) to front cover as shown in the figure. C
A : Liquid gasket application area

c : 4.0 - 5.6 mm (0.157 - 0.220 in) D
d : φ3.4 - 4.4 mm (0.134 - 0.173 in)
: Engine outside
Use Genuine Liquid Gasket or equivalent. E
I
JPBIA2257ZZ
c. Check that matching marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION: J
• Check O-ring on cylinder block is correctly installed.
• Be careful not to damage front oil seal by interference with front end of crankshaft.
d. Install front cover and power steering oil pump bracket, and K
tighten mounting bolts in numerical order as shown in the figure.
• Refer to the following for the installation position of bolts.
L
M6 bolt : No. 1
M10 bolts : No. 6, 7, 10, 11, 14
M12 bolts : No. 2, 4, 8, 12 M
M8 bolts : Except the above
CAUTION:
N
Attaching should be done within 5 minutes after liquid gas-
ket application.
e. After all bolts are tightened, retighten them to specified torque in
numerical order as shown in the figure. O
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking.
P
PBIC3164J
12. Install crankshaft pulley with the following procedure:

TIMING CHAIN
a. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Never damage front oil seal lip section.
b. Secure crankshaft pulley (1) with a pulley holder (commercial
service tool) (A).
c. Apply new engine oil to thread and seat surfaces of crankshaft
pulley bolt.
d. Tighten crankshaft pulley bolt.
: 68.6 N·m (7.0 kg-m, 51 ft-lb)

e. Completely loosen.
PBIC3961E
: 0 N·m (0 kg-m, 0 ft-lb)

f. Tighten crankshaft pulley bolt.
: 29.4 N·m (3.0 kg-m, 22 ft-lb)

g. Put a paint mark (B) on crankshaft pulley (2), matching with any
one of six easy to recognize angle marks (A) on crankshaft pul-
ley bolt (1) flange.
h. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
i. Check that crankshaft rotates clockwise smoothly.
PBIC3963E


Timing Chain
Check for cracks (A) and any excessive wear (B) at link plates and
roller links of timing chain. Replace timing chain if necessary.
PBIC3169J

Inspection for Leakage
The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases 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-8, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.

TIMING CHAIN
• Run engine to check for unusual noise and vibration.
NOTE: A
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise
will stop after hydraulic pressure rises.
EM
• Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the C
specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped D
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
E
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc. F

CAMSHAFT
CAMSHAFT
JPBIA2151GB
1. Camshaft position sensor (PHASE) 2. O-ring 3. Camshaft bracket

4. Camshaft (EXH) 5. Camshaft sprocket (EXH) 6. Camshaft sprocket (INT)
7. Camshaft (INT) 8. Valve lifter (EXH) 9. Valve lifter (INT)
10. Signal plate
A. Refer to EM-56
CAUTION:
The rotating direction in the text indicates all directions seen from the engine front.
REMOVAL
1. Remove the following parts.
• Intake manifold: Refer to EM-29, "Exploded View".
• Rocker cover: Refer to EM-43, "Exploded View".
• Front cover and timing chain related parts: Refer to EM-45, "Exploded View".
NOTE:

CAMSHAFT
Removal of balancer unit related part is not necessary.
2. Remove camshaft position sensor (PHASE) from camshaft bracket. A
CAUTION:
• Handle camshaft position sensor (PHASE) carefully and avoid impacts.
• Never disassemble camshaft position sensor (PHASE). EM
• Never place sensor where it is exposed to magnetism.
3. Put the matching mark (A) on the camshaft sprocket (INT) (2)
and the camshaft bracket (1) as shown in the figure.
C
: Engine front
NOTE: D
It prevents the knock pin of the camshaft (INT) from engaging
with the incorrect pin hole when installing the camshaft sprocket
(INT).
E
PBIC3992J
F
4. Remove camshaft sprockets (INT) and (EXH).
• Secure hexagonal part (A) of camshaft with a wrench. Loosen
camshaft sprocket mounting bolts and remove camshaft
sprocket. G

2 : Camshaft sprocket (EXH) H
CAUTION:
• Never rotate crankshaft or camshaft while timing chain
is removed. It causes interference between valve and I
piston.
• Never loosen the mounting bolts with securing anything PBIC3454J
other than the camshaft hexagonal part or with tension-

ing the timing chain. J
5. Remove camshaft bracket with the following procedure:

a. Loosen mounting bolts in reverse order as shown in the figure. K
: Engine front
L
PBIC3176J
N
b. Cut liquid gasket by prying the position ( ) shown in the figure,

and then remove the camshaft bracket. O
: Engine front
CAUTION: P
• Be careful not to damage the mating surface.
• A more adhesive liquid gasket is applied compared to pre-
vious types when shipped, so it should not be forced off
the position not specified.
PBIC3358J

CAMSHAFT
6. Remove camshafts.
7. Remove valve lifters.
• Identify installation positions, and store them without mixing them up.
8. Remove signal plate from camshaft (INT), if necessary.
INSTALLATION
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
• Clean camshaft journal to remove any foreign material.
• Distinguish between the intake and the exhaust by looking at
the different shapes of the front and rear ends of the camshaft
or using the identification colors (A) and (B).
1 : Camshaft (EXH)
2 : Camshaft (INT)
Identification color A B
Camshaft (EXH) — Yellow
Camshaft (INT) Yellow — PBIC3188J
• Install camshafts so that camshaft dowel pins (A) on the front

side are positioned as shown in the figure.
1 : Camshaft (EXH)
2 : Camshaft (INT)
NOTE:
Though camshaft does not stop at the positions as shown in
the figure, for the placement of cam nose, it is generally
accepted camshaft is placed for the same direction of the fig-
ure.
PBIC3189J
3. Install camshaft bracket with the following procedure:

a. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.

CAMSHAFT
b. Apply liquid gasket (A) to camshaft bracket as shown in the fig-
ure. A
B : Plug hole inner wall

: Engine front EM
: Engine outside

C
G
PBIC3964E
c. Tighten mounting bolts of camshaft brackets in the following

steps, in numerical order as shown in the figure. H
: Engine front
I
• There are two types of mounting bolts. Refer to the following
for locating bolts.
M6 bolts [thread length: 57.5 mm (2.264 in)] J

: 13, 14 and 15 in the figure
M6 bolts [thread length: 35.00 mm (1.378 in)] PBIC3176J
K
: Except the above
i. Tighten mounting bolts in numerical order.
L
: 1.96 N·m (0.20 kg-m, 17 in-lb)
ii. Tighten mounting bolts in numerical order. M
: 5.88 N·m (0.60 kg-m, 52 in-lb)

N
iii. Tighten mounting bolts in numerical order.
: 9.5 N·m (0.97 kg-m, 84 in-lb) O

CAUTION:
After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket
from the mating surface of cylinder head. P
4. Install the camshaft sprocket (INT) to the camshaft (INT) with the following procedure.

CAMSHAFT
a. When the camshaft sprocket (INT) (2) is removed, refer to the
paint mark (A) put according to step “3”. Securely align the
knock pin and the pin hole, and then install them.
1 : Camshaft bracket
: Engine front
PBIC3992J
b. Tighten bolts in the following steps.

• Secure the hexagonal part of camshaft (INT) using wrench to tighten mounting bolt.
i. Tighten camshaft (INT) mounting bolt.
: 35.0 N·m (3.6 kg-m, 26 ft-lb)

ii. Turn 67 degrees clockwise (angle tightening).
CAUTION:
Check the tightening angle by using an angle wrench [SST:
KV10112100] (B) or protractor. Never judge by visual
inspection without an angle wrench.

A : Camshaft (INT) hexagonal part
PBIC3455J
5. Install camshaft sprocket (EXH) (2).

• Secure the hexagonal part (A) of camshaft (EXH) using
wrench to tighten mounting bolt.
PBIC3454J
6. Install timing chain and related parts. Refer to EM-45, "Exploded View".
7. Inspect and adjust valve clearance. Refer to EM-21, "Inspection and Adjustment".

Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.

CAMSHAFT
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the A
camshaft runout on dial indicator. (Total indicator reading)
Standard and Limit : Refer to EM-117, "Camshaft". EM

4. If it exceeds the limit, replace camshaft.
PBIC3177J
D
Camshaft Cam Height
1. Measure the camshaft cam height with a micrometer (A).
E
Standard and Limit : Refer to EM-117, "Camshaft".
PBIC3178J
2. If it exceeds the limit, replace camshaft. H

Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER
Measure the outer diameter of camshaft journal with a micrometer I
(A).
Standard : Refer to EM-117, "Camshaft". J
PBIC3179J
L
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with specified torque. Refer to EM-56, "Removal and Installation". M
• Measure the inner diameter of camshaft bracket with a bore gauge
(A).
N
B : Measuring direction of inner diameter
Standard : Refer to EM-117, "Camshaft".

O
P
PBIC3180J
CAMSHAFT JOURNAL OIL CLEARANCE

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

• If it exceeds the limit, replace camshaft or cylinder head, or both.

CAMSHAFT
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace whole cylinder head assembly.
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-56, "Removal and Installation".
2. Install dial indicator in thrust direction on front end of camshaft.
Read the end play of dial indicator (A) when camshaft is moved
forward/backward (in direction to axis).
PBIC3181J
• Measure the following parts if out of the standard.

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

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

• Refer to the standards above, and then replace camshaft and/
or cylinder head.
PBIC3183J
Camshaft Sprocket Runout

1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
from the other four locations.
2. Measure the camshaft sprocket runout with a dial indicator (A).
(Total indicator reading)
Limit : Refer to EM-117, "Camshaft".

• If it exceeds the limit, replace camshaft sprocket.
PBIC3182J
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-117,
"Camshaft".
KBIA0182E

CAMSHAFT
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER A
• Measure the outer diameter of valve lifter with a micrometer (A).
Standard : Refer to EM-117, "Camshaft". EM
D
PBIC3185J
VALVE LIFTER HOLE DIAMETER E

Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer (A).
Standard : Refer to EM-117, "Camshaft". F
VALVE LIFTER CLEARANCE

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

H
• If out of the standard, referring to the each standard of valve lifter PBIC3184J
outer diameter and valve lifter hole diameter, replace either or both
valve lifter and cylinder head.
I
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION: J
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-117, "Diagnosis Pro-
cedure" (TYPE 1) or EC-456, "Diagnosis Procedure" (TYPE 2).
K
• Check when engine is cold so as to prevent burns by the splashing engine oil.
1. Check engine oil level. Refer to LU-6, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while L
checking.
a. Release the fuel pressure. Refer to EC-356, "Inspection" (TYPE 1) or EC-648, "Inspection" (TYPE2).
b. Remove intake manifold. Refer to EM-29, "Exploded View". M
c. Disconnect ignition coil and injector harness connectors.
d. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and engine mounting insulator (RH). Refer to EM-77, "Exploded View". N
3. Remove intake valve timing control solenoid valve. Refer to EM-45, "Exploded View".
• Lift the front side of the engine with a jack base to remove intake valve timing control solenoid valve.
4. Clean the mounting area of intake valve timing control solenoid valve, and then insert a clean waste with O
no oil adhesion into the oil hole of the cylinder head.
5. Install engine mounting insulator (RH) and engine mounting bracket (RH). (After the removal of intake
valve timing control solenoid valve and insertion of a waste into the oil hole.) P
6. Perform cranking to check that engine oil comes out from the oil hole (mounting hole of intake valve timing
control solenoid valve) of cylinder head.
• Regarding the engine oil check, judge it by the amount of oil adhered to the wasted inserted into the oil
hole.
WARNING:
• Never insert fingers into the oil hole.
• Be careful not to touch rotating parts (drive belts, idler pulleys and crankshaft pulley, etc.).

CAMSHAFT
CAUTION:
• Never perform cranking without installing the engine mounting insulator (RH) and engine mount-
ing bracket (RH).
• Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil
and so as to prevent engine oil contamination.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
• Remove oil filter (for intake valve timing control), and then clean it. Refer to EM-90, "Exploded View".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-3,
"Engine Lubrication System" and LU-3, "Engine Lubrication System Schematic".
8. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-3, "Engine Lubrication System" and LU-3, "Engine Lubrica-
tion System Schematic".
9. After inspection, install removed parts in the reverse order.

OIL SEAL
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000003802183
EM
REMOVAL
1. Remove camshafts. Refer to EM-56, "Exploded View".
C
2. Remove valve lifters. Refer to EM-56, "Exploded View".
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
D
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet.
• Compress valve spring with the valve spring compressor [SST: E
KV10116200] (A), the attachment [SST: KV10115900] (C), and
the adapter [SST: KV10109220] (B).
CAUTION: F
Be careful not to damage valve lifter holes.
H
JPBIA0180ZZ
5. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION: I
Never remove valve spring seat from valve spring.
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902] (A). J
PBIC3210J
M
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height (H) shown in the figure with N
the valve oil seal drift [SST: KV10115600] (A).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in) O
PBIC3211J

FRONT OIL SEAL

OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000003802184
REMOVAL
• Front fender protector (RH): Refer to EXT-24, "FENDER PROTECTOR : Exploded View".
• Drive belts: Refer to EM-15, "Exploded View".
• Crankshaft pulley: Refer to EM-45, "Exploded View".
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
A : Dust seal lip

B : Oil seal lip
: Engine outside
: Engine inside
PBIC3485J
• Press-fit front oil seal using a suitable drift with outer diameter 57 mm (2.24 in) and inner diameter 45
mm (1.77 in).
Within 0.3 mm (0.012 in) toward engine front (crankshaft pulley side)
Within 0.5 mm (0.020 in) toward engine rear (crankshaft sprocket side)
CAUTION:
• Be careful not to damage front cover and crankshaft.
• Press-fit oil seal straight to avoid causing burrs or tilting.

REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000003802185
REMOVAL
1. Remove transaxle assembly. Refer to TM-523, "Exploded View".
2. Remove drive plate. Refer to EM-90, "Exploded View".
3. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.

OIL SEAL
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure. A
A : Dust seal lip

B : Oil seal lip EM
: Engine outside
: Engine inside
C
PBIC3485J
D
• Press-fit rear oil seal with a suitable drift (A) outer diameter
115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
CAUTION: E
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Never touch grease applied onto oil seal lip. F
G
PBIC3951E
• Press in rear oil seal (1) to the position as shown in the figure. H
A : Rear end surface of cylinder block

I
K
PBIC3952E

L

CYLINDER HEAD
CYLINDER HEAD
REMOVAL
PBIC3542J
1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket

A. Refer to EM-69
DISASSEMBLY
JPBIA1753GB

CYLINDER HEAD
Valve spring A
1. Valve collet 2. Valve spring retainer 3.
(with valve spring seat) (EXH)
4. Valve oil seal 5. Valve guide (EXH) 6. Valve seat (EXH)
7. Valve (EXH) 8. Valve (INT) 9. Valve seat (INT)
EM
10. Cylinder head 11. Valve guide (INT) 12. Spark plug
Valve spring
13.
(with valve spring seat) (INT)
C
A. Refer to EM-70
Removal and Installation INFOID:0000000003802187 D
REMOVAL
1. Release fuel pressure. Refer to EC-356, "Inspection" (TYPE 1) or EC-648, "Inspection" (TYPE2). E
2. Drain engine coolant and engine oil. Refer to CO-9, "Draining" and LU-7, "Draining".
3. Remove the following components and related parts.
• Exhaust manifold: Refer to EM-32, "Exploded View". F
• Fuel tube and fuel injector assembly: Refer to EM-38, "Exploded View".
• Water outlet: Refer to CO-22, "Exploded View". G
• Front cover, timing chain: Refer to EM-45, "Exploded View".
• Camshaft: Refer to EM-56, "Exploded View". H
4. Remove cylinder head.
• Loosen cylinder head bolts in reverse order as shown in the
figure.
I
: Engine front
• Using TORX socket, loosen cylinder head bolts. J
PBIC3206J
L
5. Remove cylinder head gasket.
INSTALLATION
1. Install cylinder head gasket. M
2. Install cylinder head, and tighten cylinder head bolts in numeri-
cal order as shown in the figure with the following procedure.
N
: Engine front
CAUTION:
If cylinder head bolts are reused, check their outer diame- O
ters before installation. Refer to EM-74, "Inspection".
a. Apply new engine oil to threads and seating surface of mounting
bolts. P
b. Tighten all cylinder head bolts. PBIC3206J
: 40.0 N·m (4.1 kg-m, 30 ft-lb)

c. Turn all cylinder head bolts 100 degrees clockwise (angle tightening).
CAUTION:

CYLINDER HEAD
Check and confirm the tightening angle by using an angle
wrench [SST: KV10112100] (A) or protractor. Never judge by
visual inspection without the tool.
d. Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
In this step, loosen cylinder head bolts in reverse order that
indicated in the figure.
e. Tighten all cylinder head bolts. PBIC3208J
: 40.0 N·m (4.1 kg-m, 30 ft-lb)
f. Turn all cylinder head bolts 100 degrees clockwise (angle tightening).
g. Turn all cylinder head bolts 100 degrees clockwise again (angle tightening).
Disassembly and Assembly INFOID:0000000003802188
DISASSEMBLY
1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter.
• Compress valve spring with the valve spring compressor [SST:
the adapter [SST: KV10109220] (B). Remove valve collet with
a magnet hand.
CAUTION:
JPBIA0180ZZ
4. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
5. Push valve stem to combustion chamber side, and remove valve.
6. Remove valve oil seal with a valve oil seal puller [SST:
KV10107902] (A).
PBIC3210J
7. When valve seat must be replaced.

• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-119, "Cylinder Head".
CAUTION:

CYLINDER HEAD
Never bore excessively to prevent cylinder head from scratching.
8. When valve guide must be replaced. A
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
EM
D
PBIC3214J
b. Drive out valve guide with a hammer and valve guide drift (com- E
mercial service tool).
CAUTION:
Cylinder head contains heat, wear protective equipment to
F
avoid getting burned.
SEM931C H
ASSEMBLY
1. When valve guide is removed, install it. I
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide.
a. Ream cylinder head valve guide hole with a valve guide reamer J
(commercial service tool) (A).
For service parts: Oversize [0.2 mm (0.008 in)] K

Refer to EM-119, "Cylinder Head".
PBIC3215J
M
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
N
PBIC3214J

CYLINDER HEAD
c. Press valve guide (1) from camshaft side to dimensions as
2 : Cylinder head
Projection (H) : Refer to EM-119, "Cylinder Head".

CAUTION:
Cylinder head contains heat, wear protective equipment to
avoid getting burned.
PBIC3217J
d. Apply reamer finish to valve guide with a valve guide reamer

(commercial service tool) (A).
Standard : Refer to EM-119, "Cylinder Head".
PBIC3215J
2. When valve seat is removed, install it.

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

Refer to EM-119, "Cylinder Head".
• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
PBIC3218J

heated oil (A).
PBIC3214J
c. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION:
• Never touch cold valve seats directly.
• Cylinder head contains heat, wear protective equipment to avoid getting burned.

CYLINDER HEAD
d. Using valve seat cutter set (commercial service tool) or valve
seat grinder, finish valve seat to the specified dimensions. For A
dimensions, refer to EM-119, "Cylinder Head".
CAUTION:
When using valve seat cutter, firmly grip the cutter handle
EM
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat. C
SEM934C
D
e. Using compound, grind to adjust valve fitting.
f. Check again for normal contact. Refer to EM-74, "Inspection".
3. Install valve oil seal. E
• Install with a valve oil seal drift [SST: KV10115600] (A) to
match dimension in the figure.
NOTE:
F
Dimension is height that measured before installing valve
spring (with valve spring seat).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in) G
H
PBIC3211J
4. Install valve.
• Install larger diameter to intake side. I
5. Install valve spring (with valve spring seat).
• Install smaller pitch (valve spring seat side) to cylinder head
side (B). J
1 : Valve spring seat (Do not remove from valve spring.)

• Confirm identification color (A) of valve spring. K
Intake : White
Exhaust : Orange L
PBIC3462J
M
6. Install valve spring retainer.
7. Install valve collet.
• Compress valve spring with the valve spring compressor [SST: N
the adapter [SST: KV10109220] (B). Install valve collet with a
magnet hand.
CAUTION: O
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition. P
JPBIA0180ZZ
8. Install valve lifter.

• Install it in the original position.
9. Install spark plug with spark plug wrench (commercial service tool).

CYLINDER HEAD

Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between (d1) and (d2)
exceeds the limit, replace them with a new one.
Limit [(d1) – (d2)]: 0.15 mm (0.0059 in)

• If reduction of outer diameter appears in a position other than (d2),
use it as (d2) point.
PBIC3994E
Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to EM-99, "Inspec-
tion".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Never allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions using straightedge (A)
and feeler gauge (B).
Limit: Refer to EM-119, "Cylinder Head".

• If it exceeds the limit, replace cylinder head.
PBIC3207J
INSPECTION AFTER DISASSEMBLY

VALVE DIMENSIONS
• Check the dimensions of each valve. For the dimensions, refer to EM-119, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. Refer to "VALVE SEAT
CONTACT".
VALVE GUIDE CLEARANCE
Valve Stem Diameter

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

• Measure the inner diameter of valve guide with bore gauge.
Standard: Refer to EM-119, "Cylinder Head".
Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) PBIC3213J
Standard and Limit: Refer to EM-119, "Cylinder Head".

CYLINDER HEAD
• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced. Refer to EM-70, "Disassembly and Assembly". A
VALVE SEAT CONTACT
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure. EM
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circum- C
ference.
A : OK
D
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions (B) even after the recheck,
replace valve seat. Refer to EM-70, "Disassembly and Assembly".
E
JPBIA0187ZZ
F
VALVE SPRING SQUARENESS
• Set a try square (A) along the side of valve spring and rotate
spring. Measure the maximum clearance between the top of spring G
and try square.
B : Contact
H
Limit : Refer to EM-119, "Cylinder Head".

• If it exceeds the limit, replace valve spring. I
PBIC3219J
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD J

• Check valve spring pressure with valve spring seat installed at the
specified spring height.
CAUTION: K
Standard : Refer to EM-119, "Cylinder Head". L

• If the installation load or load with valve open is out of the stan-
dard, replace valve spring (with valve spring seat).
M
SEM113
INSPECTION AFTER INSTALLATION N

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required O
age at connection points. P
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the

CYLINDER HEAD
Items Before starting engine Engine running After engine stopped
Exhaust gases — Leakage —
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [MR20DE]
REMOVAL AND INSTALLATION A

ENGINE ASSEMBLY
EM
JPBIA2209GB K
1. Upper torque rod 2. Engine mounting bracket (RH) 3. Engine mounting insulator (RH)
4. Rear torque rod bracket 5. Rear torque rod 6. Engine mounting bracket (LH) L
7. Engine mounting bracket support (LH) 8. Engine mounting insulator (LH) 9. Dynamic damper
M
WARNING:
N
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION: O
• Always be careful to work safely, avoid forceful or uninstructed operations.
• Never start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
P
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-35, "Garage Jack and
Safety Stand and 2-Pole Lift".
REMOVAL

ENGINE ASSEMBLY
Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
Preparation
2. Drain engine coolant from radiator. Refer to CO-9, "Draining".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belts.
• Engine undercover
• Front road wheels and tires
• Front splash guards (RH and LH): Refer to EXT-24, "FENDER PROTECTOR : Exploded View".
• Drive belts: Refer to EM-16, "Removal and Installation".
• Engine cover: Refer to EM-25, "Exploded View".
• Battery: Refer to PG-144, "Exploded View".
• Air duct (inlet), air duct assembly, and air cleaner cases (upper and lower) assembly: Refer to EM-27,
"Exploded View".
• Radiator hose (upper and lower): Refer to CO-13, "Exploded View".
• Exhaust front tube: Refer to EX-5, "Exploded View".
Engine Room LH
1. Disconnect all connections of engine harness around the battery, and then temporarily secure the engine
harness into the engine side.
CAUTION:
Protect connectors using a resin bag against foreign materials during the operation.
2. Disconnect fuel feed tube at engine side. Refer to EM-38, "Exploded View".
3. Disconnect heater hoses. Refer to CO-22, "Exploded View".
4. Disconnect control cable from transaxle. Refer to TM-505, "Exploded View".
5. Remove EVAP hoses. Refer to EM-29, "Exploded View".
Engine Room RH
1. Disconnect vacuum hose from intake manifold. Refer to EM-29, "Exploded View".
2. Remove A/C compressor without disconnecting A/C piping, and temporarily fasten it on vehicle with a
rope. Refer to HA-43, "Exploded View".
3. Disconnect ground cable above the alternator.
4. Disconnect suction hoses of power steering oil pump at reservoir tank side. Refer to ST-37, "Exploded
View".
• Install plug to avoid leakage of power steering fluid.
Vehicle Underbody
1. Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to
ST-16, "Exploded View".
2. Remove ground cable at transaxle side.
3. Remove front wheel sensor (RH and LH) for ABS from steering knuckle. Refer to BRC-59, "FRONT
WHEEL SENSOR : Exploded View".
4. Remove lock plate of brake hose from strut. Refer to BR-20, "FRONT : Exploded View".
5. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the
vehicle side with a rope to avoid load on it. Refer to BR-34, "BRAKE CALIPER ASSEMBLY : Exploded
View".
6. Disconnect steering outer sockets from steering knuckle. Refer to ST-18, "Exploded View".
7. Remove rear torque rod.
8. Remove drive shafts (RH and LH). Refer to FAX-17, "Exploded View".
9. Remove stabilizer connecting rod. Refer to FSU-15, "Exploded View".
10. Remove front suspension member. Refer to FSU-17, "Exploded View".
11. Disconnect CVT fluid cooler hoses (upper and lower) from radiator. Refer to CO-13, "Exploded View".

ENGINE ASSEMBLY
12. Disconnect power steering oil cooler hose between power steering oil cooler and power steering oil pump
tube (suspension side) from power steering oil pump tube (suspension side). Refer to ST-37, "Exploded A
View".
13. Preparation for the separation work of transaxle is as follows:
• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-35, "Exploded EM
View".
Removal
1. Use a manual lift table caddy (commercial service tool) or equiv- C
alently rigid tool such as a transmission jack. Securely support
bottom of the engine and the transaxle assembly.
CAUTION: D
Put a piece of wood or an equivalent as the supporting sur-
face, secure a completely stable condition.
E
PBIC1190E F
2. Remove reservoir tank of power steering, and then move it to aside. Refer to ST-37, "Exploded View".
3. Remove upper torque rod mounting bolt to the engine side. G
4. Remove engine mounting bolts on engine mounting bracket (RH).
5. Remove engine mounting bracket (LH) mounting bolts to the transaxle.
6. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work, H
observe the following caution.
CAUTION:
• Check that no part interferes with the vehicle side. I
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to
changes in the center of gravity.
• If necessary, support the vehicle by setting jack or suitable tool at the rear. J
Separation
1. Install engine slinger to front cover front left side (A) and cylinder K
head rear right side (B).
: Engine front
L
Slinger bolts
Front cover front left M
: 32.9 N·m (3.4 kg-m, 24 ft-lb)
side:
Cylinder head rear
: 25.0 N·m (2.6 kg-m, 18 ft-lb) N
right side: JPBIA2293ZZ
2. Remove starter motor. Refer to STR-17, "MR20DE : Exploded View".

3. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-523, "Exploded View". O
INSTALLATION
CAUTION: P
• Never allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-
ing insulator.
• Check that each mounting insulator is seated properly, and tighten mounting nuts and bolts.
Preparation
1. Install the engine mounting insulator (RH) to the body.

ENGINE ASSEMBLY
a. Tighten the bolts No. 2, 3 as shown in the figure. (temporarily)
: Vehicle front
b. Tighten the bolts in numerical order as shown in the figure.

(specified torque)
JPBIA2210ZZ
2. Install the engine mounting bracket (LH) to the transaxle.

a. Tighten the bolt No. 3 as shown in the figure. (temporarily)
: Vehicle front

(specified torque)
JPBIA2211ZZ
3. Install the rear torque rod bracket to the transaxle.

: Vehicle front

(specified torque)
JPBIA2212ZZ
4. Install the engine mounting bracket support (LH) to the body.

: Vehicle front

(specified torque)
JPBIA2213ZZ
5. Install the engine mounting insulator (LH) to the engine mounting bracket support (LH).

ENGINE ASSEMBLY
a. Tighten the bolt No. 3 in numerical order as shown in the figure.
(temporarily) A
: Vehicle front
EM
(specified torque)
JPBIA2214ZZ
D
6. Install the rear torque rod to the suspension member. (temporarily)
Installation
1. Install the dynamic damper to the engine mounting bracket support (LH) and engine mounting bracket E
(LH) temporarily.
2. Install the engine mounting bracket (RH) to the engine mounting insulator (RH). (specified torque)
3. Install the engine mounting bracket (RH) to the engine. F
a. Tighten the bolt No. 4 in numerical order as shown in the figure.
(temporarily)
G
: Vehicle front
b. Tighten the bolts in numerical order as shown in the figure. H

(specified torque)
JPBIA2215ZZ
4. Tighten the dynamic damper to the specified torque. J

5. Install the rear torque rod to the rear torque rod bracket. (specified torque)
6. Install upper torque rod to the body temporarily.
K
7. Install the upper torque rod to the engine mounting bracket (RH). (specified torque)
8. Tighten the upper torque rod to the specified torque.
9. Tighten the rear torque rod to the specified torque. L
INSPECTION AFTER INSTALLATION M

• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required N
- 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 there is no leakage of fuel, exhaust gases, or any oil/fluids including P

ENGINE ASSEMBLY

ENGINE STAND SETTING
< DISASSEMBLY AND ASSEMBLY > [MR20DE]
DISASSEMBLY AND ASSEMBLY A

Setting INFOID:0000000003802193
EM
NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc. C
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-77, "Exploded View".
2. Install engine to engine stand with the following procedure: D
a. Remove drive plate.
• Secure drive plate (1) with a stopper plate [SST: KV11105210]
(A), and remove mounting bolts. E
CAUTION:
• Never disassemble them.
• Never place them with signal plate facing down. F
• When handling signal plate, take care not to damage or
scratch them.
• Handle signal plate in a manner that prevents them from
becoming magnetized. G
PBIC3226J
H
b. Remove pilot converter (1) using pilot bushing puller [SST:
ST16610001] (A) or suitable tool.
c. Lift the engine with a hoist to install it onto widely use engine I
stand.
CAUTION:
• Use the engine stand that has a load capacity [approxi-
J
mately 135 kg (298 lb) or more] large enough for support-
ing the engine weight.
• If the load capacity of stand is not adequate, remove the fol-
lowing parts beforehand to reduce the potential risk of over- K
turning stand. PBIC3229J
- Intake manifold: Refer to EM-29, "Exploded View".
- Exhaust manifold: Refer to EM-32, "Exploded View". L
- Rocker cover: Refer to EM-43, "Exploded View".
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with drive plate M
removed.
CAUTION:
Before removing the hanging chains, check the engine N
stand is stable and there is no risk of overturning.
PBIC3227J
P
CAUTION:
Be sure to clean drain plug and install with new drain plug washer.

4. Drain engine coolant by removing water drain plug (1) from
inside of the engine.
: Engine front
Tightening torque : Refer to EM-91, "Disassembly and

Assembly".
PBIC3228J

ENGINE UNIT
ENGINE UNIT
A
Disassembly INFOID:0000000003802194
1. Remove intake manifold. Refer to EM-29, "Exploded View". EM

2. Remove exhaust manifold. Refer to EM-32, "Exploded View".
4. Remove ignition coil, spark plug, and rocker cover. Refer to EM-43, "Exploded View". C
5. Remove fuel injector and fuel tube. Refer to EM-38, "Exploded View".
6. Remove timing chain. Refer to EM-45, "Exploded View".
D
8. Remove water inlet. Refer to CO-20, "Exploded View".
9. Remove water outlet. Refer to CO-22, "Exploded View". E
10. Remove cylinder head. Refer to EM-68, "Exploded View".
Assembly INFOID:0000000003802195
F
Assembly in the reverse order of disassembly.

OIL PAN (UPPER)
OIL PAN (UPPER)
JPBIA1889GB
1. Rear oil seal 2. O-ring 3. Oil pan (upper)

4. Balancer unit timing chain tensioner 5. Balancer unit timing chain 6. Crankshaft sprocket
7. Balancer unit sprocket 8. Drain plug 9. Drain plug washer
10. Oil pan (lower) 11. Oil filter 12. Oil filter stud bolt
13. O-ring 14. Oil level gauge 15. Oil level gauge guide
A. Refer to LU-9 B. Oil pan (lower) side
REMOVAL
2. Remove oil filter. Refer to LU-9, "Removal and Installation".
3. Remove front cover, timing chain, balancer unit timing chain, and other related parts. Refer to EM-45,
"Exploded View".
4. Remove oil level gauge and oil level gauge guide.
5. Remove oil pan (upper) with the following procedure:

OIL PAN (UPPER)
a. Loosen bolts in reverse order as shown in the figure.
A
: Engine front
EM
JPBIA0287ZZ
D
b. Insert a screwdriver shown by the arrow ( ) in the figure and
open up a crack between oil pan (upper) and cylinder block.
E
: Engine front
CAUTION:
A more adhesive liquid gasket is applied compared to previ- F
ous types when shipped, so it should not be forced off the
position not specified.
G
PBIC3948E
c. Insert seal cutter [SST: KV10111100] between oil pan (upper) and cylinder block, and slide it by tapping on H
the side of the tool with a hammer.
CAUTION:
Be careful not to damage the mating surface.
I
6. Remove O-ring between cylinder block and oil pan (upper).
INSTALLATION
J
1. Install oil pan (upper) with the following procedure:
a. Use a scraper (A) to remove old liquid gasket from mating sur-
faces.
• Remove the old liquid gasket from mating surface of cylinder K
block.
CAUTION: L
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
M
PBIC3949E

OIL PAN (UPPER)
b. Apply a continuous bead of liquid gasket (C) with a tube presser
(commercial service tool) as shown in the figure.
1 : Oil pan (upper)

A : 2 mm (0.08 in) protruded to outside
B : 2 mm (0.08 in) protruded to rear oil seal mounting side
: Engine front
: Engine outside

CAUTION:
• Apply liquid gasket to outside of bolt hole for the posi-
tions shown by marks.
• Attaching should be done within 5 minutes after liquid
gasket application.
JPBIA0288ZZ
c. Install new O-ring at cylinder block side.

CAUTION:
Install avoiding misalignment of O-ring.
d. Tighten bolts in numerical order as shown in the figure.
: Engine front
JPBIA0287ZZ
2. Install rear oil seal with the following procedure.

CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Always replace rear oil seal with new one.
• Never touch oil seal lip.
a. Wipe off liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using a scraper.
b. Apply engine oil to entire outside area of rear oil seal.
c. Press-fit the rear oil seal using a suitable drift (A) with outer
diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
PBIC3951E

OIL PAN (UPPER)
• Press-fit to the specified dimensions as shown in the figure. A

1 : Rear oil seal
A : Cylinder block rear end surface
EM
CAUTION:
• Never touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part of
oil pan (upper) and cylinder block or the crankshaft. C
• Press-fit straight, checking that rear oil seal does not curl
or tilt.
NOTE: PBIC3952E
D
The standard surface of the dimension is the rear end surface of
cylinder block.
3. Install in the reverse order of removal, for the rest of parts. E
INSPECTION AFTER REMOVAL F

Clean oil strainer portion (part of the oil pump) if any object attached.

CYLINDER BLOCK
CYLINDER BLOCK
JPBIA0827GB
1. Cylinder block 2. O-ring 3. Crankshaft position sensor (POS)

4. Crankshaft position sensor (POS) cover 5. Oil filter (for intake valve timing control) 6. Knock sensor
7. Oil pressure switch 8. Top ring 9. Second ring

CYLINDER BLOCK
10. Oil ring 11. Snap ring 12. Piston
13. Piston pin 14. Connecting rod 15. Thrust bearing A
16. Connecting rod bearing (upper) 17. Main bearing (upper) 18. Crankshaft key
19. Main bearing (lower) 20. Connecting rod bearing (lower) 21. Connecting rod cap
22. Connecting rod cap bolt 23. Main bearing cap 24. Main bearing cap bolt EM
25. Crankshaft 26. Pilot converter 27. Signal plate
28. Rear oil seal 29. Drive plate 30. Reinforcement plate
A. Refer to EM-91 B. Chamfered C
: Crankshaft side
D
DISASSEMBLY E
1. Remove oil pan (upper). Refer to EM-86, "Exploded View".
2. Remove thermostat housing. Refer to CO-20, "Exploded View".
F
3. Remove knock sensor.
CAUTION:
Handle it carefully and avoid impacts.
G
4. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
CAUTION:
• Handle crankshaft position sensor (POS) carefully and avoid impacts.
• Never disassemble. H
• Never place crankshaft position sensor (POS) in a location where it is exposed to magnetism.
5. Remove oil filter (for intake valve timing control).
6. Remove piston and connecting rod assembly with the following procedure: I
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-99, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. J
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side. K
CAUTION:
• Be careful not to damage matching surface with connect-
ing rod cap. L
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
M
PBIC0259E
N
7. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct. O
8. Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-99, "Inspection".
P

CYLINDER BLOCK
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
them excessively.
PBIC3233J
9. Remove piston from connecting rod with the following procedure:

a. Using snap ring pliers (A), remove snap rings.
PBIC3230J
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use

drier (A) or equivalent.
PBIC3231J
c. Push out piston pin with stick of outer diameter approximately 18

mm (0.71 in).
PBIC0262E
10. Remove main bearing cap bolts.

• Measure crankshaft end play before loosening main bearing cap bolts. Refer to EM-99, "Inspection".

CYLINDER BLOCK
• Loosen and remove main bearing cap bolts in reverse order
as shown in the figure. A
: Engine front
• Use TORX socket. EM
PBIC3235J
D
11. Remove main bearing caps.
• Tap main bearing caps lightly with a plastic hammer for removal.
CAUTION:
E
Be careful not to damage the mounting surface.
12. Remove crankshaft.
CAUTION:
• Be careful not to damage or deform signal plate (1) F
mounted on rear end of crankshaft (A).
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate G
and the floor surface.
• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket. H
PBIC3234J
I
13. Pull rear oil seal out from rear end of crankshaft.
J
14. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
Identify installation positions, and store them without mixing them up.
K
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material. L
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure.
M
2 : Washer
: Engine front
N
• Apply liquid gasket to the thread of water drain plug (4).
• Apply sealant to the thread of plug (1).
Use genuine high strength thread locking sealant or O
equivalent.
NOTE:
PBIC3999E
Do not apply liquid gasket or high strength thread locking seal- P
ant to the plug (3).
• Tighten each plug as specified below.

CYLINDER BLOCK
Part Washer Tightening torque

1 Yes 54.0 N·m (5.5 kg-m, 40 ft-lb)
3 No 19.6 N·m (2.0 kg-m, 14 ft-lb)
4 No 9.8 N·m (1.0 kg-m, 87 in-lb)
3. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap.
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing (B) on cylinder block.
: Engine front
• Install thrust bearings with the oil groove (A) facing crankshaft
arm (outside).
PBIC3258J
c. Install the main bearings paying attention to the direction.

• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new
engine oil to the back surface, but thoroughly clean it.
• When installing, align main bearing to the center position of cylinder block and main bearing cap.
• The difference (A) between main bearing (upper) (1) and main
bearing (lower) (3) should be 0.85 mm (0.0335 in) or less
when installing.
2 : Cylinder block
4 : Main bearing cap
PBIC3237J
• Ensure the oil holes on cylinder block and oil holes (A) on the
main bearings (1) are aligned.
PBIC3236J
4. Install signal plate to crankshaft if removed.

a. Set the signal plate with the flange facing toward the counter weight side (engine front side) to the crank-
shaft rear surface.
b. Apply new engine oil to threads and seat surfaces of mounting bolts.

CYLINDER BLOCK
c. Position crankshaft (2) and signal plate (1) using a dowel pin
(service part), and tighten mounting bolts in numerical order as A
shown in the figure using TORX socket.
A : Dowel pin hole

EM
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
C
d. Tighten mounting bolts in numerical order as shown in the figure
again.
PBIC3238J
e. Remove dowel pin. (service parts) D
CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block.
• While turning crankshaft by hand, check that it turns smoothly. E
6. Install main bearing caps with the following procedure:
a. Install main bearing caps referring to the journal No. stamp (A)
and front mark (B) as shown in the figure. F
: Engine front
G
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
H
PBIC3239J
I
b. Tighten main bearing cap bolts in numerical order as shown in
the figure with the following procedure:
J
: Engine front
i. Apply new engine oil to threads and seat surfaces of mounting

bolts. K
ii. Tighten main bearing cap bolts.
: 34.3 N·m (3.5 kg-m, 25 ft-lb) L

PBIC3235J
iii. Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in order from No. 1 to 10 in the fig- M
ure.
CAUTION:
Confirm the tightening angle by using an angle wrench
[SST: KV10112100] (A) or protractor. Never judge by visual N
inspection without the tool.
PBIC3240J
• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-99, "Inspection".
7. Install piston to connecting rod with the following procedure:

CYLINDER BLOCK
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
b. Assemble piston to connecting rod.
• Using an industrial use drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston
pin into piston and connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (D) on connecting rod
are positioned as shown in the figure.
C : Management code
E : Big end diameter grade
F : Front mark (connecting rod cap)
c. Install new snap ring to the groove of the piston front side.
• After installing, check that connecting rod moves smoothly. JPBIA2366ZZ
8. Using a piston ring expander (commercial service tool), install
piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown in the figure referring
to the piston front mark.
A : Oil ring upper or lower rail gap

B : Front mark
C : Second ring and oil ring spacer gap
D : Top ring gap
E : Stamped mark
CAUTION:
Never contact the rail end gap under the oil ring with the PBIC3242J
oil drain cast groove of piston.
• Install second ring with the stamped surface facing upward.
9. Install connecting rod bearing upper (2) and lower (3) to con-
necting rod (1) and connecting rod cap (4).
C : Oil hole (connecting rod)

D : View D
E : OK
F : NG
g : 2.55 - 2.95 mm (0.1004 - 0.1161 in)
: Engine front
• Install the connecting rod in the dimension shown in the figure.

• Check that connecting rod bearing oil hole (A) is completely in
the inside of connecting rod oil hole chamfered area (B).
• When installing connecting rod bearings, apply new engine oil
to the bearing surface (inside). Do not apply new engine oil to
the back surface, but thoroughly clean it.
NOTE:
• There is no positioning tab.
• Install the connecting rod bearings in the center of connect-
ing rod and connecting rod cap as shown in the figure. For
service operation, the center position can be checked, visu-
ally.
JPBIA2155ZZ

CYLINDER BLOCK
10. Install piston and connecting rod assembly to crankshaft.
• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. A
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number (D) on
connecting rod to install.
EM
B : Oil hole
C : Management code
E : Big end diameter grade C
• Install so that front mark (A) on the piston head faces the front
D
of engine.
JPBIA2366ZZ
E
• Using a piston ring compressor [SST: EM03470000] (A) or
suitable tool, install piston with the front mark on the piston
head facing the front of the engine.
CAUTION: F
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end. G
H
PBIC3244J
11. Install connecting rod cap.

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

B : Oil hole
C : Management code
E : Big end diameter grade
K
L
JPBIA2366ZZ
12. Tighten connecting rod cap bolt with the following procedure:
CAUTION: M
• Check that there is no gap in the thrust surface (A) of the
joint between connecting rod (1) and connecting rod cap
(2) and that these parts are in the correct position. And N
then, tighten the connecting rod cap bolts.
• If the connecting rod cap bolts are reused, measure the
outer diameter. Refer to EM-99, "Inspection".
O
a. Apply new engine oil to the threads and seats of connecting rod
cap bolts.
b. Tighten connecting rod cap bolts.
P
PBIC3510J
: 27.5 N·m (2.8 kg-m, 20 ft-lb)
c. Completely loosen connecting rod cap bolts.
: 0 N·m (0 kg-m, 0 ft-lb)

d. Tighten connecting rod cap bolts.

CYLINDER BLOCK
: 19.6 N·m (2.0 kg-m, 14 ft-lb)

e. Then turn all connecting rod cap bolts 60 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using an angle
wrench [SST: KV10112100] (A) or protractor. Never judge by
visual inspection without the tool.
PBIC3245J
• After tightening connecting rod cap bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-99, "Inspection".
13. Install oil pan (upper). Refer to EM-86, "Exploded View".
NOTE:
Install the rear oil seal after installing the oil pan (upper).
14. Install rear oil seal. Refer to EM-66, "REAR OIL SEAL : Removal and Installation".
15. Install drive plate.
• Secure crankshaft with a stopper plate [SST: KV11105210],
(A) and tighten mounting bolts crosswise over several times.
1 : Drive plate
PBIC3226J
• Install drive plate (1), reinforcement plate (2), and pilot con-
verter (3) as shown in the figure.
A : Crankshaft rear end

B : Rounded
C : Chamfered
• Using a drift of 33 mm (1.30 in) in dia meter, press-fit pilot con-
verter into the end of crankshaft until it stops.
PBIC3259J
16. Install knock sensor.

CYLINDER BLOCK
• Install knock sensor (1) with harness connector facing toward
the rear of engine. A
A : Cylinder block left side

: Engine front EM
CAUTION:
• Never tighten mounting bolts while holding the harness
connector. C
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
PBIC3246J
NOTE:
D
• Check that there is no foreign material on the cylinder block mating surface and the back surface of
knock sensor.
• Check that knock sensor does not interfere with other parts.
17. Install crankshaft position sensor (POS) and crankshaft position sensor (POS) cover. E
CAUTION:
• Handle crankshaft position sensor (POS) carefully and avoid impacts.
• Never disassemble. F
• Never place crankshaft position sensor (POS) in a location where it is exposed to magnetism.
18. Install oil filter (for intake valve timing control) (1) in the direction
shown in the figure. G
• Check that the oil filter (for intake valve timing control) does
not protrude from the upper surface of cylinder block (2) after
installation. H
PBIC3260J
J
19. Assemble in the reverse order of disassembly.
K
CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft L
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
Standard and Limit : Refer to EM-121, "Cylinder M

Block".
• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft N
also.
PBIC3252J
O
CONNECTING ROD SIDE CLEARANCE

CYLINDER BLOCK
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).
Standard and Limit : Refer to EM-121, "Cylinder

Block".
• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC3251J
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside
micrometer (A).
Standard : Refer to EM-121, "Cylinder Block".
PBIC3265J
Piston Pin Outer Diameter

Measure the outer diameter of piston pin with a micrometer (A).
PBIC3266J
Piston to Piston Pin Oil Clearance

(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)

• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly. Refer to EM-109, "Description".
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.)
PISTON RING SIDE CLEARANCE

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

Block". EM
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
C
PBIC3280J
D
PISTON RING END GAP
• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston (1) and piston ring (2), and E
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap with a feeler gauge (C).
F
Block".
• If the measured value exceeds the limit, replace piston ring, and G
measure again. If it still exceeds the limit, rebore cylinder and use
oversized piston and piston rings.
PBIC3267J
H
CONNECTING ROD BEND AND TORSION

• Check with a connecting rod aligner.
I
A : Bend
B : Torsion
J
C : Feeler gauge
Limit : Refer to EM-121, "Cylinder Block".

K
• If it exceeds the limit, replace connecting rod assembly.
O
PBIC3268J
CONNECTING ROD BIG END DIAMETER

P

CYLINDER BLOCK
• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod cap bolts to the specified
torque. Refer to EM-91, "Disassembly and Assembly".
2 : Connecting rod
A : Example
B : Measuring direction of inner diameter
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
PBIC3269J
• 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).
PBIC3270J

PBIC3266J
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
Standard and Limit : Refer to EM-121, "Cylinder Block".

• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly. Refer to EM-109, "Piston".
• If replacing connecting rod assembly. Refer to EM-110, "Connecting Rod Bearing".
CYLINDER BLOCK TOP SURFACE DISTORTION

• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.

CYLINDER BLOCK
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge (A) and feeler A
gauge (B).
Limit : Refer to EM-121, "Cylinder Block". EM

• If it exceeds the limit, replace cylinder block.
PBIC3250J
D
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the
specified torque. Refer to EM-91, "Disassembly and Assembly".
• Measure the inner diameter of main bearing housing with a bore gauge. E
• Measure the position shown in the figure [5 mm (0.20 in)] back-
ward from main bearing housing front side in the 2 directions as
shown in the figure. The smaller one is the measured value. F
1 : Cylinder block
2 : Main bearing cap
G
: Engine front
Standard : Refer to EM-121, "Cylinder Block". H

• If out of the standard, replace cylinder block and main bearing PBIC4005E
caps assembly.
NOTE: I
Main bearing caps cannot be replaced as a single, because it is machined together with cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
J
Cylinder Bore Inner Diameter
• Using a bore gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. [(A) and (B)
directions at (C), (D), and (E)] [(A) is in longitudinal direction of K
engine]
f : 10 mm (0.39 in) L
g : 60 mm (2.36 in)
h : 130 mm (5.12 in)
NOTE: M
When determining cylinder bore grade, measure the cylinder bore
(B) direction at (D) position. JPBIA2059ZZ
N
Standard:
Cylinder bore inner diameter
: Refer to EM-121, "Cylinder Block". O
Limit:
P
Out-of-round [Difference between (A) and (B)]
Taper [Difference between (C) and (D)]
: Refer to EM-121, "Cylinder Block".
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
NOTE:
Oversize piston is not provided.

CYLINDER BLOCK
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer (A).
PBIC3272J
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 : 60 mm (2.36 in)
h : 130 mm (5.12 in)
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame- JPBIA2059ZZ
ter)
Standard and Limit : Refer to EM-121, "Cylinder Block".

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-109, "Pis-
ton".
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a
micrometer (A).

• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-125, "Main Bearing".
PBIC3457J
CRANKSHAFT PIN JOURNAL DIAMETER

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

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to EM-124, "Connecting Rod Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

CYLINDER BLOCK
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer. A
• Out-of-round is indicated by the difference in dimensions between
(X) and (Y) at (A) and (B).
• Taper is indicated by the difference in dimension between (A) and
EM
(B) at (X) and (Y).
Limit:
C
Out-of-round [Difference between (X) and (Y)]
Taper [Difference between (A) and (B)]
PBIC3459J
: Refer to EM-121, "Cylinder Block". D
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to EM-110, "Connecting Rod Bearing" and/or EM-112, E
"Main Bearing".
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on the both end of the crankshaft. F
• Place a dial indicator (A) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)
G
Block".
H
• If it exceeds the limit, replace crankshaft.
I
PBIC3458J
CONNECTING ROD BEARING OIL CLEARANCE

J
Method by Calculation
• Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod cap bolts to
K
the specified torque. Refer to EM-91, "Disassembly and Assem-
bly".
A : Example L
B : Inner diameter measuring direction
• Measure the inner diameter of connecting rod bearing with an
inside micrometer. M
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter) PBIC3275J
N
Standard and Limit : Refer to EM-124, "Connecting Rod Bearing".
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-110, O
"Connecting Rod Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. P
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-
fied torque. Refer to EM-91, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.

CYLINDER BLOCK
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC3276J
MAIN BEARING OIL CLEARANCE

• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap mounting bolts to the specified
torque. Refer to EM-91, "Disassembly and Assembly".
A : Example
B : Inner diameter measuring direction
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
Standard and Limit : Refer to EM-125, "Main Bearing". PBIC3277J
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-112, "Main Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to
the specified torque. Refer to EM-91, "Disassembly and Assembly".
CAUTION:
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
PBIC3278J
MAIN BEARING CRUSH HEIGHT

CYLINDER BLOCK
• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of A
bearing must protrude (B). Refer to EM-91, "Disassembly and
Assembly".
EM
A : Example
Standard : There must be crush height.

C
• If the standard is not met, replace main bearings.
PBIC3279J
D
CONNECTING ROD BEARING CRUSH HEIGHT
• When connecting rod cap is removed after being tightened to the
specified torque with connecting rod bearings (1) installed, the tip
end of bearing must protrude (B). Refer to EM-91, "Disassembly E
and Assembly".
A : Example F

• If the standard is not met, replace connecting rod bearings. G
PBIC3279J
MAIN BEARING CAP BOLT OUTER DIAMETER H

• Measure the outer diameters (d1) and (d2) at two positions as
I
A : (d1) measuring position
B : (d2) measuring position
• If reduction appears in places other than (B) range, regard it as J
(d2).
Limit [(d1) – (d2)]: 0.15 mm (0.0059 in)

K
• If it exceeds the limit (a large difference in dimensions), replace PBIC4015E
main bearing cap mounting bolt with a new one.
CONNECTING ROD CAP BOLT OUTER DIAMETER L
• Measure the outer diameter (d) at position as shown in the figure.
• If reduction appears in a position other than (d), regard it as (d).
M
Limit: 7.75 mm (0.3051 in)
• When (d) exceeds the limit (when it becomes thinner), replace
connecting rod cap bolt with a new one. N
O
PBIC4016E
CLOGGED OR DAMAGED OIL FILTER (FOR INTAKE VALVE TIMING CONTROL)

P

CYLINDER BLOCK
• Check that there is no foreign material on the oil filter and check it
for clogging.
- Clean it if necessary.
• Check the oil filter for damage.
- Replace it if necessary.
PBIC3273J
DRIVE PLATE
• Check drive plate and signal plate for deformation or damage.
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.
• In anything is found, replace drive plate.
JPBIA0192ZZ

HOW TO SELECT PISTON AND BEARING
A
Description INFOID:0000000003802202
EM
Selection points Selection parts Selection items Selection methods
Determined by match of cylin-
der block bearing housing
C
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal) D
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
E
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston outer diam- Piston grade = cylinder bore
(piston is available together with F
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts. G
• 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 H
selective fitting parts, refer to the text.
Piston INFOID:0000000003802203
I
WHEN NEW CYLINDER BLOCK IS USED
• Check the cylinder bore grade on rear left side of cylinder block (L),
and select piston of the same grade. J
A : Correction stamp
B : Standard stamp
K
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
L
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade M
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade N
: Engine front
• If there is a correction stamp mark on the cylinder block, use it as a

correct reference. O
P
PBIC3264J
WHEN CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-121, "Cylinder Block".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.

3. Select piston of the same grade.
A : Piston grade number

B : Front mark
C : Identification code
D : Sub grade number
PBIC4397J
PISTON SELECTION TABLE

Unit: mm (in)
Grade number (Mark) 1 2 [or no mark (piston only)]
Cylinder bore Inner diameter 84.000 - 84.010 (3.3071 - 3.3075) 84.010 - 84.020 (3.3075 - 3.3079)
Piston skirt diameter 83.970 - 83.980 (3.3059 - 3.3063) 83.980 - 83.990 (3.3063 - 3.3067)
NOTE:
Piston is available together with piston pin as an assembly.
Connecting Rod Bearing INFOID:0000000003802204
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED

1. Apply connecting rod big end diameter grade stamped on con-
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
A : Oil hole
B : Management code
C : Cylinder number
D : Big end diameter grade
E : Front mark
JPBIA2367ZZ
2. Apply crankshaft pin journal diameter grade stamped on crank-

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

B : No. 2 pin journal diameter grade
C : No. 3 pin journal diameter grade
D : No. 4 pin journal diameter grade
E : No. 1 main journal diameter grade
F : No. 2 main journal diameter grade PBIC3261J
G : No. 3 main journal diameter grade
H : No. 4 main journal diameter grade
I : No. 5 main journal diameter grade
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-99, "Inspection".

2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection A
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
EM
CONNECTING ROD BEARING SELECTION TABLE
PBIC4077E N
CONNECTING ROD BEARING GRADE TABLE
Connecting rod bearing grade table : Refer to EM-124, "Connecting Rod Bearing". O
UNDERSIZE BEARINGS USAGE GUIDE

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod P
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:

In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
Bearing undersize table

: Refer to EM-124, "Connecting Rod Bearing".
PBIC3263J
Main Bearing INFOID:0000000003802205
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED

1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear left side of cylinder block (L).
A : Correction stamp
B : Standard stamp
C : Cylinder No. 1 bore grade
D : Cylinder No. 2 bore grade
E : Cylinder No. 3 bore grade
F : Cylinder No. 4 bore grade
G : No. 1 main bearing housing grade
H : No. 2 main bearing housing grade
I : No. 3 main bearing housing grade
J : No. 4 main bearing housing grade
K : No. 5 main bearing housing grade
: Engine front
• If there is a correction stamp mark on cylinder block, use it as

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

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

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

I : No. 5 main journal diameter grade
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4, and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.

4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE: A
Service part is available as a set of both upper and lower.
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main EM
journal diameter individually. Refer to EM-99, "Inspection".
2. Apply the measured dimension to the “Main Bearing Selection Table”.
C
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for No. 1, 4, and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the D
specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE: E
Service part is available as a set of both upper and lower.
MAIN BEARING SELECTION TABLE (No. 1, 4 AND 5 JOURNAL)
F
PBIC4078E

MAIN BEARING SELECTION TABLE (No. 2 AND 3 JOURNAL)
PBIC4079E
MAIN BEARING GRADE TABLE (ALL JOURNALS)
Main bearing grade table (All journals) : Refer to EM-125, "Main Bearing".
UNDERSIZE BEARING USAGE GUIDE

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:

In grinding crankshaft main journal to use undersize bearings,
keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A). A
Bearing undersize table:

Refer to EM-125, "Main Bearing". EM
PBIC3263J

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR20DE]

General Specification INFOID:0000000003802206
GENERAL SPECIFICATIONS
Engine type MR20DE

Cylinder arrangement In-line 4
Displacement cm3 (cu in) 1,997 (121.86)

Bore and stroke mm (in) 84.0×90.1 (3.307×3.547)
Valve arrangement DOHC
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1
Compression ratio 10.0
Standard 1,530 (15.3, 15.6, 222)
Compression pressure
Minimum 1,260 (12.6, 12.9, 183)
kPa (bar, kg/cm2, psi)/250 rpm
Differential limit between cylinders 100 (1.0, 1.0, 15)
Unit: degree
Valve timing
: Intake valve
: Exhaust valve
PBIC5304E
a b c d e f
8 (−37) 52 (7)
212 224 7 25
ATDC ABDC
( ): Valve timing control “ON”
Drive Belt INFOID:0000000003802207
DRIVE BELT
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Spark Plug INFOID:0000000003802208
SPARK PLUG
Unit: mm (in)
Make NGK
Standard type LZKAR6AP-11
Standard 1.1 (0.043)
Gap (Nominal)
Limit 1.4 (0.055)

Exhaust Manifold INFOID:0000000003802209
A
EXHAUST MANIFOLD
Unit: mm (in)
EM
Items Limit
Each exhaust port 0.3 (0.012)
Surface distortion
Entire part 0.7 (0.028) C
Camshaft INFOID:0000000003802210
CAMSHAFT D
Unit: mm (in)
Items Standard Limit

E
No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028)
No. 1 28.000 - 28.021 (1.1024 - 1.1032) — F
Camshaft bracket inner diameter
No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal diameter G
No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9831) —
Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.24 (0.0094)
Intake 44.605 - 44.795 (1.7561 - 1.7636) 44.405 (1.7482) H
Camshaft cam height “A”
Exhaust 43.175 - 43.365 (1.6998 - 1.7073) 42.975 (1.6919)
Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020)
I
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
SEM671
M
*: Total indicator reading
VALVE LIFTER
Unit: mm (in) N
Items Standard
Intake 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter outer diameter O
Exhaust 29.977 - 29.987 (1.1802 - 1.1806)
Intake 34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter hole diameter
Exhaust 30.000 - 30.021 (1.1811 - 1.1819) P
Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)
VALVE CLEARANCE

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

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

Unit: mm (in)
Identification mark Thickness
KBIA0119E
300 3.00 (0.1181)

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

Cylinder Head INFOID:0000000003802211
A
CYLINDER HEAD
Unit: mm (in)
EM
Head surface distortion — 0.1 (0.004)
Normal cylinder head height “H” 130.9 (5.15) — C
PBIC0924E
VALVE DIMENSIONS G
Unit: mm (in)
SEM188A K
Intake 33.8 - 34.1 (1.331 - 1.343)
Valve head diameter “D”
Exhaust 27.6 - 27.9 (1.087 - 1.098)
L
Intake 106.27 (4.18)
Valve length “L”
Exhaust 105.26 (4.14)
Intake 5.465 - 5.480 (0.2152 - 0.2157) M
Valve stem diameter “d”
Exhaust 5.455 - 5.470 (0.2148 - 0.2154)
Valve seat angle “α” 45°15′ - 45°45′
N
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.2 (0.047)
VALVE GUIDE O

Unit: mm (in)
PBIC2187E
Items Standard Oversize (service) [0.2 (0.008)]

Outer diameter 9.523 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832)
Valve guide
Inner diameter (Finished size) 5.500 - 5.518 (0.2165 - 0.2172)
Cylinder head valve guide hole diameter 9.475 - 9.496 (0.3730 - 0.3739) 9.675 - 9.696 (0.3809 - 0.3817)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Intake 0.020 - 0.053 (0.0008 - 0.0021)
Valve guide clearance 0.1 (0.004)
Exhaust 0.030 - 0.063 (0.0012 - 0.0025)
Projection length “H” 13.35 - 13.65 (0.5256 - 0.5374)
VALVE SEAT
Unit: mm (in)
PBIC2745E
Items Standard Oversize (service) [0.5 (0.02)]

Intake 34.700 - 34.727 (1.3661 - 1.3672) 35.200 - 35.227 (1.3858 - 1.3869)
Cylinder head seat recess diameter “D”
Exhaust 28.700 - 28.727 (1.1299 - 1.1310) 29.200 - 29.227 (1.1496 - 1.1507)
Intake 34.808 - 34.824 (1.3704 - 1.3710) 35.308 - 35.324 (1.3901 - 1.3907)
Valve seat outer diameter “d”
Exhaust 28.808 - 28.824 (1.1342 - 1.1348) 29.308 - 29.324 (1.1539 - 1.1545)
Valve seat interference fit 0.081 - 0.124 (0.0032 - 0.0049)
Intake 31.8 (1.252)
Diameter “d1”*1
Exhaust 25.3 (0.996)
Intake 33.1 - 33.6 (1.303 - 1.323)
Diameter “d2”*2
Exhaust 26.9 - 27.4 (1.059 - 1.079)
Intake 60°
Angle “α1”
Exhaust 45°
Angle “α2” 88°45′ - 90°15′
Angle “α3” 120°

Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3 A
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 5.03 - 5.13 (0.1980 - 0.2020)
Height “h” 5.9 - 6.0 (0.232 - 0.236)
Exhaust 4.95 - 5.05 (0.1949 - 0.1988) EM
Intake 6.04 (0.2378)
Depth “H”
Exhaust 6.05 (0.2382)
C
*1: Diameter made by intersection point of conic angles “α1” and “α2”
*3: Machining data D
VALVE SPRING
Standard E
Items
Intake Exhaust
Free height 44.90 - 45.10 mm (1.7677 - 1.7756 in) 45.74 - 45.94 mm (1.8008 - 1.8087 in)
F
Installation height 35.30 mm (1.390 in) 35.30 mm (1.390 in)
Installation load 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb) 137 - 159 N (14.0 - 16.2 kg, 31 - 36 lb)
Height during valve open 26.36 mm (1.0378 in) 27.80 mm (1.0945 in) G
Load with valve open 333 - 379 N (34.0 - 38.7 kg, 75 - 85 lb) 264 - 299 N (26.9 - 30.5 kg, 59 - 67 lb)
Identification color White Orange
H
Unit: mm (in)
Items Limit
Valve spring squareness 2.0 (0.079) I
Cylinder Block INFOID:0000000003802212
J
CYLINDER BLOCK
Unit: mm (in)
N
PBIC4017E
Cylinder block top surface distortion Limit 0.1 (0.004)

Grade No. 1 84.000 - 84.010 (3.3071 - 3.3075) O
Cylinder bore inner diameter Standard
Grade No. 2 84.010 - 84.020 (3.3075 - 3.3079)

Out-of-round 0.015 (0.0006)
Limit
Taper 0.010 (0.0004)
Grade No. A 55.997 - 55.998 (2.2046 - 2.2046)
Grade No. B 55.998 - 55.999 (2.2046 - 2.2047)
Grade No. C 55.999 - 56.000 (2.2047 - 2.2047)
Grade No. D 56.000 - 56.001 (2.2047 - 2.2048)
Grade No. E 56.001 - 56.002 (2.2048 - 2.2048)
Grade No. F 56.002 - 56.003 (2.2048 - 2.2048)
Grade No. G 56.003 - 56.004 (2.2048 - 2.2049)
Grade No. H 56.004 - 56.005 (2.2049 - 2.2049)
Grade No. J 56.005 - 56.006 (2.2049 - 2.2050)
Grade No. K 56.006 - 56.007 (2.2050 - 2.2050)
Main bearing housing inner diameter grade
Grade No. L 56.007 - 56.008 (2.2050 - 2.2050)
Grade No. M 56.008 - 56.009 (2.2050 - 2.2051)
Grade No. N 56.009 - 56.010 (2.2051 - 2.2051)
Grade No. P 56.010 - 56.011 (2.2051 - 2.2052)
Grade No. R 56.011 - 56.012 (2.2052 - 2.2052)
Grade No. S 56.012 - 56.013 (2.2052 - 2.2052)
Grade No. T 56.013 - 56.014 (2.2052 - 2.2053)
Grade No. U 56.014 - 56.015 (2.2053 - 2.2053)
Grade No. V 56.015 - 56.016 (2.2053 - 2.2053)
Grade No. W 56.016 - 56.017 (2.2053 - 2.2054)
AVAILABLE PISTON
Unit: mm (in)
PBIC0188E
Grade No. 1 83.970 - 83.980 (3.3059 - 3.3063)

Piston skirt diameter “A” Standard
Grade No. 2 83.980 - 83.990 (3.3063 - 3.3067)
Measure point “H” 39.9 (1.571)
Piston pin hole diameter 19.993 - 19.999 (0.7871 - 0.7874)
Standard 0.020 - 0.040 (0.0008 - 0.0016)
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
PISTON RING
Unit: mm (in)
Top 0.04 - 0.08 (0.0016 - 0.0031) 0.11 (0.0043)
Piston ring side clearance 2nd 0.03 - 0.07 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.015 - 0.185 (0.006 - 0.0073) —
Top 0.20 - 0.30 (0.0079 - 0.0118) 0.51 (0.0201)
Piston ring end gap 2nd 0.50 - 0.65 (0.0197 - 0.0256) 0.83 (0.0327)
Oil (rail ring) 0.15 - 0.45 (0.0059 - 0.0177) 0.78 (0.0307)
PISTON PIN

Unit: mm (in)
Items Standard Limit A

Piston pin outer diameter 19.989 - 19.995 (0.7870 - 0.7872) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
EM
CONNECTING ROD
Unit: mm (in)
Center distance 138.97 - 139.07 (5.47 - 5.48) C

Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
D
Connecting rod bushing inner diameter* Standard 20.000 - 20.012 (0.7874 - 0.7879)
Standard 0.005 - 0.023 (0.0002 - 0.0009)
Connecting rod bushing oil clearance
Limit 0.03 (0.0012) E
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Connecting rod side clearance
Limit 0.4 (0.016)
F
Grade No. A 47.000 - 47.001 (1.8504 - 1.8504)
Grade No. B 47.001 - 47.002 (1.8504 - 1.8505)
Grade No. C 47.002 - 47.003 (1.8505 - 1.8505)
Grade No. D 47.003 - 47.004 (1.8505 - 1.8505) G
Grade No. E 47.004 - 47.005 (1.8505 - 1.8506)
Grade No. F 47.005 - 47.006 (1.8506 - 1.8506)
Connecting rod big end diameter grade Grade No. G 47.006 - 47.007 (1.8506 - 1.8507)
Grade No. H 47.007 - 47.008 (1.8507 - 1.8507) H
Grade No. J 47.008 - 47.009 (1.8507 - 1.8507)
Grade No. K 47.009 - 47.010 (1.8507 - 1.8508)
Grade No. L 47.010 - 47.011 (1.8508 - 1.8508)
Grade No. M 47.011 - 47.012 (1.8508 - 1.8509) I
Grade No. N 47.012 - 47.013 (1.8509 - 1.8509)
*: After installing in connecting rod
J
CRANKSHAFT
Unit: mm (in)
N
SEM645 PBIC3459J
Center distance “r” 44.89 - 44.97 (1.7673 - 1.7705)

Out-of-round Limit O
0.0035 (0.0001)
Taper Limit
Standard 0.05 (0.0020)
Runout [TIR*] P
Limit 0.1 (0.004)
Standard 0.10 - 0.26 (0.0039 - 0.0102)
Crankshaft end play
Limit 0.3 (0.012)

Grade No. A 43.970 - 43.971 (1.7311 - 1.7311)
Grade No. B 43.969 - 43.970 (1.7311 - 1.7311)
Grade No. C 43.968 - 43.969 (1.7310 - 1.7311)
Grade No. D 43.967 - 43.968 (1.7310 - 1.7310)
Grade No. E 43.966 - 43.967 (1.7309 - 1.7310)
Grade No. F 43.965 - 43.966 (1.7309 - 1.7309)
Grade No. G 43.964 - 43.965 (1.7309 - 1.7309)
Grade No. H 43.963 - 43.964 (1.7308 - 1.7309)
Grade No. J 43.962 - 43.963 (1.7308 - 1.7308)
Crankshaft pin journal diameter “Dp” grade.
Grade No. K 43.961 - 43.962 (1.7307 - 1.7308)
Grade No. L 43.960 - 43.961 (1.7307 - 1.7307)
Grade No. M 43.959 - 43.960 (1.7307 - 1.7307)
Grade No. N 43.958 - 43.959 (1.7306 - 1.7307)
Grade No. P 43.957 - 43.958 (1.7306 - 1.7306)
Grade No. R 43.956 - 43.957 (1.7305 - 1.7306)
Grade No. S 43.955 - 43.956 (1.7305 - 1.7305)
Grade No. T 43.954 - 43.955 (1.7305 - 1.7305)
Grade No. U 43.953 - 43.954 (1.7304 - 1.7305)
Grade No. A 51.978 - 51.979 (2.0464 - 2.0464)
Grade No. B 51.977 - 51.978 (2.0463 - 2.0464)
Grade No. C 51.976 - 51.977 (2.0463 - 2.0463)
Grade No. D 51.975 - 51.976 (2.0463 - 2.0463)
Grade No. E 51.974 - 51.975 (2.0462 - 2.0463)
Grade No. F 51.973 - 51.974 (2.0462 - 2.0462)
Grade No. G 51.972 - 51.973 (2.0461 - 2.0462)
Grade No. H 51.971 - 51.972 (2.0461 - 2.0461)
Grade No. J 51.970 - 51.971 (2.0461 - 2.0461)
Grade No. K 51.969 - 51.970 (2.0460 - 2.0461)
Crankshaft main journal diameter “Dm” grade.
Grade No. L 51.968 - 51.969 (2.0460 - 2.0460)
Grade No. M 51.967 - 51.968 (2.0459 - 2.0460)
Grade No. N 51.966 - 51.967 (2.0459 - 2.0459)
Grade No. P 51.965 - 51.966 (2.0459 - 2.0459)
Grade No. R 51.964 - 51.965 (2.0458 - 2.0459)
Grade No. S 51.963 - 51.964 (2.0458 - 2.0458)
Grade No. T 51.962 - 51.963 (2.0457 - 2.0458)
Grade No. U 51.961 - 51.962 (2.0457 - 2.0457)
Grade No. V 51.960 - 51.961 (2.0457 - 2.0457)
Grade No. W 51.959 - 51.960 (2.0456 - 2.0457)
*: Total indicator reading

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

0 1.494 - 1.497 (0.0588 - 0.0589) Black
1 1.497 - 1.500 (0.0589 - 0.0591) Brown
Grade and color are the same
2 1.500 - 1.503 (0.0591 - 0.0592) Green
for upper and lower bearings.
3 1.503 - 1.506 (0.0592 - 0.0593) Yellow
4 1.506 - 1.509 (0.0593 - 0.0594) Blue
UPR 1.494 - 1.497 (0.0588 - 0.0589) Black
01
LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown
UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown
12
LWR 1.500 - 1.503 (0.0591 - 0.0592) Green Grade and color are different
between upper and lower bear-
UPR 1.500 - 1.503 (0.0591 - 0.0592) Green ings.
23
LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
34
LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue

UNDERSIZE TABLE
Unit: mm (in) A
Items Thickness Crank pin journal diameter
US 0.25 (0.0098) 1.623 - 1.631 (0.0639 - 0.0642) Grind so that bearing clearance is the specified value.
EM
Unit: mm (in)
Standard 0.037 - 0.047 (0.0015 - 0.0019) C

Connecting rod bearing oil clearance
Limit 0.07 (0.0028)
Main Bearing INFOID:0000000003802214 D

Unit: mm (in) E
Grade number Thickness Identification color Remarks
0 1.996 - 1.999 (0.0786 - 0.0787) Black
F
1 1.999 - 2.002 (0.0787 - 0.0788) Brown
2 2.002 - 2.005 (0.0788 - 0.0789) Green
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are the same G
4 2.008 - 2.011 (0.0791 - 0.0792) Blue for upper and lower bearings.
5 2.011 - 2.014 (0.0792 - 0.0793) Pink

H
6 2.014 - 2.017 (0.0793 - 0.0794) Purple
7 2.017 - 2.020 (0.0794 - 0.0795) White
UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
01 I
LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown
12
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green J
UPR 2.002 - 2.005 (0.0788 - 0.0789) Green
23
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
K
UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are different
34 between upper and lower bear-
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue ings.
UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue L
45
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink
56 M
LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple
UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple
67
LWR 2.017 - 2.020 (0.0794 - 0.0795) White N
UNDERSIZE TABLE
Unit: mm (in)
O
Items Thickness Main journal diameter
US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value.
MAIN BEARING OIL CLEARANCE P

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

Standard
Main bearing oil clearance No. 2 and 3 0.012 - 0.022 (0.0005 - 0.0009)
Limit 0.065 (0.0026)

< SYMPTOM DIAGNOSIS > [VQ25DE, VQ35DE]
SYMPTOM DIAGNOSIS
NVH Troubleshooting - Engine Noise INFOID:0000000003802314
JPBIA1711GB

< SYMPTOM DIAGNOSIS > [VQ25DE, VQ35DE]
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000003802315
A
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of the engine. EM
4. Check specified noise source.
If necessary, repair or replace these parts.
C
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 D
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-141
gine clicking noise E
Rocker
cover Camshaft Camshaft runout
Cylinder Rattle C A — A B C bearing Camshaft journal oil EM-261
head noise clearance F
Piston to piston pin oil
Slap or Piston pin clearance EM-268
— A — B B —
knock noise Connecting rod bushing G
oil clearance
Piston to cylinder bore
Crank- clearance
Piston ring side clear-
H
shaft pul- Slap or Piston
ley A — — B B A ance EM-268
rap slap noise
Cylinder Piston ring end gap
block Connecting rod bend
I
(Side of and torsion
engine) Connect- Connecting rod bushing EM-268
Oil pan ing rod oil clearance
Knock A B C B B B J
bearing Connecting rod bearing EM-272
noise oil clearance
Main bearing oil clear- EM-271
Main bear-
Knock A B — A B C
ing noise
ance K
Crankshaft runout EM-268
Timing
Front of chain and Timing chain cracks EM-190 L
engine Tapping or timing and wear
A A — B B B
Timing ticking chain ten- Timing chain tensioner EM-177
chain case sioner operation
noise M
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-136 N
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
O
Water CO-41,
Squall
A B — B A B pump Water pump operation "Exploded
Creak
noise View"
A: Closely related B: Related C: Sometimes related —: Not related
P

PRECAUTIONS
< PRECAUTION > [VQ25DE, VQ35DE]
PRECAUTION
PRECAUTIONS
Precaution for Procedure without Cowl Top Cover INFOID:0000000004221785
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.
PIIB3706J
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000004221787
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SRS AIR BAG” and
“SEAT BELT” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.
• 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 “SRS AIR BAG”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
Precaution Necessary for Steering Wheel Rotation after Battery Disconnect
INFOID:0000000004221786
NOTE:
• Before removing and installing any control units, first turn the push-button ignition switch to the LOCK posi-
tion, then disconnect both battery cables.
• After finishing work, confirm that all control unit connectors are connected properly, then re-connect both
battery cables.
• Always use CONSULT-III to perform self-diagnosis as a part of each function inspection after finishing work.
If a DTC is detected, perform trouble diagnosis according to self-diagnosis results.
This vehicle is equipped with a push-button ignition switch and a steering lock unit.
If the battery is disconnected or discharged, the steering wheel will lock and cannot be turned.
If turning the steering wheel is required with the battery disconnected or discharged, follow the procedure
below before starting the repair operation.
OPERATION PROCEDURE

PRECAUTIONS
1. Connect both battery cables.
NOTE: A
Supply power using jumper cables if battery is discharged.
2. Turn the push-button ignition switch to ACC position.
(At this time, the steering lock will be released.) EM
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation. C
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.) D
6. Perform self-diagnosis check of all control units using CONSULT-III.
Precaution for Drain Engine Coolant and Engine Oil INFOID:0000000003802319
E
Drain engine coolant and engine oil when the engine is cooled.
Precaution for Disconnecting Fuel Piping INFOID:0000000003802320
F
• 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. G
Precaution for Removal and Disassembly INFOID:0000000003802321
• When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or unin- H
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
I
• Cover openings of engine system with a tape or the equivalent, if necessary, 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 J
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
Precaution for Inspection, Repair and Replacement INFOID:0000000003802322
K
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary. L
Precaution for Assembly and Installation INFOID:0000000003802323
• Use torque wrench to tighten bolts or nuts to specification. M

• 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. N
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for O
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well. P
• 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.
Precaution for Angle Tightening INFOID:0000000003802324
• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
- Cylinder head bolts

PRECAUTIONS
- Main bearing cap bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening)
• Never use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000003802325
REMOVAL OF LIQUID GASKET SEALING

• After removing mounting nuts and bolts, separate the mating sur-
face using the seal cutter [SST: KV10111100] (A) and remove old
liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap the seal cutter [SST: KV10111100] to insert it (B), and then
slide it (C) by tapping on the side as shown in the figure.
• In areas where the seal cutter [SST: KV10111100] is difficult to use,
use a plastic hammer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
JPBIA0052ZZ
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper (A), remove old liquid gasket adhering to the
gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
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.
JPBIA0053ZZ
3. Attach liquid gasket tube to the tube presser (commercial ser-

vice tool).
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
• If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
EMA0622D
• As for bolt holes, normally apply liquid gasket inside the holes.
Occasionally, it should be applied outside the holes. Check to
read the text of this manual.
• Within 5 minutes of liquid gasket application, install the mating
component.
• Never retighten mounting bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill
CAUTION:
SEM159F

PRECAUTIONS
If there are specific instructions in this manual, observe them.
A
Definitions of Bank Names INFOID:0000000004835199
• In this manual, each bank name is defined as follows:

EM
A : Bank 1 (The conventional right bank)
B : Bank 2 (The conventional left bank)
: Engine front C
• For cylinder numbers and bank layout, refer to the illustration.
Bank 1 : The bank side including cylinder No. 1 D

(odd-numbered cylinder side)
Bank 2 : The other bank side of the above JPBIA1135ZZ
E
(even-numbered cylinder side)

PREPARATION
< PREPARATION > [VQ25DE, VQ35DE]
PREPARATION
PREPARATION
Special Service Tool INFOID:0000000003802326
Tool number
Description
Tool name
KV10116200 Disassembling valve mechanism
Valve spring compressor Part (1) is a component of KV10116200, but
1. KV10115900 Part (2) is not so.
Attachment
2. KV10109220
Adapter
PBIC1650E
KV10107902 Replacing valve oil seal

Valve oil seal puller
NT011
KV10115600 Installing valve oil seal

Valve oil seal drift Use side A.
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
EM03470000 Installing piston assembly into cylinder bore

Piston ring compressor
NT044
ST16610001 Removing pilot converter

Pilot bushing puller
NT045
KV10111100 Removing oil pan (lower and upper), front and

Seal cutter rear timing chain case, etc.
NT046

PREPARATION
Tool number
Description
Tool name A
KV10112100 Tightening bolts for connecting rod bearing
Angle wrench cap, cylinder head, etc. in angle
EM
C
NT014
KV10117100 Loosening or tightening air fuel ratio sensor 1

Heated oxygen sensor wrench For 22 mm (0.87 in) width hexagon nut D
NT379
F
KV10114400 Loosening or tightening heated oxygen sen-
Heated oxygen sensor wrench sor 2
a: 22 mm (0.87 in)
G
H
NT636
Commercial Service Tool INFOID:0000000003802327

Quick connector release Removing fuel tube quick connectors in en- J
gine room
(Available in SEC. 164 of PARTS CATALOG:
Part No. 16441 6N210)
K
PBIC0198E L
Power tool Loosening bolts and nuts
N
PBIC0190E
Tube presser Pressing the tube of liquid gasket

O
NT052

PREPARATION
Manual lift table caddy Removing and installing engine
ZZA1210D
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with the angle wrench [SST:
KV10112100]
a: 13 mm (0.51 in) dia.
b: 12 mm (0.47 in)
c: 10 mm (0.39 in)
NT583
1. Compression tester Checking compression pressure

2. Adapter
ZZA0008D
Spark plug wrench Removing and installing spark plug

a: 14 mm (0.55 in)
JPBIA0399ZZ
Pulley holder Removing and installing crankshaft pulley
ZZA1010D
Valve seat cutter set Finishing valve seat dimensions
NT048
Piston ring expander Removing and installing piston ring
NT030

PREPARATION
A
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. EM
C
NT015
Valve guide reamer (1): Reaming valve guide inner hole

(2): Reaming hole for oversize valve guide
Intake and Exhaust: D
d1: 6.0 mm (0.236 in) dia.
d2: 10.2 mm (0.402 in) dia.
E
NT016
Oxygen sensor thread cleaner Reconditioning the exhaust system threads F

before installing a new air fuel ratio sensor and
heated oxygen sensor (Use with anti-seize lu-
bricant shown below.)
a: 18 mm (0.71 in) dia. for zirconia heated G
oxygen sensor and air fuel ratio sensor
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor
AEM488
H
Anti-seize lubricant (Permatex 133AR Lubricating air fuel ratio sensor and oxygen
or equivalent meeting MIL specifica- sensor threads cleaning tool when recondi-
tion MIL-A-907) tioning exhaust system threads
I
J
AEM489

DRIVE BELT
< ON-VEHICLE MAINTENANCE > [VQ25DE, VQ35DE]
ON-VEHICLE MAINTENANCE
DRIVE BELT
JPBIA1625ZZ
1. Idler pulley 2. Drive belt 3. Power steering oil pump

4. Drive belt auto-tensioner 5. Crankshaft pulley 6. Idler pulley
7. A/C compressor 8. Alternator
A. Indicator B. Range when new drive belt is installed C. Possible use range
D. View D
: Engine front
Checking INFOID:0000000003802329
WARNING:
Be sure to perform the this step when engine is stopped.
• Check that the indicator (A) of drive belt auto-tensioner is within the possible use range (C).
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator should be within the range (B) in the figure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator is out of the possible use range or belt is damaged, replace drive belt.
Tension Adjustment INFOID:0000000003802330
Refer to EM-261, "Drive Belt".

REMOVAL
1. Remove front wheel and tire (RH).
2. Remove front splash guard (RH). Refer to EXT-24, "FENDER PROTECTOR : Exploded View".

DRIVE BELT
3. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han- A
dle in the direction of arrow (loosening direction of drive belt).
CAUTION:
• Avoid placing hand in a location where pinching may
EM
occur if the holding tool accidentally comes off.
• Never loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Never turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto- C
tensioner must be replaced as a unit, including the pulley.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as JPBIA1627ZZ
short-length screwdriver into the hole (A) of the retaining boss to D
fix drive belt auto-tensioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
5. Loosen drive belt from water pump pulley in sequence, and remove it. E
INSTALLATION
1. Hook drive belt on to all pulleys except for drive belt auto-tensioner pulley, and then onto drive belt auto-
tensioner pulley finally. F
CAUTION:
• Confirm drive belt is completely set to pulleys.
• Check for engine oil, working fluid, and engine coolant are not adhered to drive belt and each G
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley. H
4. Confirm tension of drive belt at indicator is within the possible use range. Refer to EM-136, "Exploded
View".
I

AIR CLEANER FILTER
AIR CLEANER FILTER
REMOVAL
1. Unhook air cleaner case (lower) side clips and lift up air cleaner case (upper).
2. Remove air cleaner filter from air cleaner case (lower).
PBIC1165E
INSTALLATION
• Install the air cleaner filter by aligning the seal with the notch of air cleaner case.

SPARK PLUG
SPARK PLUG
A
EM
J
JPBIA1637GB
1. Ignition coil 2. Spark plug 3. PCV hose K

4. Clamp 5. PCV valve 6. O-ring
7. Rocker cover (bank 1) 8. PCV hose 9. Rocker cover gasket (bank 1)
Camshaft position sensor (PHASE) L
10. O-ring 11. 12. Oil filler cap
(bank 1)
Camshaft position sensor (PHASE)
13. Rocker cover (bank 2) 14. Rocker cover gasket (bank 2) 15.
(bank 2) M
16. PCV hose 17. Clamp
A. To intake manifold collector B. Refer to EM-174 C. Camshaft bracket side
D. To air duct assembly N

O
REMOVAL
1. Remove engine cover. Refer to EM-148, "Exploded View". P
2. Remove air cleaner cases (upper and lower) and air duct assembly. Refer to EM-150, "Exploded View".
3. Remove electric throttle control actuator. Refer to EM-152, "Exploded View".
4. Remove intake manifold collector. Refer to EM-152, "Exploded View".
5. Remove ignition coil. Refer to EM-174, "Exploded View".

SPARK PLUG
6. Remove spark plug with a spark plug wrench (commercial ser-
vice tool).
a : 14 mm (0.55 in)
JPBIA0030ZZ
INSTALLATION

Use the standard type spark plug for normal condition.
Spark plug (Standard type) : Refer to EM-261, "Spark Plug".

CAUTION:
• Never drop or shock spark plug.
• Never use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used.
Cleaner air pressure: Less than 588 kPa (5.88 bar, 6 kg/
cm2, 85 psi)
Cleaning time: Less than 20 seconds
SMA773C
• Spark plug gap adjustment is not required between replace-

ment intervals.
• Measure spark plug gap. When it exceeds the limit, replace
spark plug even if it is within the specified replacement mile-
age. Refer to EM-261, "Spark Plug".
JPBIA0031ZZ

A
Inspection and Adjustment INFOID:0000000003802336
INSPECTION EM
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
In cases of removing/installing or replacing camshaft and valve- C
related parts, or of unusual engine conditions due to changes in
valve clearance (found malfunctions during stating, idling or causing
noise), perform inspection as follows:
D
: Engine front
JPBIA0164ZZ
F
1. Remove rocker covers (bank 1 and bank 2). Refer to EM-174, "Exploded View".
2. Measure the valve clearance as follows: G
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise to align timing mark
(grooved line without color) ( ) with timing indicator. H
SEM727G
K
• Check that intake and exhaust cam nose on No. 1 cylinder
(engine front side of bank 1) are located as shown in the fig-
ure. L
: Engine front
• If not, turn crankshaft one revolution (360 degrees) and align M

as shown in the figure.
N
JPBIA0044ZZ
b. Use a feeler gauge, measure the clearance between valve lifter O

and camshaft.
Valve clearance : Refer to EM-261, "Camshaft".

P
SEM139D

locations marked “×” as shown in the table below (locations
indicated in the figure).
: Engine front
• No. 1 cylinder at compression TDC
Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL.
No. 1 cylinder at com- EXH (C) × (B)

pression TDC INT (D) × (E)
Measuring position [bank 2 (H)] No. 2 CYL. No. 4 CYL. No. 6 CYL.
No. 1 cylinder at com- INT (D) × (F)

pression TDC EXH (C) × (G)
JPBIA0165ZZ
c. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at
TDC its compression stroke.
NOTE:
Mark a position 240 degrees (b) from a corner of the hexagonal
part of crankshaft pulley mounting bolt as shown in the figure.
Use the hexagonal part as a guide.
1 : Crankshaft pulley
A : Paint mark
JPBIA0166ZZ

locations marked “×” as shown in the table below (locations A
: Engine front
EM
Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL. C
No. 3 cylinder at com- EXH (C) × (B)

pression TDC INT (D) × (E)
D
No. 3 cylinder at com- INT (D) × (F)

pression TDC EXH (C) × (G) E
G
JPBIA0167ZZ
d. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at
TDC of compression stroke. H
NOTE:
Mark a position 240 degrees (b) from a corner of the hexagonal
part of crankshaft pulley mounting bolt as shown in the figure.
I
Use the hexagonal part as a guide.
A : Paint mark J
JPBIA0166ZZ

locations marked “×” as shown in the table below (locations
: Engine front
Measuring position [bank 1 (A)] No. 1 CYL. No. 3 CYL. No. 5 CYL.
No. 5 cylinder at EXH (C) × (B)

compression TDC INT (D) × (E)
No. 5 cylinder at INT (D) × (F)

compression TDC EXH (C) × (G)
JPBIA0168ZZ
3. Perform adjustment if the measured value is out of the standard. Refer to “ADJUSTMENT”.
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter.
1. Measure the valve clearance. Refer to “INSPECTION”.
3. Remove valve lifters at the locations that are out of the standard.
4. Measure the center thickness of the removed valve lifters with a
micrometer (A).
JPBIA0169ZZ
5. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1 – C2)

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.30 mm (0.012 in)
Exhaust : 0.33 mm (0.013 in)
• VQ25DE

- Thickness of new valve lifter can be identified by stamp marks
on the reverse side (inside the cylinder). A
A : Stamp
B : Thickness of valve lifter EM
Stamped mark 788P indicates 7.88 mm (0.3102 in) in thick-
ness. (intake side)
Stamped mark 666U indicates 6.66 mm (0.2622 in) in thick- C
ness. (exhaust side)
Available thickness of valve lifter: 27 size with range 7.88 to
8.40 mm (0.3102 to 0.3307 in) (intake side) and 6.66 to 7.18 JPBIA0170ZZ
mm (0.2622 to 0.2827 in) (exhaust side) in steps of 0.02 D

(0.0008 in) (when manufactured at factory). Refer to EM-261, "Camshaft".
CAUTION:
Install identification letter at the end, “P”and “U”, at each of proper positions. (Be careful of mis- E
installation between intake and exhaust)
• VQ35DE
- Thickness of new valve lifter can be identified by stamp marks
on the reverse side (inside the cylinder). F
A : Stamp
B : Thickness of valve lifter G
Stamp mark 788P indicates 7.88 mm (0.3102 in) in thickness.
JPBIA0170ZZ
I
Available thickness of valve lifter: 27 sizes with range 7.88 to 8.40 mm (0.3102 to 0.3307 in) in steps of
0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-261, "Camshaft".
J
6. Install selected valve lifter.
7. Install camshaft. Refer to EM-209, "Exploded View".
8. Manually turn crankshaft pulley a few turns. K
9. Check that the valve clearances for cold engine are within the specifications by referring to the specified
values. Refer to EM-141, "Inspection and Adjustment".
10. Install all removal parts in the reverse order of removal. L
11. Warm up the engine, and check for unusual noise and vibration.

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

3. Disconnect fuel pump fuse to avoid fuel injection during measurement. Refer to EC-666,
"Component Parts Location" (TYPE 1) or EC-1082, "Component Parts Location" (TYPE 2).
5. Remove ignition coil and spark plug from each cylinder. Refer to EM-174, "Exploded View".
6. Connect engine tachometer (not required in use of CONSULT-III).
7. Install compression gauge with an adapter (commercial service
tool) onto spark plug hole.
PBIC0900E
• Use the adapter whose picking up end inserted to spark plug

hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
a : 20 mm (0.79 in)
JPBIA0171ZZ
8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each
cylinder.
Compression pressure : Refer to EM-260, "General Specification".

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

10. Start the engine, and check that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-770, "Description" (TYPE 1) or EC-1177, A
"Description" (TYPE 2).
EM

ENGINE COVER
< ON-VEHICLE REPAIR > [VQ25DE, VQ35DE]
ON-VEHICLE REPAIR
ENGINE COVER
JPBIA1712GB
1. Engine cover
REMOVAL
1. Remove air duct (inlet). Refer to EM-150, "Exploded View".
2. Remove engine cover mounting bolts (A) and (B).
3. Draw and pull out engine cover from engine cover mounting
bolts (C) and (D).
CAUTION:
• Pull engine cover from mounting bolt (D) holding with
hand the position (E) as shown in the figure.
• Never damage or scratch engine cover when installing or
removing.
4. Remove engine cover mounting bolts (C) and (D), if necessary.
JPBIA1718ZZ
INSTALLATION

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
A
EM
G
JPBIA1626GB
1. Drive belt auto-tensioner 2. Idler pulley 3. Idler pulley

4. Bracket
H
Removal and Installation INFOID:0000000003802341 I
Removal
1. Remove drive belt. Refer to EM-136, "Removal and Installation". J
• Keep auto-tensioner pulley arm locked after drive belt is removed.
2. Remove auto-tensioner and idler pulley.
• Keep auto-tensioner pulley arm locked to install or remove auto-tensioner. K
Installation
CAUTION: L
If there is damage greater than peeled paint, replace drive belt auto-tensioner.

JPBIA2193GB
1. Mass air flow sensor 2. Air cleaner case (upper) 3. Air cleaner filter
4. Clamp 5. Air duct assembly 6. Clamp
7. PCV hose 8. Air duct (inlet) 9. Grommet
10. Collar 11. Grommet 12. Grommet
13. Bracket 14. Bracket 15. Collar
16. Grommet 17. Air cleaner case (lower)
A. To electric throttle control actuator B. To rocker cover (bank 2) C. VQ25DE
REMOVAL
NOTE:
Mass air flow sensor is removable under car-mounting condition.
1. Remove air duct (inlet).
2. Disconnect harness connector from mass air flow sensor.
3. Disconnect PCV hose.
4. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly disconnect-
ing their joints.
5. Remove mass air flow sensor from air cleaner case (upper) if necessary.
CAUTION:
Handle the mass air flow sensor with following cares.

• Never shock the mass air flow sensor.
• Never disassemble the mass air flow sensor. A
• Never touch the sensor of the mass air flow sensor.
INSTALLATION
Note the following, and install in the reverse order of removal. EM
• Align marks. Attach each joint. Screw clamps firmly.
C
Inspect air duct assembly for crack or tear.
• If anything found, replace air duct assembly. D

INTAKE MANIFOLD COLLECTOR
VQ25DE
JPBIA2469GB
1. Vacuum hose 2. Clamp 3. Clamp

4. PCV hose 5. Intake manifold collector 6. Gasket
7. Vacuum hose 8. VIAS control solenoid valve 9. Vacuum hose
Electronic controlled engine mount
10. Bracket 11. 12. Vacuum hose
13. Vacuum hose 14. Vacuum gallery 15. Vacuum hose
EVAP canister purge control solenoid
16. 17. Clamp 18. EVAP hose
valve
19. Vacuum tank 20. Bracket 21. EVAP hose
22. EVAP hose 23. EVAP pipe 24. EVAP hose
25. Clamp 26. Water hose 27. Water hose
28. Bracket 29. Electric throttle control actuator 30. Gasket
A. To brake booster B. To rocker cover (bank 1) C. To vacuum tube (front)
D. To vacuum pipe E. To heater pipe F. To water outlet
: Engine front
VQ35DE

EM
I
JPBIA2470GB
1. Vacuum hose 2. Clamp 3. Clamp

J
4. PCV hose 5. Intake manifold collector 6. Gasket
Electronic controlled engine mount
7. Vacuum hose 8. Bracket 9.
10. Vacuum hose 11. Vacuum hose 12. Vacuum hose K
13. Vacuum gallery 14. Vacuum hose 15. Vacuum hose
EVAP canister purge control solenoid
16. VIAS control solenoid valve 2 17. VIAS control solenoid valve 1 18. L
valve
19. Clamp 20. EVAP hose 21. Vacuum tank
22. Bracket 23. EVAP hose 24. EVAP hose
25. EVAP pipe 26. EVAP hose 27. Clamp M
28. Water hose 29. Water hose 30. Bracket
31. Electric throttle control actuator 32. Gasket
A. To brake booster B. To rocker cover (bank 1) C. To vacuum tube (rear) N
D. To vacuum pipe E. To heater pipe F. To water outlet
: Engine front
O
P
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when the engine is hot.
CAUTION:
Be careful not to damage or scratch engine cover.

2. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly. Refer to
3. Remove front wiper arm and extension cowl top. Refer to WW-112, "Exploded View" and EXT-22,
"Exploded View".
4. Disconnect water hoses from electric throttle control actuator as follows:
• Drain engine coolant from radiator or attach plug to prevent engine coolant leakage when engine cool-
ant is not drained. Refer to CO-32, "Draining".
CAUTION:
5. Remove electric throttle control actuator as follows:
a. Disconnect harness connector.
b. Loosen mounting bolts in reverse order as shown in the figure.
CAUTION:
• Handle carefully to avoid any shock to electric throttle
control actuator.
• Never disassemble.
JPBIA1631ZZ
6. Remove the following parts:

• Vacuum hose
• PCV hose
• High pressure piping from intake manifold collector: Refer to ST-37, "Exploded View".
• Electronic controlled engine mount control solenoid valve
7. Disconnect EVAP hoses and harness connector from EVAP canister purge control solenoid valve.
8. Remove EVAP canister purge control solenoid valve and bracket assembly.
9. Remove VIAS control solenoid valve mounting bolts and vacuum gallery mounting bolts, and then move
vacuum gallery.
10. Loosen mounting nuts and bolts in reverse order as shown in
the figure, and remove intake manifold collector and gasket.
: Engine front
CAUTION:
NOTE:
Figure is shown as an example of VQ35DE.
JPBIA1628ZZ
INSTALLATION
Intake Manifold Collector

Tighten mounting nuts and bolts in numerical order as shown in the
figure. A
: Engine front
NOTE: EM
Figure is shown as an example of VQ35DE.
JPBIA1628ZZ
D
Electric Throttle Control Actuator
• Tighten mounting bolts in numerical order as shown in the figure.
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected. E
Refer to EC-662, "THROTTLE VALVE CLOSED POSITION
LEARNING : Special Repair Requirement" (TYPE 1) or EC-1078,
"THROTTLE VALVE CLOSED POSITION LEARNING : Special F
Repair Requirement" (TYPE 2).
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed
Position Learning” when electric throttle control actuator is
replaced. Refer to EC-662, "IDLE AIR VOLUME LEARNING : Spe- G
cial Repair Requirement" (TYPE 1) or EC-1078, "IDLE AIR VOL-
JPBIA1631ZZ
UME LEARNING : Special Repair Requirement" (TYPE 2).
H

INTAKE MANIFOLD
INTAKE MANIFOLD
JPBIA1629GB
1. Intake manifold 2. Gasket

A. Refer to EM-156
REMOVAL
3. Remove fuel tube and fuel injector assembly. Refer to EM-169, "Exploded View".
4. Loosen mounting nuts and bolts in reverse order as shown in
the figure to remove intake manifold with power tool.
: Engine front
JPBIA1630ZZ
5. Remove gaskets.
CAUTION:
INSTALLATION
Note the following, and install in the reverse order or removal.
Intake Manifold
• If stud bolts were removed, install them and tighten to the specified torque below.
: 10.8 N·m (1.1 kg-m, 8 ft-lb)

INTAKE MANIFOLD
• Tighten all mounting nuts and bolts to the specified torque in two or
more steps in numerical order shown in the figure. A
: Engine front
- VQ25DE EM
1st step : 7.4 N·m (0.75 kg-m, 5 ft-lb)

: 29.0 N·m (3.0 kg-m, 21 ft-lb) C
2nd step and after
- VQ35DE JPBIA1630ZZ
D
2nd step and after : 25.5 N·m (2.6 kg-m, 19 ft-lb)
E
INSPECTION AFTER REMOVAL F

Surface Distortion
• Check the surface distortion of the intake manifold mating surface
with a straightedge (A) and a feeler gauge (B). G
Limit : Refer to EM-261, "Intake Manifold".

• If it exceeds the limit, replace intake manifold. H
JPBIA0015ZZ
J

EXHAUST MANIFOLD AND THREE WAY CATALYST
JPBIA2710GB
1. Gasket 2. Exhaust manifold (bank 1) 3. Exhaust manifold cover (bank 1)

4. Air fuel ratio sensor 1 (bank 1) 5. Ring gasket 6. Three way catalyst (bank 1)
7. Three way catalyst support (bank 1) 8. Heated oxygen sensor 2 (bank 1) 9. Three way catalyst (bank 2)
10. Three way catalyst support (bank 2) 11. Heated oxygen sensor 2 (bank 2) 12. Ring gasket
13. Exhaust manifold (bank 2) 14. Exhaust manifold cover (bank 2) 15. Air fuel ratio sensor 1 (bank 2)
Stud bolt and flange bolt type
A. To oil pan (upper) B. Upper mark C.
(bank 2)
D. Flange bolt type (bank 2)
REMOVAL
WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
1. Remove following parts:

• Air duct (inlet), air cleaner case (upper) with mass air flow sensor, and air duct assembly: Refer to EM-
150, "Exploded View". A
• Front wiper arm: Refer to WW-112, "Exploded View".
• Extension cowl top: Refer to EXT-22, "Exploded View".
EM
3. Disconnect harness connector and remove air fuel ratio sensor
1 on both banks with the heated oxygen sensor wrench [SST:
C
KV10117100] (B).
• Put marks to identify installation positions of each air fuel ratio
sensor 1.
CAUTION: D
• Be careful not to damage air fuel ratio sensor 1.
• Discard any air fuel ratio sensor 1 which has been
dropped onto a hard surface such as a concrete floor. E
Replace with a new sensor.
NOTE:
JPBIA1781ZZ
Figure is shown as an example of bank 2 (A).
F
4. Disconnect harness connector and remove heated oxygen sen-
sor 2 on both banks with the heated oxygen sensor wrench
[SST: KV10114400] (B). G
A : Bank 1
C : Bank 2 H
• Put marks to identify installation positions of each heated oxy-
gen sensor 2.
CAUTION: I
• Be careful not to damage heated oxygen sensor 2.
• Discard any heated oxygen sensor 2 which has been JPBIA2247ZZ
dropped onto a hard surface such as a concrete floor.

Replace with a new sensor. J
5. Remove exhaust manifold covers (bank 1 and bank 2).

6. Remove three way catalyst support mounting bolts (bank 1 and bank 2). K
7. Remove three way catalysts (bank 1 and bank 2) by loosening bolts first and then removing nuts. (Stud
bolt and flange bolt type)
CAUTION: L
Handle carefully to avoid any shock to three way catalyst.

8. Loosen mounting nuts in reverse order as shown in the figure to
remove exhaust manifolds (bank 1 and bank 2).
A : Bank 1
B : Bank 2
: Engine front
NOTE:
Disregard No. 7 and 8 when loosing.
JPBIA1633ZZ
9. Remove gaskets.
CAUTION:
INSTALLATION
Exhaust Manifold Gasket
Install in the direction indicated in the figure.
A : Bank 1
B : Triangle press
C : Bank 2
: Engine front
PBIC4954E
Exhaust Manifold
• If stud bolts were removed, install them and tighten to the torque specified below.
: 15.4 N·m (1.6 kg-m, 11 ft-lb)

• Tighten mounting nuts in numerical order as shown in the figure.
A
A : Bank 1
B : Bank 2
: Engine front EM
NOTE:
No. 7 and 8 mean double tightening of nuts No. 1 and 2.
C
G
JPBIA1633ZZ
Three Way Catalyst (bank 2) Flange bolt Type H

1. Temporarily tighten upper side bolts (B) and lower side bolt (A)
I
: Engine front
2. Tighten the upper side bolts (B) shown in the figure. (specified
torque) J
3. Tighten all the lower side bolts [the other four except (B)]. (spec-
ified torque)
K
JPBIA2709ZZ
Three Way Catalyst Supports

L
1. Temporarily tighten three way catalyst support mounting bolts.
2. Tighten three way catalyst support mounting bolts to oil pan (upper). (specified torque)
3. Tighten three way catalyst support mounting bolts to three way catalyst. (specified torque)
M
Air Fuel Ratio Sensor 1 and Heated Oxygen Sensor 2
• Install air fuel ratio sensor 1 and heated oxygen sensor 2 in the original position.
• Install referring the following if the installation positions cannot be N
identified.
Glass tube color

O
Air fuel ratio sensor 1 : Gray
Heated oxygen sensor 2 : White
CAUTION: P
• Before installing a new air fuel ratio sensor 1 and a new
heated oxygen sensor 2, clean exhaust system threads using
oxygen sensor thread cleaner (commercial service tool) and PBIC2652E
apply anti-seize lubricant (commercial service tool).
• Never over torque air fuel ratio sensor 1 and heated oxygen sensor 2. Doing so may cause damage
to air fuel ratio sensor and heated oxygen sensor, resulting in “MIL” coming on.


Surface Distortion
• Check the surface distortion of the exhaust manifold mating sur-
face with a straightedge and a feeler gauge.
Limit : Refer to EM-261, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.
PBIC1173E

OIL PAN AND OIL STRAINER
A
EM
J
JPBIA1636GB
1. Oil pan (upper) 2. O-ring 3. Oil pan gasket (front) K

4. Relief valve 5. Oil pressure switch 6. Oil cooler
7. Connector bolt 8. Oil filter 9. Oil strainer
10. Drain plug 11. Drain plug washer 12. Oil pan (lower) L
13. Rear plate cover 14. Crankshaft position sensor (POS) 15. Oil pan gasket (rear)
A. Refer to LU-18 B. To oil pump C. Oil pan side
N
REMOVAL
CAUTION:
To avoid the danger of being scalded, never drain engine oil when the engine is hot. O
NOTE:
When removing oil pan (lower) or oil strainer only, take step 1 then step 18 and 19.
P
CAUTION:
Never spill engine oil on drive belt.
2. Drain engine coolant. Refer to CO-32, "Draining".
CAUTION:
Never spill engine coolant on drive belt.
3. Remove following parts:
• Front road wheel and tires (RH and LH)

• Front splash guard (RH and LH): Refer to EXT-24, "FENDER PROTECTOR : Exploded View".
• Exhaust front tube: Refer to EX-11, "Exploded View".
• Drive belt: Refer to EM-136, "Removal and Installation".
4. Remove A/C compressor with piping connected, and temporarily secure it to aside. Refer to HA-103,
"Exploded View".
5. Remove oil level gauge. Refer to EM-221, "Exploded View".
6. Remove front drive shaft (RH). Refer to FAX-17, "Exploded View".
7. Remove three way catalyst (bank 1 and bank 2) from exhaust manifolds (bank 1 and bank 2). Refer to
8. Remove oil pressure switch.
9. Remove oil filter. Refer to LU-18, "Removal and Installation".
10. Remove oil cooler and water pipes. Refer to LU-19, "Exploded View".
11. Support transaxle assembly with a suitable jack.
CAUTION:
When setting the transmission jack, be careful not to allow it to collide against the drain plug.
12. Support front suspension member with a suitable jack.
13. Remove engine mounting insulator (rear). Refer to EM-192, "Exploded View".
14. Remove engine mounting insulator (LH) mounting bolts from transaxle. Refer to EM-192, "Exploded
View".
15. Remove rear torque rod through bolts from rear torque rod bracket. Refer to EM-192, "Exploded View".
16. Remove member stay, front suspension member fixing bolts and nuts. Refer to FSU-17, "Exploded View".
17. Lower the jack for the front suspension member to the height.
18. Remove oil pan (lower) as follows:
a. Loosen mounting bolts in reverse order as shown in the figure to
remove.
PBIC0782E
b. Insert the seal cutter [SST: KV10111100] (A) between oil pan
(upper) and oil pan (lower).
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert a screwdriver, this will damage the mating
surfaces.
c. Slide the seal cutter by tapping on the side of tool with a ham-
mer. Remove oil pan (lower).
JPBIA0276ZZ
19. Remove oil strainer.

20. Loosen mounting bolts in the reverse order as shown in the fig-
ure to remove. A
• Insert the seal cutter [SST: KV10111100] between oil pan
(upper) and cylinder block. Slide seal cutter by tapping on the
side of tool with a hammer. Remove oil pan (upper).
EM
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert a screwdriver, this will damage the mating
surfaces. C
PBIC1636E
D
21. Remove O-rings (2) from bottom of cylinder block (1) and oil
pump (3).
E
: Engine front
G
JPBIA1379ZZ
22. Remove oil pan gaskets (1).

H
A : Notch
B : Protrusion
I
: Engine front
JPBIA0433ZZ
K
INSTALLATION
1. Install oil pan (upper) as follows:
a. Use a scraper to remove old liquid gasket from mating surfaces. L
CAUTION:
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket. M
• Also remove old liquid gasket from mating surface of cylinder
block.
N
MEM108A
O
b. Install new oil pan gaskets.

P

• Apply liquid gasket to new oil pan gaskets as shown in the fig-
ure.
C : Sealing point
a : 15 mm (0.59 in)
b : 5 mm (0.20 in)
JPBIA0432ZZ
• To install, align protrusion (B) of oil pan gasket with notches

(A) of front timing chain case and rear oil seal retainer.
: Engine front
• Install oil pan gasket (1) with smaller arc to front timing chain
case side.
JPBIA0433ZZ
c. Install new O-rings (2) on the bottom of cylinder block (1) and oil
pump (3).
: Engine front
JPBIA1379ZZ
d. Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to the cylinder block mating surface of
oil pan (upper) to a limited portion as shown in the figure.
b : 35 mm (1.38 in)
c : φ3.5 - 4.5 mm (0.138 - 0.177 in)
: Engine front

CAUTION:
• For bolt holes with marks (5 locations), apply liquid JPBIA0434ZZ
gasket outside the holes.
• Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) diameter to area (a).
• Attaching should be done within 5 minutes after coating.
e. Install oil pan (upper).
CAUTION:
Install avoiding misalignment of both O-rings.

ure. A
• There are three types of mounting bolts. Refer to the following
for locating bolts.
EM
M8 × 135 mm (5.31 in) : 11
M8 × 92 mm (3.62 in) : 5, 7, 8
M8 × 25 mm (0.98 in) : Except the above C
PBIC1636E
D
2. Install oil strainer to oil pump.
3. Install oil pan (lower) as follows:
a. Use scraper (A) to remove old liquid gasket from mating sur- E
faces.
• Remove old liquid gasket from the bolt holes and thread.
CAUTION:
Never scratch or damage the mating surfaces when clean- F
ing off old liquid gasket.
JPBIA0025ZZ H
b. Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) (A) to the oil pan (lower) as shown in
the figure. I
b : φ4.0 - 5.0 mm (0.157 - 0.197 in)

J
CAUTION:
Attaching should be done within 5 minutes after coating.
K
JPBIA0026ZZ
c. Install oil pan (lower). L

ure.
4. Install oil pan drain plug. M
• Refer to the figure of components of former page for installa-
tion direction of drain plug washer. Refer to EM-163,
"Exploded View". N
5. Install in the reverse order of removal after this step.
NOTE:
At least 30 minutes after oil pan is installed, pour engine oil.
O
PBIC0782E
P

Clean oil strainer if any object attached.
1. Check the engine oil level and adjust engine oil. Refer to LU-15, "Inspection".
2. Start engine, and check there is no leakage of engine oil.

3. Stop engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-15, "Inspection".

A
EM
J
JPBIA1714GB
1. Fuel feed hose 2. Quick connector cap 3. Fuel tube K

4. O-ring 5. Fuel damper 6. Fuel damper cap
7. Clip 8. O-ring (black) 9. Fuel injector
10. O-ring (green) L
A. Refer to EM-169
M
CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
Removal and Installation INFOID:0000000003802357 N
REMOVAL
WARNING: O
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area. P
• To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor, and air duct
assembly. Refer to EM-150, "Exploded View".
3. Release the fuel pressure. Refer to EC-1064, "Inspection" (TYPE 1) or EC-1426, "Inspection" (TYPE 2).
4. Remove front wiper arm and extension cowl top. Refer to WW-112, "Exploded View" and EXT-22,
"Exploded View".

5. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-32, "Draining" or EM-152, "Exploded View".
CAUTION:
7. When separating fuel feed hose and fuel tube connection, disconnect quick connector as follows:
a. Remove quick connector cap from quick connector.
b. Disconnect quick connector from fuel tube as follows:
CAUTION:
Disconnect quick connector by using the quick connector release (commercial service tool), not
by picking out retainer tabs.
i. With the sleeve side of quick connector release facing to quick connector, install the quick connector
release onto fuel tube.
ii. Insert the quick connector release (A) into quick connector (2)
until sleeve (B) contacts and goes no further. Hold quick connec-
tor release on that position.
D : Insert and retain

CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
iii. Draw and pull out quick connector straight from fuel tube (1).
CAUTION: JPBIA2255ZZ
• Pull quick connector (E) holding position (C) as shown in

the figure.
• Never pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leakage out.
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed hose during installation/
removal.
• To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags, etc. or something similar.
PBIC2205E
8. Disconnect harness connector from fuel injector.

9. Loosen mounting bolts in reverse order as shown in the figure,
and remove fuel tube and fuel injector assembly. A
: Engine front
CAUTION: EM
Never tilt fuel tube, or remaining fuel in pipes may flow out
from pipes.
C
JPBIA1715ZZ
D
10. Remove fuel injector from fuel tube as follows:
a. Open and remove clip (1).
E
3 : O-ring (green)
4 : O-ring (black)
A : Installed condition F
B : Clip mounting groove
b. Remove fuel injector (2) from fuel tube (5) by pulling straight.
CAUTION: G
• Be careful with remaining fuel that may go out from fuel
tube. JPBIA1958ZZ
• Be careful not to damage injector nozzle during removal. H
• Never bump or drop fuel injector.
• Never disassemble fuel injector.
11. Remove fuel damper from fuel tube.
I
INSTALLATION
1. Install fuel damper as follows:
a. Install new O-ring (2) to fuel tube (1) as shown in the figure. J
When handling new O-ring, be careful of the following caution:
CAUTION:
• Handle O-ring with bare hands. Never wear gloves. K
• Check that O-ring and its mating part are free of foreign
material. L
• When installing O-ring, be careful not to scratch it with
tool or fingernails. Also be careful not to twist or stretch
O-ring. If O-ring was stretched while it was being M
attached, never insert it quickly into fuel tube.
• Insert new O-ring straight into fuel tube. Never twist it.
b. Install spacer (3) to fuel damper (4). N
c. Insert fuel damper straight into fuel tube.
CAUTION:
• Insert straight, checking that the axis is lined up.
O
• Never pressure-fit with excessive force.
Reference value : 130 N (13.3 kg, 29.2 lb)

P
• Insert fuel damper until (B) is touching (A) of fuel tube.
d. Tighten bolts evenly in turn. JPBIA0316ZZ
• After tightening bolts, check that there is no gap between fuel

damper cap (5) and fuel tube.
2. Install new O-rings to fuel injector paying attention to the following.
CAUTION:
• Upper and lower O-ring are different. Be careful not to confuse them.

Fuel tube side : Black

Nozzle side : Green
• Handle O-ring with bare hands. Never wear gloves.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert O-ring straight into fuel injector. Never decenter or twist it.
3. Install fuel injector to fuel tube as follows:
a. Insert clip (3) into clip mounting groove (F) on fuel injector (5).
2 : O-ring (black)
4 : O-ring (green)
• Insert clip so that protrusion (E) of fuel injector matches cutout
(C) of clip.
CAUTION:
• Never reuse clip. Replace it with new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (A) of fuel tube matches
cutout (B) of clip.
• Check that fuel tube flange (G) is securely fixed in flange fixing
groove (D) on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
• Check that protrusions of fuel injectors and fuel tubes are
aligned with cutouts of clips after installation.
JPBIA1959ZZ
4. Install fuel tube and fuel injector assembly to intake manifold.

CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.
• Tighten mounting bolts in two steps in numerical order as
: Engine front

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

6. Install intake manifold collector. Refer to EM-152, "Exploded View".
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:
a. Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage
on them.
b. Thinly apply new engine oil around fuel tube from tip end to spool end.
c. Align center to insert quick connector straightly into fuel tube.

• Insert quick connector (1) to fuel tube until top spool (2) is
completely inside quick connector, and 2nd level spool (3) A
exposes right below quick connector.
B : Fitted condition
EM
: Upright insertion
CAUTION:
• Hold (A) position as shown in the figure when inserting C
fuel tube into quick connector.
• Carefully align center to avoid inclined insertion to pre-
JPBIA0275ZZ
vent damage to O-ring inside quick connector.
D
• Insert until you hear a “click” sound and actually feel the engagement.
• To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
d. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does
not come out from fuel tube. E
e. Install quick connector cap (3) to quick connector.
1 : Fuel feed hose F

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

J
Check on Fuel Leakage K
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leakage at connection points.
NOTE: L
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leakage at connection
points.
M
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.

JPBIA1637GB
1. Ignition coil 2. Spark plug 3. PCV hose

4. Clamp 5. PCV valve 6. O-ring
7. Rocker cover (bank 1) 8. PCV hose 9. Rocker cover gasket (bank 1)
10. O-ring 11. 12. Oil filler cap
(bank 1)
13. Rocker cover (bank 2) 14. Rocker cover gasket (bank 2) 15.
(bank 2)
16. PCV hose 17. Clamp
A. To intake manifold collector B. Refer to EM-174 C. Camshaft bracket side
D. To air duct assembly
REMOVAL
• Air cleaner cases (upper and lower) and air duct assembly: Refer to EM-150, "Exploded View".
• Intake manifold collector: Refer to EM-152, "Exploded View".
2. Disconnect PCV hose from rocker cover.

3. Remove camshaft position sensor (PHASE) (bank 1 and bank
2). A
A : Keep off any magnetic materials

CAUTION: EM
• Handle carefully to avoid dropping and shocks.
• Never disassemble
• Never allow metal powder to adhere to magnetic part at
C
sensor tip.
• Never place sensors in a location where they are exposed
to magnetism. JPBIA0454ZZ
4. Remove PCV valve and O-ring from rocker cover, if necessary. D

5. Remove oil filler cap from rocker cover, if necessary.
6. Remove ignition coil.
CAUTION: E
Never shock ignition coil.
7. Remove harness clips on the rocker cover.
8. Loosen bolts in reverse order shown in the figure. F
: Engine front
G
JPBIA1634ZZ
M
9. Remove rocker cover gasket from rocker cover.
10. Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket (No. 1).
CAUTION:
Never scratch or damage the mating surface when cleaning off old liquid gasket. N
INSTALLATION
O

1. Apply liquid gasket to the position shown in the figure with the
following procedure:
A : Liquid gasket application point

F : View F
I : End surface of camshaft bracket (No. 1)
b : 4 mm (0.16 in)
c : φ2.5 - 3.5 mm (0.098 - 0.138 in)
d : 5 mm (0.20 in)
g : 10 mm (0.39 in)
: Engine front

a. Refer to figure (E) to apply liquid gasket to joint part of camshaft
bracket (No. 1) (1) and cylinder head.
b. Refer to figure (H) to apply liquid gasket in 90 degrees to figure.
JPBIA0274ZZ
2. Install rocker cover gasket to rocker cover.

3. Install rocker cover.
• Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
4. Tighten bolts in two steps separately in numerical order as
: Engine front
1st step : 1.96 N·m (0.2 kg-m, 17 in-lb)

2nd step : 8.33 N·m (0.85 kg-m, 74 in-lb)
JPBIA1634ZZ

TIMING CHAIN
TIMING CHAIN
A
EM
JPBIA2868GB
P
Timing chain tensioner (secondary) Timing chain tensioner (secondary)
1. 2. Internal chain guide 3.
(bank 2) (bank 1)
4. Oil temperature sensor 5. Camshaft sprocket (EXH) 6. O-ring
7. Timing chain (secondary) 8. Timing chain (primary) 9. Camshaft sprocket (INT)
10. Slack guide 11. Timing chain tensioner (primary) 12. Crankshaft sprocket
13. Rear timing chain case 14. Tension guide 15. O-ring
16. O-ring 17. O-ring 18. Front timing chain case

TIMING CHAIN
Valve timing control cover gasket Intake valve timing control solenoid valve
19. 20. Valve timing control cover (bank 1) 21.
(bank 1) (bank 1)
22. Seal ring 23. Water pump cover 24. Front oil seal
Intake valve timing control solenoid valve
25. Crankshaft pulley 26. Crankshaft pulley bolt 27.
(bank 2)
Valve timing control cover gasket
28. Valve timing control cover (bank 2) 29.
(bank 2)
A. Refer to EM-205 B. Refer to EM-178 C. Oil filter
REMOVAL
2. Drain engine coolant from inside engine. Refer to EM-201, "Setting".
4. Remove rocker covers (bank 1 and bank 2). Refer to EM-174, "Exploded View".
5. Remove oil pans (lower and upper) and oil strainer. Refer to EM-163, "Exploded View".
6. Remove drive belt, idler pulleys, and bracket. Refer to EM-136, "Removal and Installation" and EM-149,
"Exploded View".
7. Remove power steering oil pump with piping connected, and temporarily secure it to aside. Refer to ST-
30, "Exploded View".
8. Separate engine harness removing their brackets from front timing chain case.
9. Remove valve timing control covers.
• Loosen mounting bolts in reverse order as shown in the figure.
A : Bank 1
B : Bank 2
C : Dowel pin hole
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.
JPBIA1639ZZ
10. Obtain No. 1 cylinder at TDC of its compression stroke as follows:

a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) ( ) with timing indicator.
SEM727G

TIMING CHAIN
b. Check that intake and exhaust cam noses on No. 1 cylinder
(engine front side of bank 1) are located as shown in the figure. A
: Engine front
• If not, turn crankshaft one revolution (360 degrees) and align EM

JPBIA0044ZZ
D
11. Remove crankshaft pulley as follows:
a. Fix crankshaft with the pulley holder (commercial service tool)
(A). E
b. Loosen crankshaft pulley bolt and locate bolt seating surface at F
10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt as it will be used as a
G
supporting point for suitable puller.
PBIC3961E
H
c. Place suitable puller tab on holes of crankshaft pulley, and pull
crankshaft pulley through.
CAUTION:
Never put suitable puller tab on crankshaft pulley periphery, I
as this will damage internal damper.
K
SEM915E
12. Remove front timing chain case as follows:

L
O
JPBIA1640ZZ

TIMING CHAIN
b. Insert a suitable tool (A) into the notch at the top of front timing
chain case as shown in the figure.
c. Pry off case by moving the tool as shown in the figure.
• Use the seal cutter [SST: KV10111100] to cut liquid gasket for
removal.
CAUTION:
• Never use screwdriver or something similar.
• After removal, handle front timing chain case carefully so
it does not tilt, cant, or warp under a load.
JPBIA0048ZZ
13. Remove water pump cover from front timing chain case.
• Use the seal cutter [SST: KV10111100] to cut liquid gasket for removal.
14. Remove front oil seal from front timing chain case using a suit-
able tool.
• Use a screwdriver for removal.
CAUTION:
Be careful not to damage front timing chain case.
EMQ0032D
15. Remove O-ring (1) from rear timing chain case.
A : Bank 1
B : Bank 2
JPBIA1111ZZ
16. Remove timing chain tensioner (primary) as follows:

a. Remove lower mounting bolt (A).
b. Loosen upper mounting bolt (B) slowly, and then turn timing
chain tensioner (primary) (1) on the upper mounting bolt so that
plunger (C) is fully expanded.
NOTE:
Even if plunger is fully expanded, it is not dropped from the body
of timing chain tensioner (primary).
c. Remove upper mounting bolt, and then remove timing chain ten-
sioner (primary).
JPBIA1537ZZ

TIMING CHAIN
17. Remove internal chain guide (1), tension guide (3), and slack
guide (2). A
NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
EM
G
JPBIA1104ZZ
18. Remove timing chain (primary) and crankshaft sprocket.

CAUTION: H
After removing timing chain (primary), never turn crankshaft and camshaft separately, or valves
will strike the piston heads.
19. Remove timing chain (secondary) and camshaft sprockets as follows: I
a. Attach a suitable stopper pin (B) to the bank 1 (A) and bank 2
(C) timing chain tensioners (secondary) (1).
NOTE: J
• Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
• For removal of timing chain tensioner (secondary), refer to
EM-209, "Exploded View". [Removing camshaft bracket (No. K
1) is required.]
L
JPBIA1727ZZ
b. Remove camshaft sprockets (INT and EXH) mounting bolts. M

• Secure the hexagonal portion of camshaft using a wrench to
loosen mounting bolts.
CAUTION:
Never loosen mounting bolts with securing anything N
other than the camshaft hexagonal portion or with ten-
sioning the timing chain.
O
P
KBIA1698J
c. Remove timing chain (secondary) together with camshaft sprockets.

• Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.

TIMING CHAIN
• Insert 0.5 mm (0.020 in) thick metal or resin plate between tim-
ing chain (secondary) (2) and timing chain tensioner plunger
(guide) (E). Remove timing chain (secondary) together with
camshaft sprockets with timing chain loose from guide groove.
1 : Timing chain tensioner (secondary)

A : Bank 1
B : View B
C : Stopper pin
D : Plate
JPBIA2527ZZ
F : Timing chain tensioner (body)
CAUTION:
Be careful of plunger coming-off when removing timing chain (secondary). This is because
plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of
fixed stopper pin.
NOTE:
• Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing
chain (secondary).
• Figure is shown as an example of bank 1.
• When handling camshaft sprocket (INT), be careful of the following caution:
CAUTION:
• Handle carefully to avoid any shock to camshaft sprocket.
• Never disassemble. [Never loosen bolts (A) as shown in
the figure].
PBIC2980E
20. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
• Remove timing chain tensioners (secondary) with a stopper pin attached.
21. Use a scraper to remove all traces of old liquid gasket from front
timing chain case, and opposite mating surfaces.
SEM737G

TIMING CHAIN
• Remove old liquid gasket from bolt hole (B) and thread.
A
A : Remove sticking old liquid gasket
EM
JPBIA0051ZZ
D
22. Use a scraper to remove all traces of old liquid gasket from
water pump cover.
E
G
SEM926E
INSTALLATION
NOTE: H
The below figure shows the relationship between the matching mark on each timing chain and that on the cor-
responding sprocket, with the components installed.
I
P
JPBIA1716GB
1. Internal chain guide 2. Camshaft sprocket (INT) 3. Timing chain (secondary)

4. Camshaft sprocket (EXH) 5. Timing chain tensioner (primary) 6. Slack guide
7. Timing chain (primary) 8. Crankshaft sprocket 9. Water pump
10. Tension guide 11. Timing chain tensioner (secondary) 12. Crankshaft key

TIMING CHAIN
A. Matching mark (punched) B. Matching mark (pink link) C. Matching mark (punched)
D. Matching mark (orange) E. Matching mark (notched)
1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to EM-209,
"Exploded View".
• Install timing chain tensioners (secondary) with a stopper pin attached and new O-ring.
2. Check that dowel pin (A) and crankshaft key (1) are located as
shown in the figure. (No. 1 cylinder at compression TDC)
NOTE:
Though camshaft does not stop at the position as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure.
Camshaft dowel pin

: At cylinder head upper face side in each bank
Crankshaft key
JPBIA0094ZZ
: At cylinder head side of bank 1
CAUTION:
Hole on small dia. side must be used for intake side dowel pin hole. Never misidentify (ignore big
dia. side).
3. Install timing chain (secondary) and camshaft sprockets (INT and EXH) as follows:
CAUTION:
Matching marks between timing chain and sprockets slip easily. Confirm all matching mark posi-
tions repeatedly during the installation process.
a. Push plunger of timing chain tensioner (secondary) and keep it
pressed in with stopper pin (A).
JPBIA0095ZZ

TIMING CHAIN
b. Install timing chain (secondary) (1) and camshaft sprockets (INT
and EXH). A
A : Camshaft sprocket (INT) back face

B : Orange link EM
C : Matching mark (Circle)
D : Camshaft sprocket (EXH) back face
E : Matching mark (2 circle on front face) C
F : Dowel pin groove
G : Matching mark (2 ovals on front face)
H : Matching mark (Oval) D
I : Dowel pin hole
NOTE:
Figure shows bank 1 (rear view). E
• Align the matching marks on timing chain (secondary) (orange
link) with the ones on camshaft sprockets (INT and EXH)
(punched), and install them.
F
NOTE:
• Matching marks for camshaft sprocket (INT) are on the back
side of camshaft sprocket (secondary).
• There are two types of matching mark, circle and oval types. G
They should be used for the bank 1 and bank 2, respectively. JPBIA1726ZZ
Bank 1 : Use circle type. H

Bank 2 : Use oval type.
• Align dowel pin on camshafts with the groove on sprockets, and install them.
• On the intake side, align dowel pin of the camshaft front end with dowel pin hole on the back side of I
camshaft sprocket, and install them.
• On the exhaust side, align dowel pin on camshaft front end with dowel pin groove on camshaft sprocket,
and install them. J
• In case that positions of each matching mark and each dowel pin are not fit on mating parts, make fine
adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent.
• Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is
enough to prevent the dislocation of dowel pins. K
• It may be difficult to visually check the dislocation of matching
marks during and after installation. To make the matching eas-
ier, make a matching mark (A) on the top of sprocket teeth and L
its extended line in advance with paint.
B : Matching mark (orange link)

M
N
JPBIA2260ZZ
c. After confirming the matching marks are aligned, tighten camshaft sprocket mounting bolts.
O
• Secure camshaft using wrench at the hexagonal portion to
tighten mounting bolts.
KBIA1698J

TIMING CHAIN
d. Pull stopper pins (B) out from timing chain tensioners (second-
ary) (1).
A : Bank 1
C : Bank 2
JPBIA1727ZZ
4. Install tension guide.

5. Install timing chain (primary) as follows:
a. Install crankshaft sprocket (1).
A : Crankshaft side
B : Engine front side
C : Matching mark (Front side)
• Check the matching marks on crankshaft sprocket face the
front of the engine.
JPBIA0273ZZ
b. Install timing chain (primary).

• Install timing chain (primary) so the matching mark (punched)
(B) on camshaft sprocket (INT) (1) is aligned with the pink link
(A) on timing chain, while the matching mark (notched) (C) on
crankshaft sprocket (2) is aligned with the orange link (D) on
timing chain, as shown in the figure.
3 : Water pump
• When it is difficult to align matching marks of timing chain (pri-
mary) with each sprocket, gradually turn camshaft using
wrench on the hexagonal portion to align it with the matching
marks.
• During alignment, be careful to prevent dislocation of matching
mark alignments of timing chains (secondary).
JPBIA1601ZZ

TIMING CHAIN
6. Install internal chain guide (1) and slack guide (2).
A
3 : Tension guide
EM
G
JPBIA1104ZZ
CAUTION:
Never overtighten slack guide mounting bolt (2). It is nor- H
mal for a gap (A) to exist under the bolt seat when mounting
bolt is tightened to specification.
I
1 : Slack guide
3 : Cylinder block
J
K
JPBIA0117ZZ
7. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to L
remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
M
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet. N
d. To secure lever, insert stopper pin (E) through hole of lever into
tensioner body hole (B).
• The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition. JPBIA0118ZZ O
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
P

TIMING CHAIN
e. Install timing chain tensioner (primary) (1).
• Remove any dirt and foreign materials completely from the
back and the mounting surfaces of timing chain tensioner (pri-
mary).
f. Pull out stopper pin (A) after installing, and then release plunger.
JPBIA0119ZZ
8. Check again that the matching marks on each sprocket and each timing chain have not slipped out of
alignment.
9. Install new O-rings (1) on rear timing chain case.
A : Bank 1
B : Bank 2
JPBIA1111ZZ
10. Install new front oil seal on front timing chain case.
• Apply new engine oil to both oil seal lip and dust seal lip.
• Install it 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 a suitable drift [outer diameter: 60 mm (2.36 in)], press-

fit oil seal until it becomes flush with front timing chain case
end face.
• Check the garter spring is in position and seal lip is not
inverted.
PBIC0790E
11. Install water pump cover to front timing chain case.

TIMING CHAIN
• Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to water pump cover (1) as shown in A
the figure.
a : φ2.3 - 3.3 mm (0.091 - 0.130 in)

EM
JPBIA1722ZZ
D
12. Install front timing chain case as follows:
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to front timing chain case back side as E
D : Bolt hole
F
E : Protrusion
f : φ2.6 - 3.6 mm (0.102 - 0.142 in)
Use Genuine Liquid Gasket or equivalent. G
K
JPBIA2472ZZ
b. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
c. Tighten mounting bolts to the specified torque in numerical order L
• There are two types of mounting bolt. Refer to the following for
locating bolts. M
M8 bolts : 1, 2
: 28.4 N·m (2.9 kg-m, 21 ft-lb) N
M6 bolts : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb) O
JPBIA1640ZZ
d. After all bolts tightening, retighten them to the specified torque in
numerical order as shown in the figure.
CAUTION: P
Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper).

TIMING CHAIN
e. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan (upper)
mounting surface.
Standard
Front timing chain case to rear timing chain case:
−0.14 to 0.14 mm (−0.006 to 0.006 in)
• If not within the standard, repeat the installation procedure.
SEM943G
13. Install intake valve timing control covers as follows:

a. Install new seal rings in shaft grooves.
b. Being careful not to move seal rings from the installation grooves, align dowel pins on front timing chain
case with the holes to install valve timing control covers.
c. Tighten mounting bolts in numerical order as shown in the fig-
ure.
A : Bank 1
B : Bank 2
C : Dowel pin hole
JPBIA1639ZZ
14. Install crankshaft pulley as follows:

a. Install crankshaft pulley, taking care not to damage front oil seal.
• When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
b. Fix crankshaft with the pulley holder (commercial service tool).
c. Tighten crankshaft pulley bolt.
: 44.1 N·m (4.5 kg-m, 33 ft-lb)

d. Place a paint mark (A) on crankshaft pulley (1) aligning with the
angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90
degrees (angle tightening).
PBIC4627J
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.

Timing Chain

TIMING CHAIN
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain if necessary. A
A : Crack
B : Wear EM
JPBIA0091ZZ
D
E
The following are procedures for checking fluids leakage, lubricates leakage.
• Use procedure below to check for fuel leakage. F
- Start engine. With engine speed increased, check again for fuel leakage at connection points. G
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate an unusualness. Noise H
will stop after hydraulic pressure rises.
engine coolant. I
J
K
Fuel Leakage Leakage Leakage L

ENGINE ASSEMBLY
< REMOVAL AND INSTALLATION > [VQ25DE, VQ35DE]
REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
JPBIA2195GB
1. Upper torque rod 2. Engine mounting insulator (RH) 3. Engine mounting bracket (RH)
4. Engine mounting bracket (front) 5. Engine mounting insulator (front) 6. Vacuum hose
7. Vacuum tube (front) 8. Vacuum hose 9. Engine mounting insulator (LH)
10. Vacuum hose (VQ35DE) 11. Engine mounting insulator (rear) 12. Engine mounting bracket (rear)
13. Vacuum tube (rear) (VQ35DE) 14. Gusset 15. Rear torque rod
16. Rear torque rod bracket
To electronic controlled engine mount
A. To transaxle B. C. VQ25DE
: Vehicle front
WARNING:
• Situate the vehicle on a flat and solid surface.

ENGINE ASSEMBLY
• Place chocks at front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS A
CATALOG.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
EM
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid- C
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-35, "Garage Jack and D
Safety Stand and 2-Pole Lift".
REMOVAL
Outline E
At first, remove the engine and the transaxle assembly with front suspension member downward. Then sepa-
rate the engine and the transaxle.
Preparation F
2. Drain engine coolant. Refer to CO-32, "Draining".
G
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant on drive belt.
3. Remove the following parts: H
• Front road wheel and tires
• Front splash guards (RH and LH): Refer to EXT-24, "FENDER PROTECTOR : Exploded View". I
• Air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor, and air duct assembly:
Refer to EM-150, "Exploded View".
• Battery and battery tray: Refer to PG-144, "Exploded View".
J
• Reservoir tank of radiator: Refer to CO-36, "Exploded View".
• Front wiper arm: Refer to WW-112, "Exploded View".
4. Disconnect engine room harness at the TCM, ECM, and other sides. K
CAUTION:
To keep clean harness connector and avoid damage and foreign materials, cover them completely
with plastic bags or something similar. L
5. Remove battery bracket with ECM and TCM.
6. Remove extension cowl top. Refer to EXT-22, "Exploded View".
Engine Room M
1. Disconnect heater hoses. Refer to CO-48, "Exploded View".
• Install plug to avoid leakage of engine coolant.
N
2. Remove EVAP hose. Refer to EM-152, "Exploded View".
3. Disconnect fuel feed hose quick connector at fuel tube side. Refer to EM-169, "Exploded View".
• Install plug to avoid leakage of fuel.
O
4. Disconnect transaxle shift control cable at transaxle side. Refer to TM-340, "Exploded View" (VQ25DE) or
TM-162, "Exploded View" (VQ35DE).
5. Disconnect brake booster vacuum hose at engine side. Refer to EM-152, "Exploded View".
P
6. Disconnect ground cable.
7. Disconnect A/C compressor piping at A/C compressor side. Refer to HA-105, "Exploded View".
8. Disconnect suction hoses of power steering oil pump at reservoir tank side. Refer to ST-37, "Exploded
View".
9. Disconnect CVT fluid cooler hoses from radiator. Refer to CO-36, "Exploded View".

ENGINE ASSEMBLY
10. Remove starter motor. Refer to STR-22, "VQ25DE : Exploded View" (VQ25DE) or STR-27, "VQ35DE :
Exploded View" (VQ35DE).
Vehicle Underbody
1. Remove front drive shafts (RH and LH). Refer to FAX-17, "Exploded View".
3. Remove heat insulator.
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
Refer to ST-16, "Exploded View".
5. Disconnect front stabilizer connecting rod. Refer to FSU-15, "Exploded View".
6. Remove strut assembly and steering knuckle fixing nuts and bolts. Refer to FSU-9, "Exploded View" and
FAX-8, "Exploded View".
7. Remove front wheel sensor (RH and LH) for ABS from steering knuckle. Refer to BRC-59, "FRONT
WHEEL SENSOR : Exploded View".
8. Remove front brake caliper assembly with piping connected, and temporarily secure it to aside for vehicle
side. Refer to BR-34, "BRAKE CALIPER ASSEMBLY : Exploded View".
9. Disconnect power steering piping at a point between vehicle and engine. Refer to ST-37, "Exploded
View".
10. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter.
Refer to EM-163, "Exploded View" and TM-356, "Removal and Installation" (VQ25DE) or TM-173,
"Removal and Installation" (VQ35DE).
11. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-163, "Exploded
View".
12. Remove crankshaft position sensor (POS). Refer to EM-163, "Exploded View".
CAUTION:
• Handle carefully to avoid dropping and shocks.
• Never disassemble.
• Never allow metal powder to adhere to magnetic part at sensor tip.
• Never place sensors in a location where they are exposed to magnetism.
Removal
1. Use a manual lift table caddy (commercial service tool) or equiv-
alently rigid tool such as a transmission jack. Securely support
bottom of front suspension member.
CAUTION:
Put a piece of wood or something similar as the supporting
surface, secure a completely stable condition.
PBIC1190E
2. Remove engine mounting insulator (RH) and engine mounting bracket (RH).
3. Remove front suspension member mounting nuts and bolts. Refer to FSU-17, "Exploded View".
4. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly and front suspension
member. When performing work, observe the following caution:
CAUTION:
• Confirm there is no interference with the vehicle.
• Check all connection points have been disconnected.
• Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support the vehi-
cle at rear jacking point(s) to prevent it from falling it off the lift.
Separation

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

4 : Engine front slinger (upper) EM
5 : Engine front slinger (lower)
: Engine front
C
G
JPBIA1729ZZ
2. Remove power steering oil pump, power steering piping, and power steering bracket from engine and
transaxle assembly. Refer to ST-30, "Exploded View". H
3. Disconnect vacuum hoses of engine mounting insulator (front and rear).
4. Lift with hoist the engine and the transaxle assembly and front suspension member.
CAUTION: I
• Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove rear torque rod and rear torque rod bracket. J
6. Remove each engine mounting insulator and each engine mounting bracket from engine, transaxle, and
front suspension member.
7. Separate engine and transaxle assembly from front suspension member. K
CAUTION:
• Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
L
8. Separate engine and transaxle assembly. Refer to TM-356, "Exploded View" (VQ25DE) or TM-173,
"Exploded View" (VQ35DE).
INSTALLATION M
CAUTION:
• Never allow engine mounting insulator to be damage and careful no oil gets on it.
N
• Check all mounting insulators are seated properly, then tighten mounting nuts and bolts.
Preparation
1. Install the engine mounting bracket (RH) to the engine as follows: O

ENGINE ASSEMBLY
: Vehicle front

(specified torque)
JPBIA1730ZZ
2. Install the engine mounting bracket (front) to the engine as follows:

: Engine front

(specified torque)
JPBIA1731ZZ
3. Install the engine mounting bracket (rear) and gusset to the engine as follows:
: Engine front

(specified torque)
JPBIA1732ZZ
4. Install the rear torque rod bracket to the engine as follows:


ENGINE ASSEMBLY
• VQ25DE
A
: Engine front
EM
JPBIA2376ZZ
D
• VQ35DE
: Engine front E
G
JPBIA2377ZZ
b. Tighten the bolts in numerical order as shown in the figure. (specified torque)
H
5. Install the engine mounting insulator (LH) to the transaxle as follows:
• VQ25DE I
: Vehicle front
J
JPBIA2196ZZ
L
• VQ35DE
M
: Vehicle front
JPBIA1734ZZ
P
b. Tighten the bolts in numerical order as shown in the figure. (specified torque)
6. Install the engine mounting insulator (front) to the front suspension member as follows:

ENGINE ASSEMBLY
: Vehicle front

(specified torque)
JPBIA1735ZZ
7. Install the engine mounting insulator (rear) to the front suspension member as follows:
: Vehicle front

(specified torque)
JPBIA2373ZZ
8. Install the rear torque rod to the front suspension member as follows:
: Vehicle front

(specified torque)
JPBIA1738ZZ
9. Install the engine mounting brackets (front and rear) to the engine mounting insulators (front and rear).
10. Install the engine mounting insulator (LH) to the front suspension member.
• Tighten the bolts in numerical order as shown in the figure.
- VQ25DE
: Vehicle front
JPBIA2197ZZ

ENGINE ASSEMBLY
- VQ35DE
A
: Vehicle front
EM
JPBIA1739ZZ
D
11. Install the rear torque rod to the rear torque rod bracket.
12. Install the vacuum tube (front) as follows:
a. Tighten the bolt No. 3 as shown in the figure. (temporarily) E
: Engine front
b. Tighten the bolts in numerical order as shown in the figure. F

(specified torque)
JPBIA1740ZZ H
13. Install the vacuum tube (rear) as follows (VQ35DE):

a. Tighten the bolt No. 3 as shown in the figure. (temporarily) I
: Engine front
b. Tighten the bolts in numerical order as shown in the figure. J

(specified torque)
JPBIA1741ZZ
L
Installation
1. Install the engine mounting insulator (RH) as follows: M
: Vehicle front N
b. Tighten the bolts No. 2, 3 in numerical order as shown in the fig-
ure. (specified torque)
c. Tighten the bolt No. 1 as shown in the figure. (specified torque) O
d. Tighten the bolts No. 4, 5, 6 in numerical order as shown in the
figure. (specified torque)
P
JPBIA1742ZZ
2. Install the upper torque rod as follows:

ENGINE ASSEMBLY
: Vehicle front

(specified torque)
JPBIA1743ZZ


< DISASSEMBLY AND ASSEMBLY > [VQ25DE, VQ35DE]
DISASSEMBLY AND ASSEMBLY A

Setting INFOID:0000000003802370
EM
NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc. C
1. Remove the engine assembly from the vehicle. Refer to EM-192, "Exploded View".
2. Remove the parts that may restrict installation of engine to widely use engine stand.
NOTE: D
The procedure is described assuming that you use a widely use engine stand holding the surface, to
which transaxle is installed.
• Remove drive plate. Fix crankshaft pulley with the pulley holder (commercial service tool), and remove E
mounting bolts.
• Loosen mounting bolts in diagonal order.
• Check for deformation or damage drive plate.
CAUTION: F
• Never disassemble drive plate.
• When handling signal plate, take care not to damage or scratch it. G
• Handle signal plate in a manner that prevents it from becoming magnetized.
3. Remove pilot converter using the pilot bushing puller (SST) if

H
necessary.
PBIC1618E
K
4. Lift the engine with hoist to install it onto the widely use engine stand.
CAUTION:
L
Use an engine stand that has a load capacity [220 kg (485 lb) or more] large enough for supporting
the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the
potential risk of overturning the stand. M
- Remove intake manifold collector. Refer to EM-152, "Exploded View".
- Remove fuel injector and fuel tube assembly. Refer to EM-169, "Exploded View".
- Remove intake manifold. Refer to EM-156, "Exploded View".
N
- Remove ignition coil. Refer to EM-174, "Exploded View".
- Remove rocker cover. Refer to EM-174, "Exploded View".
- Remove exhaust manifold. Refer to EM-158, "Exploded View".
- Other removable brackets. O
NOTE:

The figure shows an example of widely use engine stand (A)
that can hold mating surface of transaxle with drive plate
removed.
CAUTION:
Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.
JPBIA0190ZZ

6. Drain engine coolant by removing water drain plugs (A) and (B)
from cylinder block both sides as shown in the figure.
C : Plug
D : Connector bolt
Tightening torque : Refer to EM-235, "Disassem-

bly and Assembly".
PBIC2487E

ENGINE UNIT
ENGINE UNIT
A
Disassembly INFOID:0000000003802371
1. Remove intake manifold collector. Refer to EM-152, "Exploded View". EM

2. Remove fuel injector and fuel tube. Refer to EM-169, "Exploded View".
3. Remove intake manifold. Refer to EM-156, "Exploded View".
4. Remove exhaust manifold. Refer to EM-158, "Exploded View". C
5. Remove oil pan (upper and lower). Refer to EM-163, "Exploded View".
6. Remove ignition coil, spark plug, and rocker cover. Refer to EM-174, "Exploded View".
D
7. Remove timing chain and rear timing chain case. Refer to EM-177, "Exploded View" and EM-204,
"Exploded View".
E
9. Remove cylinder head. Refer to EM-221, "Exploded View".
Assembly INFOID:0000000003802372
F
Assembly in the reverse order of disassembly.

REAR TIMING CHAIN CASE
JPBIA2868GB
Timing chain tensioner (secondary) Timing chain tensioner (secondary)

1. 2. Internal chain guide 3.
(bank 2) (bank 1)
4. Oil temperature sensor 5. Camshaft sprocket (EXH) 6. O-ring
7. Timing chain (secondary) 8. Timing chain (primary) 9. Camshaft sprocket (INT)
10. Slack guide 11. Timing chain tensioner (primary) 12. Crankshaft sprocket
13. Rear timing chain case 14. Tension guide 15. O-ring
16. O-ring 17. O-ring 18. Front timing chain case

Valve timing control cover gasket Intake valve timing control solenoid valve
19. 20. Valve timing control cover (bank 1) 21.
(bank 1) (bank 1) A
22. Seal ring 23. Water pump cover 24. Front oil seal
Intake valve timing control solenoid valve
25. Crankshaft pulley 26. Crankshaft pulley bolt 27.
(bank 2) EM
Valve timing control cover gasket
28. Valve timing control cover (bank 2) 29.
(bank 2)
A. Refer to EM-205 B. Refer to EM-178 C. Oil filter
C

D
DISASSEMBLY
1. Remove front timing chain case and timing chain. Refer to EM-177, "Exploded View".
E
2. Remove water pump. Refer to CO-41, "Exploded View".
3. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in reverse order as shown in F
the figure.
b. Cut liquid gasket using the seal cutter [SST: KV10111100] and
remove rear timing chain case. G
JPBIA1641ZZ I
CAUTION:
• Never remove plate metal cover (1) of oil passage. J
• After removal, handle rear timing chain case carefully so
it does not tilt, cant, or warp under a load.
K
JPBIA0088ZZ M
4. Remove O-rings (1) from cylinder block.

N
: Engine front
JPBIA0090ZZ
5. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-209, "Exploded View".

b. Remove timing chain tensioners (secondary) (1) with a stopper
pin (B) attached.
A : Bank 1
C : Bank 2
JPBIA1727ZZ
6. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and oppo-
site mating surfaces.
• Remove old liquid gasket from bolt hole (B) and thread.
A : Remove sticking old liquid gasket
JPBIA0051ZZ
ASSEMBLY
1. Install rear timing chain case as follows:
• Install new O-rings (1) onto cylinder block.
: Engine front
JPBIA0090ZZ
a. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as
CAUTION:
• For (A) in the figure, completely wipe out liquid gasket extended on a portion touching at engine
coolant.

• Apply liquid gasket on installation position of water pump and cylinder head very completely.
A
EM
I
PBIC2616E
b. Align rear timing chain case with dowel pins (bank 1 and bank 2) on cylinder block and install rear timing
chain case. J
• Check O-rings stay in place during installation to cylinder block and cylinder head.
c. Tighten mounting bolts in numerical order as shown in the fig-
ure.
• There are two types of mounting bolts. Refer to the following K
for locating bolts.
Bolt length: Bolt position L
20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) : Except the above M
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
JPBIA1641ZZ
d. After all bolts tightening, retighten them to the specified torque in

numerical order as shown in the figure. N
e. After installing rear timing chain case (1), check the surface O
height difference between the following parts on the oil pan
(upper) mounting surface.
P
2 : Cylinder block
Standard
Rear timing chain case to cylinder block:
−0.24 to 0.14 mm (−0.009 to 0.006 in)
• If not within the standard, repeat the installation procedure. JPBIA1944ZZ

2. Install water pump with new O-rings. Refer to CO-41, "Exploded View".
3. Install front timing chain case and timing chain. Refer to EM-177, "Exploded View".
4. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan (upper)
mounting surface.
Standard
Front timing chain case to rear timing chain case:
−0.14 to 0.14 mm (−0.006 to 0.006 in)
• If not within the standard, repeat the installation procedure.
SEM943G

CAMSHAFT
CAMSHAFT
A
EM
L
JPBIA1719GB
1. Camshaft bracket (No. 3, 4) 2. Camshaft bracket (No. 2) 3. Seal washer M

4. Camshaft bracket (No. 1) 5. Dowel pin 6. Camshaft (EXH) (bank 1)
Timing chain tensioner (secondary)
7. Camshaft (INT) (bank 1) 8. Valve lifter 9.
(bank 1)
N
Timing chain tensioner (secondary)
10. Spring 11. Plunger 12.
(bank 2)
13. Cylinder head (bank 2) 14. Dowel pin 15. Camshaft sensor bracket (bank 2)
16. Camshaft (EXH) (bank 2) 17. Camshaft signal plate (bank 2) 18. Camshaft (INT) (bank 2)
O
19. Cylinder head (bank 1) 20. Camshaft signal plate (bank 1) 21. Camshaft sensor bracket (bank 1)
A. Refer to EM-209
P
REMOVAL
1. Remove front timing chain case, camshaft sprocket, timing chain, and rear timing chain case. Refer to
EM-177, "Exploded View" and EM-204, "Exploded View".

CAMSHAFT
2. Loosen camshaft sensor bracket bolts in reverse order as
: Engine front
NOTE:
The order of loosening bolts in the same for bank 1 and bank 2.
JPBIA1960ZZ
3. Remove camshaft brackets.

• Mark camshafts, camshaft brackets, and bolts so they are placed in the same position and direction for
installation.
• Equally loosen camshaft bracket bolts in several steps in
reverse order as shown in the figure.
: Engine front
JPBIA0257ZZ
4. Remove camshafts.
5. Remove valve lifters.
6. Remove timing chain tensioners (secondary) (1) from cylinder
head.
A : Bank 1
B : Bank 2
• Remove timing chain tensioner (secondary) with its stopper
pin (C) attached.
NOTE:
Stopper pin should be attached when timing chain (secondary)
is removed.
JPBIA0121ZZ
INSTALLATION

CAMSHAFT
1. Install timing chain tensioners (secondary) (1) on both sides of
cylinder head. A
A : Bank 1
B : Bank 2 EM
• Install timing chain tensioner (secondary) with its stopper pin
(C) attached.
• Install timing chain tensioner (secondary) with sliding part fac- C
ing downward on cylinder head (bank 1), and with sliding part
facing upward on cylinder head (bank 2).
JPBIA0121ZZ
D
2. Install valve lifters.
3. Install camshafts. E
: Engine front
• Follow your identification marks made during removal, or fol- F

low the identification marks that are present on new camshafts
for proper placement and direction.
G
JPBIA1749ZZ H
VQ25DE
Paint marks
Bank INT/EXH Dowel pin (1) I
M1 (D) M2 (E) M3 (C)
EXH (B) Yes No Yellow Light blue
1
INT (A) Yes Yellow No Light blue J
INT (A) Yes Yellow No Light blue
2
EXH (B) Yes No Yellow Light blue
K
VQ35DE
Paint marks
Bank INT/EXH Dowel pin (1)
M1 (D) M2 (E) M3 (C) L
EXH (B) Yes No Light blue Light blue
1
INT (A) Yes Pink No Light blue
INT (A) Yes Pink No Light blue
M
2
EXH (B) Yes No Light blue Light blue
N
• Install camshaft so that dowel pin (A) on front end face are
positioned as shown in the figure. (No. 1 cylinder TDC on its
compression stroke)
NOTE: O
Though camshaft does not stop at the portion as shown in the
figure, for the placement of cam nose, it is generally accepted
camshaft is placed for the same direction of the figure. P
JPBIA2368ZZ
4. Install camshaft brackets.

CAMSHAFT
• Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face.
• Install camshaft bracket in original position and direction as
A : No. 1
B : No. 2
C : No. 3
D : No. 4
E : Bank 1
F : Exhaust side
G : Intake side
H : Bank 2
I : Intake side
J : Exhaust side
: Engine front
JPBIA0258ZZ
• Install camshaft brackets (No. 2 to 4) aligning the stamp marks

(A) as shown in the figure.
B : Bank 1
C : Bank 2
: Engine front
NOTE:
There are no identification marks indicating bank 1 and bank 2
for camshaft bracket (No. 1).
JPBIA0272ZZ
• Apply liquid gasket to mating surface of camshaft bracket (No.

1) as shown in the figure on bank 1 and bank 2.
a : 8.5 mm (0.335 in)

b : 2 mm (0.08 in)
c : Clearance 5 mm (0.20 in)
d : φ2.0 - 2.3 mm (0.079 - 0.091 in)
* : Apply liquid gasket to rear timing chain case side
JPBIA0255ZZ

CAMSHAFT
5. Tighten camshaft bracket bolts in the following steps, in numeri-
cal order as shown in the figure. A
: Engine front
a. Tighten No. 7 to 10 in order as shown. EM
: 1.96 N·m (0.20 kg-m, 1 ft-lb)

C
b. Tighten No. 1 to 6 in order as shown.
: 1.96 N·m (0.20 kg-m, 1 ft-lb) D

c. Tighten No. 1 to 10 in numerical order as shown.
: 5.88 N·m (0.60 kg-m, 4 ft-lb) E
d. Tighten No. 1 to 10 in numerical order as shown.

F
: 10.4 N·m (1.1 kg-m, 8 ft-lb)
CAUTION:
After tightening mounting bolts of camshaft brackets (No. G
1), be sure to wipe off excessive liquid gasket from the JPBIA0257ZZ
parts list below.

• Mating surface of rocker cover
• Mating surface of rear timing chain case H
6. Tighten camshaft sensor bracket bolts in numerical order as
I
: Engine front
NOTE:
J
The order of tightening bolts in the same for bank 1 and bank 2.
JPBIA1960ZZ
7. Measure difference in levels between front end faces of cam- L

shaft bracket (No. 1) and cylinder head.
Standard : −0.14 to 0.14 mm (−0.0055 to 0.0055 in) M

• Measure two positions (both intake and exhaust side) for a
single bank.
• If the measured value is out of the standard, reinstall camshaft N
bracket (No. 1).
EMQ0044D
O
8. Inspect and adjust the valve clearance. Refer to EM-141, "Inspection and Adjustment".
9. Install in the reverse order of removal after this step. P

Camshaft Runout

CAMSHAFT
CAUTION:
from the other three locations.
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on a dial indicator. (Total indicator reading)
Standard and limit : Refer to EM-261, "Camshaft".

4. If it exceeds the limit, replace camshaft.
PBIC0929E
Camshaft Cam Height

1. Measure the camshaft cam height with a micrometer.
Standard cam height : Refer to EM-261, "Cam-

(Intake and exhaust) shaft".
Cam wear limit : Refer to EM-261, "Cam-
shaft".
2. If wear exceeds the limit, replace camshaft.
EMQ0072D
Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL DIAMETER

• Measure the outer diameter of camshaft journal with a micrometer
(A).
JPBIA0122ZZ
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolt with the specified torque. Refer to EM-209, "Removal and Installation" for the
tightening procedure.
• Measure inner diameter (A) of camshaft bracket with a bore gauge.
PBIC1645E
CAMSHAFT JOURNAL OIL CLEARANCE

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

CAMSHAFT
Standard and limit : Refer to EM-261, "Camshaft". A

• If the calculated value exceeds the limit, replace either or both camshaft and cylinder head.
NOTE:
Camshaft brackets cannot be replaced as single parts, because there are machined together with cylinder EM
head. Replace whole cylinder head assembly.
Camshaft End Play
• Install a dial indicator in thrust direction on front end of camshaft. C
Measure the end play of a dial indicator when camshaft is moved
forward/backward (in direction to axis).
D
SEM864E F
• Measure the following parts if out of the limit.

- Dimension (A) for camshaft No. 1 journal G
Standard : 27.500 - 27.548 mm (1.0827 - 1.0846 in)

- Dimension (B) for cylinder head No. 1 journal bearing H
Standard : 27.360 - 27.385 mm (1.0772 - 1.0781 in)

• Refer to the standards above, and then replace camshaft and/or I
cylinder head.
KBIA2404J
Camshaft Sprocket Runout J

CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter K
from the other three locations.
2. Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading) L
Limit : Refer to EM-261, "Camshaft".

M
• If it exceeds the limit, replace camshaft sprocket.
PBIC0930E
O
Valve Lifter

CAMSHAFT
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-261,
"Camshaft".
KBIA0182E
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER

• Measure the outer diameter at 1/2 height of valve lifter with a
micrometer (A) since valve lifter is in barrel shape.
Standard
: Refer to EM-261, "Camshaft".
(Intake and exhaust)
JPBIA0125ZZ
VALVE LIFTER HOLE DIAMETER

• Measure the inner diameter of valve lifter hole of cylinder head with
an inside micrometer.
Standard
SEM867E
VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
Standard
• If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and
valve lifter hole diameter, replace either or both valve lifter and cylinder head.
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-782, "DTC Logic"
(TYPE 1) or EC-1189, "DTC Logic" (TYPE 2).
• Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-15, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release the fuel pressure. Refer to EC-1064, "Inspection" (TYPE 1) or EC-1426, "Inspection" (TYPE 2).

CAMSHAFT
b. Disconnect ignition coil and injector harness connectors. Refer to EM-174, "Exploded View" and EM-169,
"Exploded View". A
3. Remove intake valve timing control solenoid valve. Refer to EM-204, "Exploded View".
4. Crank engine, and then check that engine oil comes out from
intake valve timing control solenoid valve hole (A). End crank EM
after checking.
1 : Valve timing control cover (bank 2)

C
: Engine front
WARNING:
Be careful not to touch rotating parts. (drive belt, idler pul- D
ley, and crankshaft pulley, etc.)
CAUTION:
JPBIA1783ZZ
• Prevent splashing by using a shop cloth so as to prevent E
the worker from injury from engine oil and so as to prevent engine oil contamination.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful no to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed. F
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
• Remove oil filter, and then clean it. Refer to EM-177, "Exploded View". G
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-11,
"Engine Lubrication System".
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), H
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-11, "Engine Lubrication System".
7. After inspection, install removed parts in the reverse order.
I
The following are procedures for checking fluids leakage, lubricates leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required J
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- K
NOTE: L
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises. M
engine coolant.
N
O
Engine oil Level Leakage Level P

OIL SEAL
OIL SEAL
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000003802378
REMOVAL
1. Remove camshaft relating to valve oil seal to be removed. Refer to EM-209, "Exploded View".
2. Remove valve lifters. Refer to EM-209, "Exploded View".
3. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent valve from dropping
into cylinder.
a magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes.
JPBIA0180ZZ
5. Remove valve spring retainer and valve spring.

6. Remove valve oil seal using the valve oil seal puller [SST:
KV10107902] (A).
JPBIA0177ZZ
INSTALLATION
1. Apply new engine oil on new valve oil seal joint and seal lip.
2. Using the valve oil seal drift [SST: KV10115600] (A), press fit
valve seal to height (b) shown in the figure.
NOTE:
Dimension: Height measured before valve spring seat installa-
tion
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
JPBIA0178ZZ

FRONT OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000003802379
REMOVAL

OIL SEAL
• Front road wheel and tire (RH) A
• Front splash guard (RH): Refer to EXT-24, "FENDER PROTECTOR : Exploded View".
• Crankshaft pulley: Refer to EM-177, "Exploded View".
EM
2. Remove front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crank-
shaft. C
E
SEM829E
INSTALLATION F
1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.
2. Install front oil seal.
• Install front oil seal so that each seal lip is oriented as shown in G
the figure.
A : Oil seal lip

H
B : Dust seal lip
: Engine inside
: Engine outside I
JPBIA0054ZZ J
• Using a suitable drift, press-fit until the height of front oil seal is
level with the mounting surface. K
- Suitable drift: outer diameter 60 mm (2.36 in), inner diameter
50 mm (1.97 in).
• Check the garter spring is in position and seal lips not inverted.
CAUTION: L
• Be careful not to damage front timing chain case and
crankshaft.
• Press-fit straight and avoid causing burrs or tilting oil M
seal.
3. Install in the reverse order of removal after this step. SEM829E
REAR OIL SEAL N
REAR OIL SEAL : Removal and Installation INFOID:0000000003802380
O
REMOVAL
1. Remove transaxle assembly. Refer to TM-356, "Exploded View" (VQ25DE) or TM-173, "Exploded View"
(VQ35DE). P
2. Remove drive plate. Refer to EM-232, "Exploded View".
3. Remove oil pan (upper). Refer to EM-163, "Exploded View".

OIL SEAL
4. Use a seal cutter (SST) to cut away liquid gasket and remove
rear oil seal retainer.
CAUTION:
Be careful not to damage mating surfaces.
NOTE:
Regard both rear oil seal and retainer as an assembly.
PBIC1612E
INSTALLATION
1. Remove old liquid gasket on mating surfaces of cylinder block and oil pan (upper) using scraper.
2. Apply new engine oil to both oil seal lip and dust seal lip of new oil seal retainer.
3. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to rear oil seal
retainer as shown in the figure.
• VQ25DE
a : φ2.0 - 3.0 mm (0.08 - 0.12 in)
JPBIA2863ZZ
• VQ35DE
a : φ2.0 - 3.0 mm (0.08 - 0.12 in)

CAUTION:
Attaching should be done within 5 minutes after coating.
JPBIA0542ZZ
4. Install rear oil seal retainer to cylinder block. Refer to EM-232, "Exploded View".
• Check the garter spring is in position and seal lips not inverted.

CYLINDER HEAD
CYLINDER HEAD
A
REMOVAL EM
JPBIA1748ZZ
J
1. Oil level gauge 2. Cylinder head assembly (bank 2) 3. Cylinder head bolt
4. Cylinder head assembly (bank 1) 5. Cylinder head gasket (bank 1) 6. Cylinder head gasket (bank 2)
A. Refer to EM-222 K
DISASSEMBLY L

CYLINDER HEAD
JPBIA1728GB
1. Valve lifter 2. Valve collet 3. Valve spring retainer

4. Valve spring 5. Valve oil seal 6. Valve spring seat
7. Valve guide (EXH) 8. Spark plug 9. Spark plug tube
10. Cylinder head (bank 1) 11. Valve seat (EXH) 12. Valve (EXH)
13. Valve (INT) 14. Valve seat (INT) 15. Valve guide (INT)
16. Cylinder head (bank 2)
: Apply genuine high strength thread locking sealant or equivalent.
Refer to GI-4, "Components" for symbols not described on the above.
REMOVAL
• Oil level gauge
• Fuel tube and fuel injector assembly: Refer to EM-169, "Exploded View".
• Exhaust manifold: Refer to EM-158, "Exploded View".
• Water inlet and thermostat assembly: Refer to CO-46, "Exploded View".
• Water outlet, water connector, water bypass pipe, and heater pipe: Refer to CO-48, "Exploded View".
• Timing chain and rear timing chain case: Refer to EM-177, "Exploded View" and EM-204, "Exploded
View".
• Camshaft: Refer to EM-209, "Exploded View".

CYLINDER HEAD
2. Loosen cylinder head bolts in reverse order as shown in the fig-
ure with cylinder head bolt wrench (commercial service tool) and A
power tool.
A : Bank 1
EM
B : Bank 2
: Engine front
G
JPBIA0172ZZ
3. Remove cylinder head assembly (bank 1 and bank 2).

4. Remove cylinder head gaskets. H
INSTALLATION
1. Install new cylinder head gaskets. I
2. Turn crankshaft until No. 1 piston is set at TDC.
• Crankshaft key should line up with the bank 1 cylinder center
line as shown in the figure.
J
1 : Crankshaft key
: Bank 1 side
K
JPBIA1752ZZ

CYLINDER HEAD
3. Install cylinder head follow the steps below to tighten cylinder
head bolts in numerical order as shown in the figure with cylin-
der head bolts wrench (commercial service tool).
A : Bank 1
B : Bank 2
: Engine front
CAUTION:
• If cylinder head bolts reused, check their outer diameters
before installation. Refer to EM-229, "Inspection".
• Before installing cylinder head, inspect cylinder head dis-
tortion. Refer to EM-229, "Inspection".
a. Apply new engine oil to threads and seat surfaces of cylinder
head bolts.
b. Tighten all cylinder head bolts.
: 98.1 N·m (10 kg-m, 72 ft-lb)

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

JPBIA0172ZZ
CAUTION:
In step “c”, loosen bolts in reverse order of that indicated in the figure.
d. Tighten all cylinder head bolts.
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
e. Turn all cylinder head bolts 103 degrees clockwise (angle tightening).
CAUTION:
Check the tightening angle by using the angle wrench [SST:
KV10112100] (A). Avoid judgment by visual inspection with-
out.
• Check tightening angle indicated on the angle wrench indica-
tor plate.
f. Turn all cylinder head bolts 103 degrees clockwise again (angle
tightening).
JPBIA0175ZZ
4. After installing cylinder head, measure distance between front

end faces of cylinder block and cylinder head (bank 1 and bank
2).
Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)

• If measured value is out of the standard, reinstall cylinder
head.
EMQ0662D

CYLINDER HEAD
A
DISASSEMBLY
1. Remove spark plug with spark plug wrench (commercial service tool).
EM
2. Remove valve lifter.
• Compress valve spring with the valve spring compressor [SST: C
a magnet hand. D
CAUTION:
E
F
JPBIA0180ZZ
4. Remove valve spring retainer, valve spring, and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve. G
6. Remove valve oil seal with the valve oil seal puller [SST:
KV10107902] (A). H
JPBIA0177ZZ
K
7. Remove valve seat, if valve seat must be replaced.
• Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat
recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-264, "Cylinder Head". L
CAUTION:
Prevent to scratch cylinder head by excessive boring.
8. Remove valve guide, if valve guide must be replaced.
M
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
N
P
JPBIA0184ZZ

CYLINDER HEAD
b. Drive out valve guide with a press [under a 20 kN (2 ton, 2.0 lmp
ton) pressure] or a hammer and the valve guide drift (commer-
cial service tool).
WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
SEM931C
9. Remove spark plug tube if necessary.

• Using a pliers, pull spark plug tube out of cylinder head.
CAUTION:
• Take care not to damage cylinder head.
• Once removed, spark plug tube will be deformed and cannot be reused. Never remove it unless
absolutely necessary.
ASSEMBLY
1. If valve guide is removed in step 8 (DISASSEMBLY), install it.
Replace with oversized [0.2 mm (0.008 in)] valve guide.
a. Using the valve guide reamer (commercial service tool) (A),
ream cylinder head valve guide hole.
Valve guide hole diameter (for service parts):

Intake and exhaust
: Refer to EM-264, "Cylinder Head".
JPBIA0185ZZ

heated oil (A).
JPBIA0184ZZ
c. Using the valve guide drift (commercial service tool), press valve
guide from camshaft side to the dimensions as shown in the fig-
ure.
Projection (A)
Intake and exhaust
WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned. JPBIA0186ZZ

CYLINDER HEAD
d. Using the valve guide reamer (commercial service tool) (A),
apply reamer finish to valve guide. A
Standard : Refer to EM-264,

(Intake and exhaust) "Cylinder Head". EM
JPBIA0185ZZ
D
2. If valve seat is removed in step 7 (DISASSEMBLY), install it.
Replace with oversize [0.5 mm (0.020 in)] valve seat.
a. Ream cylinder head recess diameter (a) for service valve seat.
E
Oversize : Refer to EM-264,
(Intake and exhaust) "Cylinder Head".
F
• Be sure to ream in circles concentric to valve guide center.
This will enable valve to fit correctly.
G
JPBIA0188ZZ
H

heated oil (A). I
JPBIA0184ZZ
L
c. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head.
WARNING:
Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. M
CAUTION:
Avoid directly touching cold valve seats.
d. Using the valve seat cutter set (commercial service tool) or valve
seat grinder, finish seat to the specified dimensions. Refer to N
EM-264, "Cylinder Head".
CAUTION:
When using the valve seat cutter, firmly grip cutter handle O
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with cutter or cutting many different times may
P
result in stage valve seat.
SEM934C
e. Using compound, grind to adjust valve fitting.

f. Check again for normal contact. Refer to "VALVE SEAT CONTACT".
3. Install new valve oil seals as follows:

CYLINDER HEAD
a. Apply new engine oil on valve oil seal joint and seal lip.
b. Install with the valve oil seal drift [SST: KV10115600] (A) press fit
valve seal to height (b) shown in the figure.
NOTE:
Dimension: Height measured before valve spring seat installa-
tion.
Intake and exhaust : 14.3 - 14.9 mm (0.563 - 0.587 in)
JPBIA0178ZZ
4. Install valve spring seat.

5. Install valve.
NOTE:
Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type).
• Install narrow pitch end (paint mark) to cylinder head side
(valve spring seat side).
A : Wide pitch
B : Narrow pitch
C : Paint mark
: Cylinder head side
JPBIA0179ZZ
7. Install valve spring retainer.

8. Install valve collet.
the adapter [SST: KV10109220] (B). Install valve collet with a
magnet hand.
CAUTION:
• Tap valve stem edge lightly with plastic hammer after installa-
tion to check its installed condition.
JPBIA0180ZZ
9. Install valve lifter.

10. Install spark plug tube.
• Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side.
Use genuine high strength thread locking sealant or equivalent.

CYLINDER HEAD
c. Using a drift, press-fit spark plug tube so that its height (A) is as
specified in the figure. A
B : Genuine high strength thread locking sealant application area
EM
Standard press-fit height: 37.7 - 38.7 mm (1.484 - 1.524 in)
CAUTION:
• When press-fitting, take care not to deform spark plug C
tube.
• After press-fitting, wipe off liquid gasket protruding onto
JPBIA0181ZZ
cylinder-head upper face.
D
11. Install spark plug with the spark plug wrench (commercial service tool).
E

Cylinder Head Bolts Outer Diameter F
• Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between (C) and (B)
exceeds the limit, replace them with new one. G
Limit [(C) - (B)] : 0.11 mm (0.0043 in)

H
A : Measuring point
d : 11 mm (0.43 in)
e : 48 mm (1.89 in) I
• If reduction of outer diameter appears in a position other than (B), JPBIA0173ZZ
use it as (B) point.
Cylinder Head Distortion J
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-244, "Inspec-
tion". K
1. Using a scraper, wipe off oil, scale, gasket, sealant, and carbon deposits from surface of cylinder head.
CAUTION:
Never allow gasket fragments to enter engine oil or engine coolant passages. L
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions (A), (B), (C), (D), (E), and
(F).
M
• If it exceeds the limit, replace cylinder head. N
O
JPBIA0176ZZ
INSPECTION AFTER DISASSEMBLY

P
Valve Dimensions
• Check the dimensions of each valve. For the dimensions, refer to EM-264, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. Refer to "Valve Seat Con-
tact".
Valve Stem Diameter

CYLINDER HEAD
• Measure the diameter of valve stem with micrometer (A).

Valve Guide Inner Diameter

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

JPBIA0183ZZ

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

Standard and limit (Intake and exhaust)
• If the calculated value exceeds the limit, replace valve and/or valve guide. When valve guide must be
replaced, refer to EM-225, "Disassembly and Assembly".
Valve Seat Contact
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circumference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions (B) even after the recheck,
replace valve seat. Refer to EM-225, "Disassembly and Assem-
bly".
A : OK
JPBIA0187ZZ
Valve Spring Squareness

• Set a try square (A) along the side of valve spring and rotate
spring. Measure the maximum clearance between the top of spring
and try square.
B : Contact

• If it exceeds the limit, replace valve spring.
JPBIA0189ZZ
Valve Spring Dimensions and Valve Spring Pressure Load

CYLINDER HEAD
• Check the valve spring pressure at specified spring height.
A
Standard (Intake and exhaust)
Free height
Installation height : Refer to EM-264, EM
Installation load "Cylinder Head".
Height during valve open
C
Load with valve open
• If the installation load or load with valve open is out of the stan- SEM113
dard, replace valve spring. D

Inspection for Leakage E
quantity, fill to the specified level. Refer to MA-8, "Fluids and Lubricants". F
G
engine oil and engine coolant. H
specified level, if necessary. I
Engine coolant Level Leakage Level J
K
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc. L

CYLINDER BLOCK
CYLINDER BLOCK
VQ25DE
JPBIA2236GB

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

4. Cylinder block 5. Knock sensor 6. Sub harness
7. Thrust bearing (upper) 8. Main bearing (upper) 9. Crankshaft
10. Crankshaft key 11. Thrust bearing (lower) 12. Main bearing (lower) EM
13. Main bearing cap 14. Main bearing cap bolt 15. Main bearing beam
16. Baffle plate 17. Connecting rod bolt 18. Connecting rod bearing cap
19. Connecting rod bearing 20. Connecting rod 21. Snap ring C
22. Piston pin 23. Piston 24. Oil ring
25. Second ring 26. Top ring 27. Pilot converter
A. Crankshaft side B. Chamfered C. Refer to EM-235 D
D. Front mark
E
VQ35DE

CYLINDER BLOCK
JPBIA2237GB
1. Reinforcement plate 2. Drive plate 3. Rear oil seal retainer

4. Sub harness 5. Knock sensor 6. Cylinder block
7. Thrust bearing (upper) 8. Main bearing (upper) 9. Crankshaft
10. Crankshaft key 11. Thrust bearing (lower) 12. Main bearing (lower)
13. Main bearing cap 14. Main bearing cap bolt 15. Main bearing beam
16. Baffle plate 17. Connecting rod bolt 18. Connecting rod bearing cap

CYLINDER BLOCK
19. Connecting rod bearing 20. Connecting rod 21. Snap ring
22. Piston pin 23. Piston 24. Oil ring A
25. Second ring 26. Top ring 27. Pilot converter
28. Oil jet
A. Crankshaft side B. Chamfered C. Refer to EM-235 EM
D. Front mark
C
DISASSEMBLY D
• Intake manifold: Refer to EM-156, "Exploded View". E
• Oil pans (upper and lower): Refer to EM-163, "Exploded View".
• Front and rear timing chain case: Refer to EM-204, "Exploded View".
• Cylinder head: Refer to EM-221, "Exploded View".
F
2. Remove knock sensor.
CAUTION:
Carefully handle sensor avoiding shocks.
G
3. Remove rear oil seal retainer.
• Remove by inserting screwdriver between main bearing cap and rear oil seal retainer.
CAUTION:
If rear oil seal retainer is removed, replace it with new one. H
NOTE:
Regard both rear oil seal and retainer as an assembly.
4. Remove baffle plate from main bearing beam. I
5. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-244, "Inspection". J
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
K
b. Remove connecting rod bearing cap.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side. L
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end. M
EMQ0191D
O
6. Remove connecting rod bearings from connecting rod and connecting rod bearing cap.
CAUTION:
• Be careful not to drop connecting rod bearing, and to scratch the surface.
• Identify installation positions, and store them without mixing them up. P
7. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-244, "Inspection".

CYLINDER BLOCK
• Use a piston ring expander (commercial service tool) (A).
CAUTION:
• When removing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expanding them
excessively.
JPBIA0194ZZ
8. Remove piston from connecting rod as follows:

a. Using a snap ring pliers (A), remove snap rings.
JPBIA0195ZZ
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use

drier (A) or equivalent.
JPBIA0196ZZ
c. Push out piston pin with stick of outer diameter approximately 20

mm (0.79 in).
PBIC0262E
9. Remove main bearing cap bolts.

NOTE:
• Before loosening main bearing cap bolts, measure the crankshaft end play. Refer to EM-244, "Inspec-
tion".

CYLINDER BLOCK
• Loosen main bearing cap bolts in the reverse order as shown
in the figure in several different steps. A
: Engine front
EM
JPBIA0439ZZ
D
10. Remove main bearing beam.
G
PBIC0881E
11. Remove main bearing caps.

CAUTION: H
Be careful not to drop main bearing, and to scratch the sur-
face.
• Using main bearing cap bolts, remove main bearing cap while I
shaking it back-and-forth.
EMQ0195D
K
12. Remove crankshaft.
13. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION: L
• Be careful not to drop main bearing, and to scratch the surface.
14. Remove oil jet. (VQ35DE) M
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material. N
CAUTION:
Use a goggles to protect your eye.
O

CYLINDER BLOCK
2. Install each plug to cylinder block as shown in the figure.
B : Water drain plug

• Apply sealant to the thread of water drain plug (A).
• Apply sealant to the thread of connector bolt (D).
• Apply sealant to the thread of plug (C).
Use genuine high strength thread locking sealant or
equivalent.
• Replace washers with new one.
PBIC2487E
• Tighten each plug and connector bolt as specified below.
Part Washer Tightening torque

A Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
B No 9.8 N·m (1.0 kg-m, 87 in-lb)
C Yes 62.0 N·m (6.3 kg-m, 46 ft-lb)
D No 39.2 N·m (4.0 kg-m, 29 ft-lb)
3. Install oil jet. (VQ35DE)

• Insert oil jet dowel pin (A) into cylinder block dowel pin hole,
and tighten mounting bolts.
: Engine front
JPBIA0198ZZ
4. Install main bearings and thrust bearings as follows:

CAUTION:
Be careful not to drop main bearing, and to scratch the surface.
a. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps.

CYLINDER BLOCK
b. Install thrust bearings (1) to the both sides of the No. 3 journal
housing on cylinder block and main bearing cap. A
A : No. 1
B : No. 2 EM
C : No. 3
D : No. 4
F : Thrust bearing installation position C
: Engine front
• Install thrust bearings with the oil groove (E) facing crankshaft JPBIA0199ZZ
arm (outside). D
• Install thrust bearing with a projection on one end on cylinder block, and thrust bearing with a projection
at center on main bearing cap. Align each projection with mating notch.
E
c. Install main bearings paying attention to the direction.
• Main bearing with oil hole (B) and groove (C) goes on cylinder
block. The one without them goes on main bearing cap.
F
A : Cylinder block side
D : Main bearing cap side
: Engine front G
• Before installing main bearings, apply engine oil to the bearing

surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it. H
• When installing, align main bearing stopper protrusion to cut- JPBIA0200ZZ
out of cylinder block and main bearing caps.
• Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned. I
5. Install crankshaft to cylinder block.

• While turning crankshaft by hand, check that it turns smoothly.
J
6. Install main bearing caps.
• Main bearing caps are identified by identification mark cast on
them. For installation, face front mark (E) to front side.
K
A : No. 1
B : No. 2
C : No. 3 L
D : No. 4
: Engine front
M
NOTE:
Main bearing cap cannot be replaced as a single part, because it JPBIA0440ZZ
is machined together with cylinder block.

N
7. Install main bearing beam.
• Install main bearing beam with front mark facing downward (oil pan side).
• Install main bearing beam with front mark facing front of the O
engine.
PBIC0881E

CYLINDER BLOCK
8. Install main bearing cap bolts in numerical order as shown in the
figure as follows:
: Engine front
a. Inspect the outer diameter of main bearing cap bolt. Refer to

EM-244, "Inspection".
b. Apply new engine oil to threads and seat surfaces of main bear-
ing cap bolts.
c. Tighten main bearing cap bolts in several different steps.
JPBIA0439ZZ
: 35.3 N·m (3.6 kg-m, 26 ft-lb)
d. Turn all main bearing cap bolts 90 degrees clockwise (angle tightening).
CAUTION:
Use the angle wrench [SST: KV10112100] to check tighten-
ing angle. Never make judgment by visual inspection.
• After installing main bearing cap bolts, check that crankshaft
can be rotated smoothly by hand.
• Check the crankshaft end play. Refer to EM-244, "Inspection".
PBIC0921E
9. Install piston to connecting rod as follows:

a. Using snap ring pliers, install new snap ring to the groove of piston rear side.
b. Install piston to connecting rod.
• Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without
excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into
piston and connecting rod.
• Assemble so that the front mark on the piston crown and the
cylinder number on connecting rod are positioned as shown in
the figure.
c. Install new snap ring to the groove of the piston front side.
• After installing, check that connecting rod moves smoothly.
SEM838F
10. Using a piston ring expander (commercial service tool) (A),

install piston rings.
CAUTION:
• When installing piston rings, be careful not to damage
piston.
• Be careful not to damage piston rings by expending them
excessively.
JPBIA0194ZZ

CYLINDER BLOCK
• If there is stamped mark on ring, mount it with marked side up.
NOTE: A
If there is no stamp on ring, no specific orientation is required
for installation.
EM
Stamped mark: VQ25DE VQ35DE
Top ring (A) R —
Second ring (B) R2 2R C
JPBIA0263ZZ
D
• Position each ring with the gap as shown in the figure referring
to the piston front mark (D).
E
C : Top ring gap
E : Oil ring upper or lower rail gap (either of then)
F : Second ring and oil ring spacer gap
F
a : 90 degrees
b : 45 degrees
G
JPBIA0205ZZ
• Check the piston rings side clearance. Refer to EM-244, "Inspection". H

11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface. I
• Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.
• When installing, align connecting rod bearing stopper protru-
sion (B) with cutout (C) of connecting rod and connecting rod J
bearing cap to install.
• Ensure the oil hole (A) on connecting rod and that on the cor-
responding bearing are aligned. K
JPBIA0206ZZ
M
12. Install piston and connecting rod assembly to crankshaft.
• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply engine oil sufficiently to the cylinder bore, piston, and crankshaft pin journal. N
• Match the cylinder position with the cylinder number on connecting rod to install.
• Be sure that front mark on piston crown is facing front of engine.
• Using a piston ring compressor [SST: EM03470000] (A) or
suitable tool, install piston with the front mark on the piston O
crown facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft P
pin, resulting from an interference of the connecting rod big
end.
JPBIA0207ZZ

CYLINDER BLOCK
13. Install connecting rod bearing cap.
• Match the stamped cylinder number marks on connecting rod
with those on connecting rod bearing cap to install.
A : Sample codes
B : Bearing stopper groove
C : Small-end diameter grade
D : Standard stamp
E : Weight grade
F : Cylinder No.
G : Management code
JPBIA0208ZZ
I : Management code
• Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
14. Tighten connecting rod bolt as follows:

a. Inspect the outer diameter of connecting rod bolt. Refer to EM-244, "Inspection".
b. Apply engine oil to the threads and seats of connecting rod bolts.
c. Tighten connecting rod bolts.
: 19.6 N·m (2.0 kg-m, 14 ft-lb)

d. Then tighten all connecting rod bolts 90 degrees clockwise (angle tightening).
CAUTION:
Always use the angle wrench [SST: KV10112100]. Avoid
tightening based on visual check alone.
• After tightening connecting rod bolts, check that crankshaft
rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-244,
"Inspection".
SEM953E
15. Install baffle plate to main bearing beam.

16. Install new rear oil seal retainer to cylinder block. Refer to EM-219, "REAR OIL SEAL : Removal and
Installation".
17. Install pilot converter.
• With drift [outer diameter: approximately 33 mm (1.30 in)],
press-fit as far as it will go.
PBIC0899E

CYLINDER BLOCK
• Press-fit pilot converter with its chamfer facing crankshaft as
shown in the figure. A
: Crankshaft side
EM
JPBIA0210ZZ
D
18. Install knock sensors.
• VQ25DE
- Install knock sensor (1) so that connector faces the front of the
engine. E
: Engine front
- After installing knock sensor, connect harness connector, and F

lay it out to rear of engine.
CAUTION:
• Never tighten mounting bolts while holding connector. G
• If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE: JPBIA0535ZZ
H
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
I
• VQ35DE
- Install knock sensor so that connector faces the rear of the
engine. J
A : Bank 1
B : Bank 2
K
: Engine front
- After installing knock sensor, connect harness connector, and

lay it out to rear of engine. L
CAUTION:
• Never tighten mounting bolts while holding connector.
• If any impact by dropping is applied to knock sensor, M
replace it with new one.
NOTE:
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor. N
P
JPBIA0211ZZ
19. Note the following, assemble in the reverse order of disassembly after this step.
Drive plate
• When installing drive plate to crankshaft, be sure to correctly align crankshaft side dowel pin and drive
plate side dowel pin hole.
- If these are not aligned correctly, engine runs roughly and “MIL” turns on.

CYLINDER BLOCK
• Install drive plate (2) and reinforcement plate (3) as shown in
the figure.
1 : Ring gear
4 : Pilot converter
5 : Crankshaft
A : Rounded
: Engine front
• Holding ring gear with the pulley holder (commercial service

tool). JPBIA0212ZZ
• Tighten mounting bolts crosswise over several times.

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator.
Standard and limit : Refer to EM-268, "Cylinder Block".

• If the measured value exceeds the limit, replace thrust bearings,
also.
EMQ0196D
CONNECTING ROD SIDE CLEARANCE

• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A).
• If the measured value exceeds the limit, replace connecting rod,

also.
JPBIA0536ZZ
PISTON TO PISTON PIN OIL CLEARANCE

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

CYLINDER BLOCK
A
EM
JPBIA0218ZZ
D
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
Standard : Refer to EM-268, "Cylinder Block". E
• If the calculated value is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to EM-254, "Description".
NOTE: F
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.) G
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C). H
A : NG
B : OK I

• If the measured value exceeds the limit, replace piston ring, and J
measure again. If it still exceeds the limit, replace piston also.
JPBIA0219ZZ
K
PISTON RING END GAP
• Check that the cylinder bore inner diameter is within the specification. Refer to “Cylinder Bore Inner Diame-
ter”.
L
• 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).
M
A : Press-fit
C : Measuring point
N
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, rebore cylinder and use O
JPBIA0220ZZ
oversize piston and piston rings.
CONNECTING ROD BEND AND TORSION
P

CYLINDER BLOCK
• Check with a connecting rod aligner.
A : Bend
B : Torsion
C : Feeler gauge
Bend limit
Torsion 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 tightening connecting rod bolts to the specified
torque. Refer to EM-235, "Disassembly and Assembly" for the
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

CYLINDER BLOCK
A
EM
JPBIA0218ZZ
D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
• 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-254, "Description".
• If replacing connecting rod assembly, refer to EM-255,
"Connecting Rod Bearing" to select the connecting rod bearing. G
A : Sample codes
B : Bearing stopper groove H
C : Small-end diameter grade
D : Standard stamp
E : Weight grade I
F : Cylinder No.
G : Management code
JPBIA0208ZZ
H : Front mark J
I : Management code
Factory installed parts grading: K

• Service parts apply only to grade “0”.
- VQ25DE
A : Piston grade number L

B : Front mark
C : Piston pin grade number
D : Identification code M
JPBIA2198ZZ
- VQ35DE O

B : Front mark P
C : Piston pin grade number
D : Identification code
JPBIA2199ZZ

CYLINDER BLOCK
Unit: mm (in)
Grade 0 1
22.000 - 22.006 22.006 - 22.012
Connecting rod bushing inner diameter *
(0.8661 - 0.8664) (0.8664 - 0.8666)
21.993 - 21.999 21.999 - 22. 005
Piston pin hole diameter
(0.8659 - 0.8661) (0.8661 - 0.8663)
21.989 - 21.995 21.995 - 22.001
Piston pin outer diameter
(0.8657 - 0.8659) (0.8659 - 0.8662)
CYLINDER BLOCK DISTORTION

• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination.
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some
different points in six directions (C), (D), (E), (F), (G), and (H) with a
straightedge (A) and a feeler gauge (B).

• If it exceeds the limit, replace cylinder block.
JPBIA0224ZZ
MAIN BEARING HOUSING INNER DIAMETER

• Install main bearing caps (2) and main bearing beam without
installing main bearings, and tighten main bearing cap bolts to the
specified torque. Refer to EM-235, "Disassembly and Assembly"
for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge.

• If out of the standard, replace cylinder block (1) and main bearing
caps as assembly.
NOTE: JPBIA0225ZZ
Cylinder block cannot be replaced as a single part, because it is

machined together with main bearing caps.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore inner Diameter
• Using a bore gauge, measure cylinder bore for wear, out-of-round
and taper at six different points on each cylinder. [(A) and (B) direc-
tions at (C), (D), and (E)] is in longitudinal direction of engine.
f : 10 mm (0.39 in)
g : 60 mm (2.36 in)
h : 120 mm (4.72 in)

JPBIA0226ZZ

CYLINDER BLOCK
• If the measured value exceeds the limit, or if there are scratches
and/or seizure on the cylinder inner wall, hone or rebore the inner A
wall.
• Oversize piston is provided. When using oversize piston, rebore
cylinder so that the clearance of the piston to cylinder bore satis-
EM
fies the standard.
CAUTION:
When using oversize piston, use oversize pistons for all cylin-
ders with oversize piston rings. C
Oversize (O/S) : 0.2 mm (0.008 in) SEM843E
D
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer (A).
Measure point E
Standard
G
JPBIA0227ZZ
Piston-to-Cylinder Bore Clearance H

Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].
I
A : Direction A
C : Position C
E : Position E
J
f : 10 mm (0.39 in)
g : 60 mm (2.36 in)
h : 120 mm (4.72 in)
K
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame- JPBIA0226ZZ
ter).
L
• If the calculated value exceeds the limit, replace piston and piston pin assembly. Refer to EM-254, "Piston".
Reboring Cylinder Bore M
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Rebored size calculation: D = A + B – C N

where,
A: Piston skirt diameter as measured O
B: Piston to cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
D: Bored diameter P
2. Install main bearing caps and main bearing beam, and tighten to the specified torque. Otherwise, cylinder
bores may be distorted in final assembly.
3. Cut cylinder bores.
NOTE:
• When any cylinder needs boring, all other cylinders must also be bored.

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

• If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-
257, "Main Bearing".
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).

• If out of the standard, measure the connecting rod bearing oil
clearance. Then use undersize bearing. Refer to EM-255,
JPBIA0228ZZ
CRANKSHAFT OUT-OF-ROUND AND TAPER

• 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.

• If the measured value exceeds the limit, correct or replace crank-
shaft.
• If corrected, measure the bearing oil clearance of the corrected
main journal and/or pin journal. Then select the main bearing and/ JPBIA0229ZZ
or connecting rod bearing. Refer to EM-257, "Main Bearing" and/

or EM-255, "Connecting Rod Bearing".
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on the both end 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)

• If it exceeds the limit, replace crankshaft.
SEM346D


CYLINDER BLOCK
• Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod cap, and tighten connecting rod bolts to the specified A
torque. Refer to EM-235, "Disassembly and Assembly" for the
• Measure the inner diameter of connecting rod bearing with an
EM
inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crank-
shaft pin journal diameter)
C
Standard and limit : Refer to EM-272,
"Connecting Rod Bearing". JPBIA0230ZZ
• If the calculated value exceeds the limit, select proper connecting D

rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the
specified bearing oil clearance. Refer to EM-255, "Connecting Rod Bearing".
Method of Using Plastigage E
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
holes. F
• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-235, "Disassembly and Assembly" for the tightening proce-
dure.
G
CAUTION:
• Remove connecting rod bearing cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width. H
NOTE:
same as that described in the “Method by Calculation”. I
JPBIA0231ZZ
K
• Install main bearings (3) to cylinder block (1) and main bearing L
caps (2), and main bearing cap bolts with main bearing beam to
the specified torque. Refer to EM-235, "Disassembly and Assem-
bly" for the tightening procedure.
M
• Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)
N
Standard and limit : Refer to EM-271, "Main Bearing".
• If the calculated value exceeds the limit, select proper main bear-
ing according to main bearing inner diameter and crankshaft main JPBIA0232ZZ O
journal diameter to obtain the specified bearing oil clearance.
Refer to EM-257, "Main Bearing".
Method of Using Plastigage P
• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
holes.
• Install main bearing to cylinder block and main bearing caps, and tighten main bearing cap bolts with main
bearing beam to the specified torque. Refer to EM-235, "Disassembly and Assembly" for the tightening pro-
cedure.
CAUTION:

CYLINDER BLOCK
• Remove main bearing caps and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
JPBIA0231ZZ
MAIN BEARING CRUSH HEIGHT

• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of
bearing must protrude. Refer to EM-235, "Disassembly and
Assembly" for the tightening procedure.
A : 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-235, "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 OUTER DIAMETER

• Measure the outer diameters (c) and (d) at two positions as shown
in the figure.
a : 20 mm (0.79 in)
b : 30 mm (1.18 in)
e : 10 mm (0.39 in)
• If reduction appears in (a) range, regard it (c).
Limit [(d) – (c)] : 0.11 mm (0.0043 in)

• If it exceeds the limit (large difference in dimensions), replace main JPBIA0234ZZ
bearing cap bolt with new one.

CONNECTING ROD BOLT OUTER DIAMETER

CYLINDER BLOCK
• Measure the outer diameter (d) at position shown in the figure.
• If the reduction appears in a position other than (d), regard it as (d). A
Standard : 7.90 - 8.00 mm (0.3110 - 0.3150 in)

Limit : 7.75 mm (0.3051 in) EM
• When (d) exceeds the limit (when it becomes thinner), replace
connecting rod bolt with new one.
C
PBIC0912E
D
DRIVE PLATE
• Check drive plate and signal plate for deformation or damage.
CAUTION:
• Never disassemble drive plate. E
scratch it. F
• Handle signal plate in a manner that prevents it from becom-
ing magnetized.
• If anything is found, replace drive plate.
G
JPBIA0192ZZ
OIL JET (VQ35DE) H

• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
• If it is not satisfied, clean or replace oil jet.
I
OIL JET RELIEF VALVE (VQ35DE)
• Using a clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force. J
• If it is not satisfied, replace oil jet relief valve.
EMU0468D

Description INFOID:0000000003802388
Selection points Selection parts Selection items Selection methods

Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade grade (inner diameter of hous-
Main bearing
crankshaft (bearing thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade Piston grade = cylinder bore
(Piston is available together
ton (piston skirt diameter) grade (inner diameter of bore)
with piston pin as assembly.)
Between piston and connecting
— — —
rod*
*: For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only “0” grade is available.) The
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000003802389
WHEN NEW CYLINDER BLOCK IS USED

Check the cylinder bore grade (“1”, “2” or “3”) on rear side of cylinder
block, and select piston of the same grade.
NOTE:
Piston is available with piston pin as a set for the service part. (Only
“0” grade piston pin is available.)
SEM756G
WHEN NEW CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-244, "Inspection".
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “PISTON SELECTION TABLE”.

• VQ25DE
A
B : Front mark
C : Piston pin grade EM
D : Identification code
JPBIA2198ZZ
D
• VQ35DE
A : Piston grade number E

B : Front mark
C : Piston pin grade
D : Identification code F
G
JPBIA2199ZZ
3. Select piston of the same grade.

H
PISTON SELECTION TABLE
VQ25DE
Unit: mm (in) I
Grade 1 2 3
85.000 - 85.010 85.010 - 85.020 85.020 - 85.030
Cylinder bore inner diameter J
(3.3465 - 3.3468) (3.3468 - 3.3472) (3.3472 - 3.3476)
84.980 - 84.990 84.990 - 85.000 85.000 - 85.010
Piston skirt diameter
(3.3457 - 3.3461) (3.3461 - 3.3465) (3.3465 - 3.3468)
K
VQ35DE
Unit: mm (in)
Grade 1 2 3 L
95.500 - 95.510 95.510 - 95.520 95.520 - 95.530
Cylinder bore inner diameter
(3.7598 - 3.7602) (3.7602 - 3.7606) (3.7606 - 3.7610)
95.480 - 95.490 95.490 - 95.500 95.500 - 95.510 M
Piston skirt diameter
(3.7590 - 3.7594) (3.7594 - 3.7598) (3.7598 - 3.7602)
NOTE:
• Piston is available together with piston pin as assembly. N
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no pis-
ton pin grades can be selected. (Only “0” grade is available.)
• No second grade mark is available on piston. O
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED P

• Check pin diameter grade (“0”, “1” or “2”) on front of crankshaft,
and select connecting rod bearing of the same grade.
A : Journal diameter grade No. 1

B : Journal diameter grade No. 2
C : Journal diameter grade No. 3
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
JPBIA0269ZZ
H : Pin diameter grade No. 4
I : Pin diameter grade No. 5
J : Pin diameter grade No. 6
K : Identification
NOTE:
There is no grading for connecting rod big end diameter.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the connecting rod big end diameter. Refer to EM-244, "Inspection".
2. Check that the connecting rod big end diameter is within the standard value.
3. Measure the crankshaft pin journal diameter. Refer to EM-244, "Inspection".
4. Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in
“Crankshaft pin journal diameter” column of “CONNECTING ROD BEARING SELECTION TABLE”.
5. Select connecting rod bearing of the same grade.
CONNECTING ROD BEARING SELECTION TABLE
VQ25DE
Unit: mm (in)
Connecting rod big end diameter 48.000 - 48.013 (1.8898 - 1.8903)

Unit: mm (in)
Crankshaft Connecting rod bearing

Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
44.968 - 44.974 (1.7704 - 1.7706) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 Black
44.962 - 44.968 (1.7702 - 1.7704) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
44.956 - 44.962 (1.7699 - 1.7702) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green
VQ35DE
Unit: mm (in)
Connecting rod big end diameter 55.000 - 55.013 (2.1654 - 2.1659)

Unit: mm (in)
Crankshaft Connecting rod bearing

Crankshaft pin journal diameter Grade (Mark) Dimension (Bearing thickness range) Bearing grade No. Color
51.968 - 51.974 (2.0460 - 2.0462) 0 1.500 - 1.503 (0.0591 - 0.0592) STD 0 Black
51.962 - 51.968 (2.0457 - 2.0460) 1 1.503 - 1.506 (0.0592 - 0.0593) STD 1 Brown
51.956 - 51.962 (2.0455 - 2.0457) 2 1.506 - 1.509 (0.0593 - 0.0594) STD 2 Green
Connecting rod bearing grade table : Refer to EM-272, "Connecting Rod Bearing".

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.

• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. A
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)].
EM
Bearing undersize table : Refer to EM-272,
C
JPBIA0216ZZ

E
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED

F
1. “MAIN BEARING SELECTION TABLE” rows correspond to
bearing housing grade on rear left side of cylinder block.
I
SEM756G
2. “MAIN BEARING SELECTION TABLE” columns correspond to

journal diameter grade on front side of crankshaft. J
A : Journal diameter grade No. 1

B : Journal diameter grade No. 2 K
C : Journal diameter grade No. 3
D : Journal diameter grade No. 4
E : Pin diameter grade No. 1 L
F : Pin diameter grade No. 2
G : Pin diameter grade No. 3
JPBIA0269ZZ
H : Pin diameter grade No. 4 M
I : Pin diameter grade No. 5
J : Pin diameter grade No. 6
K : Identification code N
3. Select main bearing grade at the point where selected row and column meet in “MAIN BEARING SELEC-
TION TABLE”.
O
4. Apply sign at crossing in above step 3 to “MAIN BEARING GRADE TABLE”.
NOTE:
• “MAIN BEARING GRADE TABLE” applies to all journals.
• Service parts is available as a set of both upper and lower. P
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED

1. Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter. Refer
to EM-244, "Inspection".
2. Correspond the measured dimension in “Cylinder block main bearing housing inner diameter” row of
“MAIN BEARING SELECTION TABLE”.

3. Correspond the measured dimension in “Crankshaft main journal diameter” column of “MAIN BEARING
SELECTION TABLE”.
4. Follow step 3 and later in “When New Cylinder Block and Crankshaft are Used”.
MAIN BEARING SELECTION TABLE
PBIC5332E
Main bearing grade table (All journals) : Refer to EM-271, "Main Bearing".

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:

In grinding crankshaft main journal to use undersize bearings,
keep the fillet R (A) [1.5 - 1.7 mm (0.059 - 0.067 in)]. A
Bearing undersize table : Refer to EM-271,

"Main Bearing". EM
JPBIA0216ZZ

< SERVICE DATA AND SPECIFICATIONS (SDS) [VQ25DE, VQ35DE]

General Specification INFOID:0000000003802392
GENERAL SPECIFICATIONS
Engine VQ25DE VQ35DE

Cylinder arrangement V-6
Displacement cm3 (cu in) 2,495 (152.24) 3,498 (213.45)

85.0×73.3 95.5×81.4
Bore and stroke mm (in)
(3.346×2.886) (3.760×3.205)
Valve arrangement DOHC
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1
Number of main bearings 4
Compression ratio 9.8 10.3
Standard 1,275 (12.8, 13.0, 185)
Compression pressure
Minimum 981 (9.8, 10.0, 142)
kPa (bar, kg/cm2, psi)/300 rpm
Differential limit between cylinders 98 (1.0, 1.0, 14)
Cylinder number
SEM713A
Valve timing
(Valve timing control - “OFF”)
PBIC0187E
Unit: degree
a b c d e f
VQ25DE 240 244 −6 58 8 52
VQ35DE 240 260 −10 70 10 50

Drive Belt INFOID:0000000003802393
A
DRIVE BELT
EM
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Spark Plug INFOID:0000000003802394
C
SPARK PLUG
Unit: mm (in)
D
Make DENSO
VQ25DE FXE20HR11
Standard type
VQ35DE FXE22HR11 E
Standard 1.1 (0.043)
Gap (Nominal)
Limit 1.4 (0.055)
F
Intake Manifold INFOID:0000000003802395
INTAKE MANIFOLD G
Unit: mm (in)
Items Limit
Surface distortion Intake manifold 0.1 (0.004) H
Exhaust Manifold INFOID:0000000003802396
I
EXHAUST MANIFOLD
Unit: mm (in)
Items Limit J
Surface distortion Exhaust manifold 0.3 (0.012)
Camshaft INFOID:0000000003802397
K
CAMSHAFT
Unit: mm (in)
L
Standard
Items Limit
VQ25DE VQ35DE
No. 1 0.045 - 0.086 (0.0018 - 0.0034) M
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4 0.035 - 0.076 (0.0014 - 0.0030)
No. 1 26.000 - 26.021 (1.0236 - 1.0244) —
Camshaft bracket inner diameter N
No. 2, 3, 4 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 25.935 - 25.955 (1.0211 - 1.0218) —
Camshaft journal diameter
No. 2, 3, 4 23.445 - 23.465 (0.9230 - 0.9238) — O
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)
44.665 - 44.855 45.465 - 45.655
Intake
(1.7585 - 1.7659) (1.7900 - 1.7974) 0.2 (0.008)*1 P
Camshaft cam height “A”
44.775 - 44.965 45.475 - 45.665
Exhaust
(1.7628 - 1.7703) (1.7904 - 1.7978) 0.2 (0.008)*1
Camshaft runout [TIR*2] Less than 0.02 (0.0008) 0.05 (0.0020)

Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)
SEM671
*1: Cam wear limit

*2: Total indicator reading
VALVE LIFTER
Unit: mm (in)
Standard
Items
VQ25DE VQ35DE
Intake 33.980 - 33.990 (1.3378 - 1.3382)
Valve lifter outer diameter 33.980 - 33.990 (1.3378 - 1.3382)
Exhaust 29.977 - 29.987 (1.1802 - 1.1806)
Intake 34.000 - 34.016 (1.3386 - 1.3392)
Valve lifter hole diameter 34.000 - 34.016 (1.3386 - 1.3392)
Exhaust 29.997 - 30.013 (1.1810 - 1.1816)
Valve lifter clearance 0.010 - 0.036 (0.0004 - 0.0014)
VALVE CLEARANCE
Unit: mm (in)
Items Cold Hot* (reference data)

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

VQ25DE
Unit: mm (in)
Intake Exhaust
Identification (stamped) mark Thickness Identification (stamped) mark Thickness
788P 7.88 (0.3102) 666U 6.66 (0.2622)
790P 7.90 (0.3110) 668U 6.68 (0.2630)
792P 7.92 (0.3118) 670U 6.70 (0.2638)
794P 7.94 (0.3126) 672U 6.72 (0.2646)
796P 7.96 (0.3134) 674U 6.74 (0.2654)
798P 7.98 (0.3142) 676U 6.76 (0.2661)
800P 8.00 (0.3150) 678U 6.78 (0.2669)
802P 8.02 (0.3157) 680U 6.80 (0.2677)
804P 8.04 (0.3165) 682U 6.82 (0.2685)
806P 8.06 (0.3173) 684U 6.84 (0.2693)
808P 8.08 (0.3181) 686U 6.86 (0.2701)
810P 8.10 (0.3189) 688U 6.88 (0.2709)

Intake Exhaust
A
Identification (stamped) mark Thickness Identification (stamped) mark Thickness
812P 8.12 (0.3197) 690U 6.90 (0.2717)
814P 8.14 (0.3205) 692U 6.92 (0.2724) EM
816P 8.16 (0.3213) 694U 6.94 (0.2732)
818P 8.18 (0.3220) 696U 6.96 (0.2740)
820P 8.20 (0.3228) 698U 6.98 (0.2748) C
822P 8.22 (0.3236) 700U 7.00 (0.2756)
824P 8.24 (0.3244) 702U 7.02 (0.2764)
D
826P 8.26 (0.3252) 704U 7.04 (0.2772)
828P 8.28 (0.3260) 706U 7.06 (0.2780)
830P 8.30 (0.3268) 708U 7.08 (0.2787) E
832P 8.32 (0.3276) 710U 7.10 (0.2795)
834P 8.34 (0.3283) 712U 7.12 (0.2803)
F
836P 8.36 (0.3291) 714U 7.14 (0.2811)
838P 8.38 (0.3299) 716U 7.16 (0.2819)
840P 8.40 (0.3307) 718U 7.18 (0.2827) G
SEM758G
K
VQ35DE
Unit: mm (in)
Identification (stamped) mark Thickness

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

Identification (stamped) mark Thickness
820P 8.20 (0.3228)
822P 8.22 (0.3236)
824P 8.24 (0.3244)
826P 8.26 (0.3252)
828P 8.28 (0.3260)
830P 8.30 (0.3268)
832P 8.32 (0.3276)
834P 8.34 (0.3283)
836P 8.36 (0.3291)
838P 8.38 (0.3299)
840P 8.40 (0.3307)
SEM758G
Cylinder Head INFOID:0000000003802398
CYLINDER HEAD
Unit: mm (in)

Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)
Normal cylinder head height “H” 126.3 - 126.5 (4.97 - 4.98) —
PBIC0924E
VALVE DIMENSIONS

Unit: mm (in)
A
EM
D
SEM188

E
Intake 34.0 - 34.3 (1.339 - 1.350) 36.6 - 36.9 (1.441 - 1.453)
Valve head diameter “D”
Exhaust 29.0 - 29.3 (1.142 - 1.154) 30.2 - 30.5 (1.189 - 1.201)
Intake 98.06 (3.8606) 97.13 (3.8240)
Valve length “L” F
Exhaust 96.81 (3.8114) 94.67 (3.7272)
Intake 5.965 - 5.980 (0.2348 - 0.2354) 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350) 5.962 - 5.970 (0.2347 - 0.2350) G
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
H
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.3 (0.051)
Valve margin “T” limit 0.5 (0.020) I
Valve stem end surface grinding limit 0.2 (0.008)
VALVE GUIDE J
Unit: mm (in)
SEM950E
N
Items Standard Oversize (Service) [0.2 (0.008)]
Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369) O
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)
P
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.030 - 0.056 (0.0012 - 0.0022) 0.09 (0.0035)
Projection length “L” 12.6 - 12.8 (0.496 - 0.504)
VALVE SEAT

VQ25DE
Unit: mm (in)
PBIC2745E

Intake 35.000 - 35.016 (1.3780 - 1.3786) 35.500 - 35.516 (1.3976 - 1.3983)
Exhaust 30.000 - 30.016 (1.1811 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014)
Intake 35.080 - 35.096 (1.3811 - 1.3817) 35.580 - 35.596 (1.4008 - 1.4014)
Valve seat outer diameter “d”
Exhaust 30.080 - 30.096 (1.1842 - 1.1849) 30.580 - 30.596 (1.2669 - 1.2676)
Intake 0.064 - 0.096 (0.0025 - 0.0038)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038)
Intake 35.3 (1.390)
Diameter “d1”*1
Exhaust 30.3 (1.193)
Intake 33.3 - 33.8 (1.311 - 1.331)
Diameter “d2”*2
Exhaust 28.1 - 28.6 (1.106 - 1.126)
Intake 60°
Angle “α1”
Exhaust 60°
Intake 88°45′ - 90°15′
Angle “α2”
Exhaust 88°45′ - 90°15′
Intake 120°
Angle “α3”
Exhaust 120°
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake 6.2 - 6.3 (0.244 - 0.248) 5.4 - 5.5 (0.213 - 0.217)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)
Intake 6.35 (0.2500)
Depth “H”
Exhaust 6.0 (0.236)
*3: Machining data
VQ35DE

Unit: mm (in)
A
EM
D
PBIC2745E

E
Intake 38.000 - 38.016 (1.4961 - 1.4967) 38.500 - 38.516 (1.5157 - 1.5164)
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Intake 38.097 - 38.113 (1.4999 - 1.5005) 38.597 - 38.613 (1.5196 - 1.5202)
Valve seat outer diameter “d” F
Exhaust 31.680 - 31.696 (1.2472 - 1.2479) 32.180 - 32.196 (1.2669 - 1.2676)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.064 - 0.096 (0.0025 - 0.0038) G
Intake 34.6 (1.362)
Diameter “d1”*1
Exhaust 27.7 (1.091)
H
Intake 35.9 - 36.4 (1.413 - 1.433)
Diameter “d2”*2
Exhaust 29.3 - 29.8 (1.154 - 1.173)
Intake 60° I
Angle “α1”
Exhaust 60°
Intake 88°45′ - 90°15′
Angle “α2” J
Exhaust 88°45′ - 90°15′
Intake 120°
Angle “α3”
Exhaust 120° K
Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3
Exhaust 1.2 - 1.6 (0.047 - 0.063)
L
Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.9 - 5.0 (0.193 - 0.197)
Depth “H” 6.0 (0.236) M
N
*3: Machining data
VALVE SPRING
O
Items Standard
Free height 47.07 mm (1.8531 in)
P
Installation height 37.00 mm (1.4567 in)
Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb)
Height during valve open 27.20 mm (1.0709 in)
Load with valve open 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb)

Unit: mm (in)
Items Limit
Squareness 2.1 (0.083)
Cylinder Block INFOID:0000000003802399
CYLINDER BLOCK
Unit: mm (in)
JPBIA2238GB

Standard Less than 0.03 (0.0012)
Surface flatness
Limit 0.1 (0.004)
Main bearing housing inner
Standard 63.993 - 64.017 (2.5194 - 2.5203)
diameter
Grade No. 1 85.000 - 85.010 (3.3465 - 3.3468) 95.500 - 95.510 (3.7598 - 3.7602)
Cylinder Inner diame- Standard Grade No. 2 85.010 - 85.020 (3.3468 - 3.3472) 95.510 - 95.520 (3.7602 - 3.7606)
bore ter Grade No. 3 85.020 - 85.030 (3.3472 - 3.3476) 95.520 - 95.530 (3.7606 - 3.7610)
Wear limit 0.2 (0.008)
Out-of-round 0.015 (0.0006)
Limit
Taper 0.010 (0.0004)
Grade No. A 63.993 - 63.994 (2.5194 - 2.5194)
Grade No. B 63.994 - 63.995 (2.5194 - 2.5195)
Grade No. C 63.995 - 63.996 (2.5195 - 2.5195)
Grade No. D 63.996 - 63.997 (2.5195 - 2.5196)
Grade No. E 63.997 - 63.998 (2.5196 - 2.5196)
Grade No. F 63.998 - 63.999 (2.5196 - 2.5196)
Grade No. G 63.999 - 64.000 (2.5196 - 2.5197)
Grade No. H 64.000 - 64.001 (2.5197 - 2.5197)
Grade No. J 64.001 - 64.002 (2.5197 - 2.5198)
Grade No. K 64.002 - 64.003 (2.5198 - 2.5198)
Grade No. L 64.003 - 64.004 (2.5198 - 2.5198)
Main bearing housing inner diameter Grade No. M 64.004 - 64.005 (2.5198 - 2.5199)
grade (Without bearing) Grade No. N 64.005 - 64.006 (2.5199 - 2.5199)
Grade No. P 64.006 - 64.007 (2.5199 - 2.5200)
Grade No. R 64.007 - 64.008 (2.5200 - 2.5200)
Grade No. S 64.008 - 64.009 (2.5200 - 2.5200)
Grade No. T 64.009 - 64.010 (2.5200 - 2.5201)
Grade No. U 64.010 - 64.011 (2.5201 - 2.5201)
Grade No. V 64.011 - 64.012 (2.5201 - 2.5202)
Grade No. W 64.012 - 64.013 (2.5202 - 2.5202)
Grade No. X 64.013 - 64.014 (2.5202 - 2.5202)
Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203)
Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203)
Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203)
Difference in inner diameter
between cylinders

AVAILABLE PISTON
A
VQ25DE
Unit: mm (in)
EM
E
SEM882E

Grade No. 1 84.980 - 84.990 (3.3457 - 3.3461) — F
Grade No. 2 84.990 - 85.000 (3.3461 - 3.3465) —
Piston skirt diameter “A”
Grade No. 3 85.000 - 85.010 (3.3465 - 3.3468) —
Service — 85.180 - 85.210 (3.3535 - 3.3547)
G

“a” dimension 38.8 (1.528) — H
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031) I
VQ35DE
Unit: mm (in)
J
SEM882E
Items Standard Oversize (Service) [0.2 (0.008)] N

Grade No. 1 95.480 - 95.490 (3.7590 - 3.7594) —
Grade No. 2 95.490 - 95.500 (3.7594 - 3.7598) —
Piston skirt diameter “A” O
Grade No. 3 95.500 - 95.510 (3.7598 - 3.7602) —
Service — 95.680 - 95.710 (3.7669 - 3.7681)
P
“a” dimension 38.0 (1.496) —
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661) —
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663) —
Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) 0.08 (0.0031)
PISTON RING

VQ25DE
Unit: mm (in)
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.045 - 0.125 (0.0018 - 0.0049) —
Top 0.20 - 0.30 (0.0079 - 0.0118) 0.54 (0.0213)
End gap 2nd 0.31 - 0.46 (0.0122 - 0.0181) 0.67 (0.0264)
Oil (rail ring) 0.20 - 0.50 (0.0079 - 0.0197) 0.95 (0.0374)
VQ35DE
Unit: mm (in)
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.065 - 0.125 (0.0026 - 0.0049) —
Top 0.23 - 0.28 (0.0091 - 0.0110) 0.49 (0.0193)
End gap 2nd 0.33 - 0.43 (0.0130 - 0.0169) 0.90 (0.0354)
Oil (rail ring) 0.20 - 0.45 (0.0079 - 0.0177) 0.95 (0.0374)
PISTON PIN
Unit: mm (in)

Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659) —
Piston pin outer diameter
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
Connecting rod bushing oil clearance 0.005 - 0.017 (0.0002 - 0.0007) 0.030 (0.0012)
CONNECTING ROD
Unit: mm (in)
Standard
Items Limit
VQ25DE VQ35DE
Center distance 147.60 - 147.70 (5.81 - 5.81) 144.15 - 144.25 (5.68 - 5.68) —
Bend [per 100 (3.94)] — 0.15 (0.0059)
Torsion [per 100 (3.94)] — 0.30 (0.0118)
Connecting rod bushing inner Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664) —
diameter* Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666) —
Connecting rod big end diameter (Without
48.000 - 48.013 (1.8898 - 1.8903) 55.000 - 55.013 (2.1654 - 2.1659) —
bearing)
Side clearance 0.20 - 0.35 (0.0079 - 0.0138) 0.40 (0.0157)
CRANKSHAFT

Unit: mm (in)
A
EM
D
SEM645 SBIA0535E

E
Grade No. A 59.975 - 59.974 (2.3612 - 2.3612)
Grade No. B 59.974 - 59.973 (2.3612 - 2.3611)
Grade No. C 59.973 - 59.972 (2.3611 - 2.3611)
Grade No. D 59.972 - 59.971 (2.3611 - 2.3611) F
Grade No. E 59.971 - 59.970 (2.3611 - 2.3610)
Grade No. F 59.970 - 59.969 (2.3610 - 2.3610)
Grade No. G 59.969 - 59.968 (2.3610 - 2.3609)
Grade No. H 59.968 - 59.967 (2.3609 - 2.3609) G
Grade No. J 59.967 - 59.966 (2.3609 - 2.3609)
Grade No. K 59.966 - 59.965 (2.3609 - 2.3608)
Grade No. L 59.965 - 59.964 (2.3608 - 2.3608)
Main journal diameter. “Dm” Grade No. M 59.964 - 59.963 (2.3608 - 2.3607) H
Standard
grade Grade No. N 59.963 - 59.962 (2.3607 - 2.3607)
Grade No. P 59.962 - 59.961 (2.3607 - 2.3607)
Grade No. R 59.961 - 59.960 (2.3607 - 2.3606)
Grade No. S 59.960 - 59.959 (2.3606 - 2.3606) I
Grade No. T 59.959 - 59.958 (2.3606 - 2.3605)
Grade No. U 59.958 - 59.957 (2.3605 - 2.3605)
Grade No. V 59.957 - 59.956 (2.3605 - 2.3605)
J
Grade No. W 59.956 - 59.955 (2.3605 - 2.3604)
Grade No. X 59.955 - 59.954 (2.3604 - 2.3604)
Grade No. Y 59.954 - 59.953 (2.3604 - 2.3603)
Grade No. 4 59.953 - 59.952 (2.3603 - 2.3603) K
Grade No. 7 59.952 - 59.951 (2.3603 - 2.3603)
Grade No. 0 44.968 - 44.974 (1.7704 - 1.7706) 51.968 - 51.974 (2.0460 - 2.0462)
Pin journal diameter. “Dp” grade Standard Grade No. 1 44.962 - 44.968 (1.7702 - 1.7704) 51.962 - 51.968 (2.0457 - 2.0460) L
Grade No. 2 44.956 - 44.962 (1.7699 - 1.7702) 51.956 - 51.962 (2.0455 - 2.0457)
Center distance “r” 36.61 - 36.69 (1.4413 - 1.4445) 40.66 - 40.74 (1.6008 - 1.6039)
M
Taper (Difference between “A”
0.002 (0.0001)
and “B”)
Limit
Out-of-round (Difference between
0.002 (0.0001) N
“X” and “Y”)
Crankshaft runout [TIR*]
Limit 0.10 (0.0039)
O
Standard 0.10 - 0.25 (0.0039 - 0.0098)
Crankshaft end play
Limit 0.30 (0.0118)
*: Total indicator reading P
MAIN BEARING

Unit: mm (in)
PBIC2619E
Grade number Thickness Width Identification color Remarks

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

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

Unit: mm (in)

Main bearing oil clearance 0.035 - 0.045 (0.0014 - 0.0018)* 0.065 (0.0026)
*: Actual clearance
CONNECTING ROD BEARING

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

0 1.500 - 1.503 (0.0591 - 0.0592) Black
1 1.503 - 1.506 (0.0592 - 0.0593) Brown
EM
2 1.506 - 1.509 (0.0593 - 0.0594) Green
UNDERSIZE
Unit: mm (in) C
Items Thickness Crank pin journal diameter
0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643) Grind so that bearing clearance is the specified value.
D
Unit: mm (in)
Items Standard Limit E

Connecting rod bearing oil clearance 0.020 - 0.045 (0.0008 - 0.0018)* 0.070 (0.0028)
*: Actual clearance
F

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ENGINE

DRIVE BELTS ....................................................15 Inspection ................................................................33

Revision: 2008 December EM-1 J32

OIL PAN (UPPER) ............................................. 86 PREPARATION ......................................... 132

Revision: 2008 December EM-2 J32

SPARK PLUG .................................................. 139 REMOVAL AND INSTALLATION ............. 192

Revision: 2008 December EM-3 J32

Revision: 2008 December EM-4 J32

1. Locate the area where noise occurs.

Revision: 2008 December EM-5 J32

Operating condition of engine

Piston to piston pin oil

Revision: 2008 December EM-6 J32

Precaution Necessary for Steering Wheel Rotation after Battery Disconnect F

1. Connect both battery cables.

Revision: 2008 December EM-7 J32

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

Revision: 2008 December EM-8 J32

REMOVAL OF LIQUID GASKET SEALING D

3. Attach liquid gasket tube to the tube presser (commercial ser-

Revision: 2008 December EM-9 J32

Revision: 2008 December EM-10 J32

KV10116200 Disassembling and assembling valve mecha-

KV10117100 Loosening or tightening heated oxygen sen-

KV10107902 Removing valve oil seal M

Revision: 2008 December EM-11 J32

ST1661001 Removing pilot converter

KV11103000 Removing crankshaft pulley

KV11105210 Fixing drive plate

Commercial Service Tools INFOID:0000000003802148

Tool name Description

Spark plug wrench Removing and installing spark plug

Revision: 2008 December EM-12 J32

Valve seat cutter set Finishing valve seat dimensions

Piston ring expander Removing and installing piston ring F

Valve guide reamer 1: Reaming valve guide inner hole

Oxygen sensor thread cleaner Reconditioning the exhaust system threads M

Revision: 2008 December EM-13 J32

Tube presser Pressing the tube of liquid gasket

Revision: 2008 December EM-14 J32

Alternator, water pump and A/C compressor

Refer to : EM-116, "Drive Belt".

Revision: 2008 December EM-15 J32

Revision: 2008 December EM-16 J32

Revision: 2008 December EM-17 J32

Revision: 2008 December EM-18 J32

1. PCV hose 2. Rocker cover 3. Spark plug K

Removal and Installation INFOID:0000000003802155 M

Revision: 2008 December EM-19 J32

INSPECTION AFTER REMOVAL

Spark plug (Standard type) : Refer to EM-116, "Spark Plug".

Cleaner air pressure : Less than 588 kPa (5.88 bar, 6

• Checking and adjusting plug gap is not required between

Revision: 2008 December EM-20 J32

C : White paint mark (Not use for service)

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

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

Revision: 2008 December EM-21 J32