PRECAUTIONS

< SERVICE INFORMATION > [YD]

SERVICE INFORMATION
PRECAUTIONS
Precaution Necessary for Steering Wheel Rotation After Battery Disconnect
INFOID:0000000006109138

NOTE:
• This Procedure is applied only to models with Intelligent Key system and NVIS/IVIS (NISSAN/INFINITI
VEHICLE IMMOBILIZER SYSTEM - NATS).
• Remove and install all control units after disconnecting both battery cables with the ignition knob in the
″LOCK″ position.
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing work. If
DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NVIS/IVIS, an electrically controlled steering lock
mechanism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before
starting the repair operation.
OPERATION PROCEDURE
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting
the battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT.
Precaution for Procedure without Cowl Top Cover INFOID:0000000006109139

When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc.

PIIB3706J

Precautions For Engine Service INFOID:0000000008180051

DISCONNECTING FUEL PIPING

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

DRAINING ENGINE COOLANT

Drain engine coolant and engine oil when the engine is cooled.

INSPECTION, REPAIR AND REPLACEMENT

EM-142
 PRECAUTIONS
< SERVICE INFORMATION > [YD]
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary. A

REMOVAL AND DISASSEMBLY

• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin- EM
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, C
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 D
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
E
ASSEMBLY AND INSTALLATION
• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the F
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 G
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. H
• 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.
I

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000006109140 J

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 “SUPPLEMENTAL K
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in L
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 M
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
• 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- N
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
O
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 P
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.
Parts Requiring Angle Tightening INFOID:0000000006109146

• Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:

EM-143
 PRECAUTIONS
< SERVICE INFORMATION > [YD]
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000006109147

REMOVAL OF LIQUID GASKET

• After removing the mounting bolts and nuts, separate the mating
surface using the seal cutter (SST) and remove the old liquid gas-
ket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap seal cutter to insert it, and then slide it by tapping on the side
as shown in the figure.
• In areas where seal cutter (SST) is difficult to use, use plastic ham-
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
PBIC0275E
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the
liquid gasket 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.

PBIC0003E

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

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

EMA0622D

EM-144
 PRECAUTIONS
< SERVICE INFORMATION > [YD]
• As for the bolt holes, normally apply the liquid gasket inside
the holes. If specified, it should be applied outside the holes. A
Check to read the text of this manual.
• Within five minutes of liquid gasket application, install the mat-
ing component.
EM
• If the 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
the engine oil and engine coolant. C
CAUTION:
If there are instructions in this manual, observe them.
SEM159F

EM-145
 PREPARATION
< SERVICE INFORMATION > [YD]
PREPARATION
Special Service Tool INFOID:0000000006109148

Tool number
Description
Tool name
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
Side A
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
NT603
f: 5 (0.20)
Unit: mm (in)
KV10107902 Removing valve oil seal
Valve oil seal puller
1. KV10116100
Valve oil seal puller adapter

S-NT605

KV11103000 Removing crankshaft pulley

Pulley puller

NT676

KV11300QAM Checking compression pressure

Compression gauge adapter

ZZA1188D

KV101056S0 Preventing crankshaft from rotating

Ring gear stopper a: 3 (0.12)
1. KV10105630 b: 6.4 (0.252)
Adapter c: 2.8 (0.110)
2. KV10105610 d: 6.6 (0.260)
Plate e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79)
NT617
h: 14 (0.55) dia.
Unit: mm (in)
KV101151S0 Changing adjusting shim
Lifter stopper set
1. KV10115110
Camshaft pliers
2. KV10115120
Lifter stopper

NT041

EM-146
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool number
Description
Tool name A
KV10116200 Disassembling and assembling valve mecha-
Valve spring compressor nism
1. KV10115900 Part (1) is a component of KV10116200, but EM
Attachment Part (2) is not so.
2. KV10109220
Adapter
C
PBIC1650E

ST16610001 Removing crankshaft pilot bush

Pilot bushing puller D

NT045
F
KV10111100 Removing oil pan upper, oil pan lower and rear
Seal cutter chain case, etc.

H
NT046

KV10112100 Tightening bolts for bearing cap, cylinder

Angle wrench head, etc.
I

NT014

EM03470000 Installing piston assembly into cylinder bore K

Piston ring compressor

NT044 M
KV11106010 Removing and installing chain tensioner
Hexagon wrench a: 5 mm (0.20 in) (Face to face)
b: 20 mm (0.79 in)
N

O
NT801

KV11106020 Removing and installing slack guide

Hexagon wrench a: 6 mm (0.24 in) (Face to face) P
b: 20 mm (0.79 in)

NT803

EM-147
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool number
Description
Tool name
KV11106030 Fixing fuel pump sprocket
Positioning stopper pin a: 6 mm (0.24 in) dia.
b: 80 mm (3.15 in)

NT804

KV11106040 Removing and installing fuel pump sprocket

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

NT805

KV11106050 Removing and installing fuel pump sprocket

Hexagonal wrench a: 6 mm (0.24 in) (Face to face)
b: 42 mm (1.65 in)

SBIA0224E

KV11106060 Holding fuel pump sprocket

Sprocket holder

SBIA0225E

Commercial Service Tool INFOID:0000000006109149

Tool name Description

Tube presser Pressing the tube of liquid gasket

NT052

Valve seat cutter set Finishing valve seat dimensions

NT048

EM-148
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool name Description
A
Piston ring expander Removing and installing piston ring

EM

C
NT030

Valve guide reamer Reaming valve guide with (1) or hole for over-
size valve guide with (2)
Intake and Exhaust: D
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia.
E

NT016

Valve guide drift Removing and installing valve guide F

Intake and Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.
G

NT015
H
TORX socket Loosening and tightening fuel pump mounting
bolt
Size: E10
I

J
NT807

TORX socket Loosening and tightening flywheel mounting

bolt K
Size: T55

PBIC1113E

TORX socket Loosening and tightening drive plate mounting M

bolt
Size: E20
N

NT807
O
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with angle wrench [SST:
KV10112100] P
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583

EM-149
 PREPARATION
< SERVICE INFORMATION > [YD]
Tool name Description
TORX socket Loosening and tightening main bearing cap
bolt
Size: E14

NT807

Pully holder Crankshaft pulley removing and instalingl

ZZA1010D

EM-150
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [YD]
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
A
NVH Troubleshooting - Engine Noise INFOID:0000000007042363

EM

E1BIA0268GB O

Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000007042364
P
1. Locate the area where noise occurs.
2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.

EM-151
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SERVICE INFORMATION > [YD]

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-206
gine clicking noise
Rocker
cover Camshaft
Camshaft oil clearance EM-271
Cylinder Rattle C A — A B C bearing
Camshaft runout EM-206
head noise

Piston to piston pin

Slap or Piston pin clearance EM-237
— A — B B —
knock noise Connecting rod bushing EM-271
oil clearance
Piston to cylinder bore
Crank- clearance
shaft pul- Piston ring side clear-
Slap or Piston EM-237
ley A — — B B A ance
rap slap noise EM-271
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-265
Knock A B C B B B
bearing Connecting rod bearing EM-271
noise oil clearance (Big end)
Main bearing oil clear-
Main bear- EM-265
Knock A B — A B C ance
ing noise EM-271
Crankshaft runout
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-230
Timing ticking Timing chain tensioner
sioner
chain case operation
noise
Drive belts
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belts deflection
or slip-
ing EM-271
ping)
Front of
Drive belts Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-51
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

EM-152
 DRIVE BELTS
< SERVICE INFORMATION > [YD]
DRIVE BELTS
A
Checking Drive Belts INFOID:0000000007042365

EM

E1BIA0262ZZ
E
1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
A/C compressor (Models with A/C)
4. Crankshaft pulley 5. 6. Alternator F
Dummy pulley (Models without A/C)
7. Idler pulley 8. Fan pulley 9. Automatic tensioner
10. Drive belt
G
• Before inspecting engine, check engine has cooled down, wait approximately 30 minutes after engine has
been stopped.
• Visually inspect all belts for wear, damage or cracks on contacting surfaces and edge areas.
• Measure deflection at the marked point ( ). H
CAUTION:
• When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation I
in deflection between pulleys.
• Tighten idler pulley lock nut by hand and measure deflection without looseness.
Belt Deflection: J
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
New Adjusted Limit for re-adjusting
K
Alternator and water pump belt or A/C
compresseor, alternator and water Automatic adjustment. Refer to EM-154, "Deflection Adjustment"
pump belt
4.6 - 5.4 7.1 - 7.7 L
Power steering oil pump belt 11.3 (0.445)
(0.181 - 0.213) (0.280 - 0.303)
*: When engine is cold.
M
Belt Frequency:

Belt frequency (Hertz)

Applied belt
New Adjusted Limit for re-adjusting N
Power steering oil pump belt 290±7 245±7 162
*: When engine is cold.
O

EM-153
 DRIVE BELTS
< SERVICE INFORMATION > [YD]
Deflection Adjustment INFOID:0000000007042366

E1BIA0352ZZ

1. Idler pulley 2. Power steering oil pump belt 3. Power steering oil pump
Dummy pulley (Models without A/C)
4. Crankshaft pulley 5. 6. Alternator
A/C compressor (Models with A/C)
7. Idler pulley 8. Water pump pulley 9. Automatic tensioner
10. A/C compressor, alternator and wa- A. Adjusting bolt B. Idler pulley lock nut
ter pump belt

• Adjust belts with the parts shown below.

Applied belt Belt adjustment method

Power steering oil pump belt Adjusting bolt on idler pulley (A)
Alternator and water pump belt or A/C compressor, alternator and
Automatic adjustment
water pump belt
CAUTION:
• When a new belt is installed as a replacement, adjust it to the specified value under “New” value
because of insufficient adaptability with pulley grooves.
• If the belt deflection of the current belt is out of the “Limit for re-adjusting”, adjust to the
“Adjusted” value.
• When checking belt deflection immediately after installation, first adjust it to the specified value.
Then, after turning crankshaft two turns or more, re-adjust it to the specified value to avoid varia-
tion in deflection between pulleys.
• Check the belts are fully fitted into the pulley grooves during installation.
• Handle with care to avoid smearing the belts with engine oil or engine coolant.
• Never twist or bend the belts with strong force.
POWER STEERING OIL PUMP BELT
1. Remove engine undercover front. Refer to EI-12.
2. Loosen idler pulley lock nut (B).
3. Turn adjusting bolt (A) to adjust.
4. Tighten idler pulley lock nut (B).

Nut B:
: 28.0 N·m (2.9 kg-m, 21 ft-lb)

A/C COMPRESSOR, ALTERNATOR AND WATER PUMP BELT

EM-154
 DRIVE BELTS
< SERVICE INFORMATION > [YD]

EM

E1BIA0285ZZ

D
1. Water Pump 2. Automatic tensioner 3. Idler pulley
Dummy pulley (Models without A/C)
4. Alternator 5. Crankshaft pulley 6.
A/C compressor (Models with A/C)
E
A/C compressor, alternator and wa- Range when new drive belt is in-
7. Retaining pin 8. A.
ter pump belt stalled
B. Possible use range C. Indicator D. View
F
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(B). G
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (A) in the fig- H
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
I
CAUTION:
• Replace the drive belt that has been removed with a new one.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
J
REMOVAL
1. Insert a stopper pin (A) in diameter such as short-length screw-
driver into the hole of the retaining boss to fix drive belt auto-ten-
K
sioner pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed.
NOTE: L
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin.
M

JPBIA0661ZZ

N
2. Remove drive belt.
INSTALLATION
O
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each P
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.
4. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-154, "Deflection Adjustment".

EM-155
 DRIVE BELTS
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042367

REMOVAL
1. Loosen each belt. Refer to EM-154, "Deflection Adjustment".
2. Remove power steering oil pump belt. Refer to EM-154, "Deflection Adjustment".
3. Remove A/C compressor, alternator and water pump belt. Refer to EM-154, "Deflection Adjustment".
INSTALLATION
1. Install each belt on pulley in the reverse order of removal.
2. Adjust belt deflection. Refer to EM-154, "Deflection Adjustment".
3. Tighten nuts provided for adjustment to the specified torque.
4. Check again that each belt deflection is as specified.

EM-156
 AIR CLEANER AND AIR DUCT
< SERVICE INFORMATION > [YD]
AIR CLEANER AND AIR DUCT
A
Component INFOID:0000000007042368

EM

L
E1BIA0288GB

1. Clean side duct 2. Blow by 3. Mounting rubber M

4. Mass air flow sensor 5. O-ring 6. Air cleaner cover
7. Air cleaner filter 8. Air cleaner body 9. Air duct side
A. To rocker cover B. To turbocharger N
• Refer to GI-9, "Component" for symbol marks in the figure.
Removal and Installation INFOID:0000000007042369
O

REMOVAL
1. Remove mass air flow sensor harness clamp from air cleaner cover. P
2. Disconnect harness connector from mass air flow sensor.
3. Remove air cleaner cover and air cleaner filter.
• Add marks as necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
• Never shock mass air flow sensor.
• Never disassemble mass air flow sensor.

EM-157
 AIR CLEANER AND AIR DUCT
< SERVICE INFORMATION > [YD]
• Never touch mass air flow sensor.
5. Remove air duct with ventilation hose and vacuum hoses disconnected.
• Add marks as necessary for easier installation.
6. Remove air cleaner body and air duct side.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Align marks. Attach each joint. Screw clamps firmly.
- Install vacuum hose by referring to paint marks avoiding twisting.
- When an insert stopper is not provided with the pipe, insert the hose up to dimension A. When the pipe is
shorter than dimension A, insert hose fully until it reaches the end.

Dimension A : 15 - 20 mm (0.59 - 0.79 in)

- When an insert stopper is provided on the pipe side, insert the hose until it reaches the stopper.
CHANGING AIR CLEANER FILTER
Removal
1. Remove mass air flow sensor harness clamp from air cleaner cover.
2. Disconnect harness connector from mass air flow sensor.
3. Unfasten clips and lift up air cleaner cover.
4. Remove air cleaner filter.
Installation
Installation is the reverse order of removal.

EM-158
 EGR SYSTEM
< SERVICE INFORMATION > [YD]
EGR SYSTEM
A
Exploded View INFOID:0000000007042370

EM

E1BIA0286GB

P
1. EGR cooler 2. Heat plate 3. Bolt
4. Bolt 5. Gasket 6. Stud
7. Nut 8. Cover 9. EGR guide tube
10. Washer 11. Nut 12. Bolt
13. Gasket 14. Bolt 15. EGR tube
16. Gasket 17. Nut 18. Gasket
19. Gasket 20. Egr control valve 21. Gasket

EM-159
 EGR SYSTEM
< SERVICE INFORMATION > [YD]
22. Bolt 23. Bolt
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000007042371

REMOVAL
1. Drain engine coolant. Refer to CO-38, "Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
2. Remove battery. Refer to SC-11, "Removal and Installation".
3. Remove Air duct. Refer to EM-157, "Component".
4. Disconnect water hoses from EGR cooler tube.
5. Remove EGR tube (front) and EGR volume control valve assembly.
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Never disassemble EGR volume control valve.
• Cover engine openings to avoid entry of foreign materials.
6. Remove Exhaust pressure sensor tube and bracket. Refer to EM-167, "Component".
7. Remove Turbocharger heat cover. Refer to EM-167, "Component".
8. Disconnect and put aside the vaccum hose.
9. Remove EGR guide tube. Refer to EM-159, "Exploded View".
10. Remove EGR cooler. Refer to EM-159, "Exploded View"
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Clean each joint surface before installation.
EGR Volume Control Valve
Perform “EGR Volume Control Valve Closed Position Learning Value Clear” and “EGR Volume Control Valve
Closed Position Learning” after repair when removing or replacing EGR volume control valve. Refer to EC-
1044, "Description" .

EM-160
 CHARGE AIR COOLER
< SERVICE INFORMATION > [YD]
CHARGE AIR COOLER
A
Component INFOID:0000000007042372

EM

I
E1BIA0273GB

1. Turbocharger boost sensor 2. Grommet 3. Vacuum hose J

4. Air inlet hose 5. Charge air cooler 6. Mounting rubber
7. Bracket 8. Bracket 9. Air inlet hose
10. Bracket 11. Air inlet tube 12. Air inlet hose K
13. Bracket 14. Air inlet tube 15. Air inlet hose
Turbocharger boost control solenoid
16. Turbocharger 18. 18. Bracket
valve L
19. Bracket A. To throttle chamber

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

M
Removal and Installation INFOID:0000000007042373

REMOVAL N
1. Remove front grille. Refer to EI-16.
2. Disconnect harness connector from turbocharger boost sensor.
3. Remove turbocharger boost control solenoid valve. O
4. Remove air inlet tube and air inlet hose.
• Add marks as necessary for easier installation.
5. Remove charge air cooler. P
6. Remove turbocharger boost sensor if necessary.
CAUTION:
When removing charge air cooler, close opening on turbocharger and on intake manifold with shop
cloth or other suitable material.
INSPECTION AFTER REMOVAL

EM-161
 CHARGE AIR COOLER
< SERVICE INFORMATION > [YD]
Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Be careful not to deform core fins.
• For cleaning procedure of charge air cooler core, refer to EI-16, "Removal and Installation".
INSTALLATION
Note the following, and install in the reverse order of removal.
• Pay attention to identification mark color and direction when installing air inlet hose.
• Align marks. Attach each joint. Screw clamps firmly.

EM-162
 INTAKE MANIFOLD
< SERVICE INFORMATION > [YD]
INTAKE MANIFOLD
A
Component INFOID:0000000007042374

EM

E1BIA0353GB

P
1. Cylinder head 2. Gasket 3. Intake manifold
4. Gasket 5. Collector intake manifold 6. Air intake temperature sensor
7. Gasket 8. Electric throttle control actuator 9. Gasket
10. Bracket 11. Bracket 12. EGR tube

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

EM-163
 INTAKE MANIFOLD
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042375

REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove engine cover (1).
CAUTION:
Be careful not to damage engine cover surface.

PBIC3409E

2. Disconnect air inlet hose from throttle chamber. Refer to EM-161.

3. Remove fuel filter. Refer to FL-16.
4. Remove oil level gauge guide. Refer to EM-173.
5. Remove fuel hoses and fuel gallery. Refer to EM-186, "Component".
• To prevent fuel from flowing out, plug the opening of the hose with plug after disconnection.
CAUTION:
Be careful not to spill fuel in the engine component.
• Add marks as necessary for easier installation.
6. Remove vacuum hoses.
• Add marks as necessary for easier installation.
7. Disconnect heater feed hose, water hoses, and remove heater feed pipe.
8. Remove intake manifold bracket, and put aside wire.
9. Remove EGR tube.
10. Remove injection tube center. Refer to EM-182, "Removal and Installation".
CAUTION:
Be careful not to spill fuel in the engine component.
11. Disconnect air intake temperature sensor.
12. Remove collector intake manifold.
13. Loosen bolts and nuts in the reverse order of that shown in the figure, and remove intake manifold.
CAUTION:
Cover engine openings to avoid entry of foreign materials.

E1BIA0282ZZ

14. Remove throttle chamber from intake manifold.

INSPECTION AFTER REMOVAL
Surface Distortion

EM-164
 INTAKE MANIFOLD
< SERVICE INFORMATION > [YD]
• Check distortion on the mounting surface with a straightedge and
feeler gauge. A

Limit : 0.1 mm (0.004 in)

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

PBIC3411E

D
INSTALLATION
Note the following, and install in the reverse order of removal.
1. Install intake manifold.
E
• Tighten fixing bolts and nuts in numerical order as shown in
the figure.
• If stud bolts were removed, tighten them to the specified
torque. F

: 10.8 N·m (1.1 kg-m, 8 ft-lb)

G

H
E1BIA0282ZZ

2. Before starting engine, bleed air from fuel piping. Refer to FL-17, "Air Bleeding".
I
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak.
CAUTION:
J
Never touch the engine immediately after stopped as engine becomes extremely hot.
NOTE:
Use mirrors for checking at points out of clear sight.
K

EM-165
 CATALYST
< SERVICE INFORMATION > [YD]
CATALYST
Component INFOID:0000000007042376

E1BIA0276GB

1. Catalyst 2. Bracket 3. Bracket

4. Catalyst cover (upper) 5. Catalyst cover (lower) 6. Catalyst cover (lower
7. Gasket

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

Removal and Installation INFOID:0000000007042377

REMOVAL
1. Remove engine undercover.
2. Remove catalyst cover.
3. Remove exhaust front tube. Refer to EX-6, "Checking Exhaust System".
4. Remove air inlet hose and air inlet tube. Refer to EM-157, "Component".
5. Remove catalyst and exhaust outlet.
INSTALLATION
Note the following, and install in the reverse order of removal.
• If stud bolts of turbocharger were removed, tighten them to the specified torque.

: 25.5 N·m (2.6 kg-m, 19 ft-lb)

• If stud bolts of catalyst were removed, tighten them to the specified torque.

: 45.0 N·m (4.6 kg-m, 33 ft-lb)

• Pushing bracket against the cylinder block and the catalyst, temporarily tighten the mounting bolt. And then
tighten it to the specified torque.

EM-166
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
TURBO CHARGER
A
Component INFOID:0000000007042378

EM

L
E1BIA0284GB

1. Turbocharger 2. Exhaust manifold 3. Nut M

4. Gasket 5. Stud 6. Stud
7. Heat insulator 8. Clip 9. Turbocharger pressure sensor
10. Clamp 11. Hose 12. Bracket N
13. Bolt 14. Tube 15. Bolt
16. Gasket 17. Oil pipe 18. Eye-bolt
19. Gasket 20. Clamp 21. Oil connector O
22. Gasket 23. Clamp 24. Clamp
25. Clamp 26. Water pipe return 27. Clamp
28. Water hose feed 29. Clamp 30. Gasket P
31. Water pipe feed 32. Gasket 33. Nut
34. Catalyst
A. To air inlet hose B. To cylinder block C. To cylinder block
D. To Water outlet E. To water pipe

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

EM-167
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042379

REMOVAL
• After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and then
loosen the nuts to remove.
1. Drain engine coolant. Refer to CO-38, "Changing Engine Coolant"
2. Remove air inlet hose and air inlet pipe. Refer to EM-161.
3. Remove air duct and air inlet pipes. Refer to EM-157, "Removal and Installation".
4. Remove exhaust manifold cover. Refer to EM-171, "Removal and Installation".
5. Remove catalyst. Refer to EM-166, "Removal and Installation".
6. Remove eye bolts and water hose from water tube and oil feed tube and oil return tube.
7. Disconnect connector from turbocharger.
8. Remove turbocharger with water tube and oil feed tube and oil return tube.
CAUTION:
• Be careful not to deform water tube and oil-feed-and-return tube.
• Never disassemble or adjust the turbocharger.
• Be careful not to contact with the vehicle.
• Never hold turbocharger boost control actuator and actuator rod.
9. Remove water tube and oil feed tube and oil return tube from turbocharger.
10. Remove turbocharger.
CAUTION:
• Never disassemble or adjust the turbocharger.
• Never hold turbocharger boost control actuator and actuator rod.
Oil Tube and Water Tube
• Clean inside of oil feed tube and oil return tube and water tube, and check tubes for clogging.
• Replace oil feed tube and oil return tube and/or water tube if clogging still exists after cleaning.
INSPECTION AFTER REMOVAL

E1BIA0289ZZ

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

A. Check for charge air pressure leaks B. Check for exhaust gas leaks C. Check for engine coolant leaks
D. Check for engine oil leaks

CAUTION:
When the compressor wheel turbine, wheel or rotor shaft is damaged, remove all the fragments and
foreign matter left in the following passages in order to prevent a secondary malfunction:

Suction side : Between turbocharger and charge air cooler

Exhaust side : Between turbocharger and catalyst
Rotor Shaft Clearance
EM-168
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
• Check that the rotor shaft (1) rotates smoothly without any resis-
tance when it is rotated by your fingertips. A
• Check that the rotor shaft is not loose when it is moved vertically or
horizontally.
• Measure looseness with a dial gauge inserting its measuring rod
EM
through oil drain hole of turbocharger.

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

C
• Replace turbocharger if out of standard.

E1BIA0290ZZ

D
Rotor Shaft End Play
• Place a dial gauge (A) at the rotor shaft (1) end in the axial direc-
tion to measure the end play.
E
Standard : 0.030 - 0.111 mm (0.0012 - 0.0044 in)
• Replace turbocharger if out of standard.
F

G
E1BIA0292ZZ

Turbine Wheel H
• Check that there is no engine oil adhesion.
• Check that there is no carbon accumulation.
• Check that blades of turbine wheel (1) are not bent or broken.
• Check that turbine wheel does not interfere with turbine housing I
(2).

K
E1BIA0291ZZ

Compressor Wheel
• Check that there is no engine oil adhesion inside the air inlet. L
• Check that compressor wheel (1) does not interfere with compres-
sor housing (2).
• Check that compressor wheel is not bent or broken.
M

E1BIA0293ZZ O
Turbocharger Boost Control Actuator :
Inspect turbocharger boost control actuator. Refer to EC-924, "Turbocharger Boost Control Actuator"
P
TROUBLE DIAGNOSIS OF TURBOCHARGER
Preliminary check:
• Check that the engine oil level is between MIN and MAX of the oil level gauge. (When engine oil amount is
more than MAX, engine oil flows into the inlet duct through blow-by gas passage, and turbocharger is mis-
judged malfunction.)
• Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.

EM-169
 TURBO CHARGER
< SERVICE INFORMATION > [YD]
• Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no malfunction.
Check the other parts again.

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

INSTALLATION
• When a stud bolt is pulled out, replace it with a new one and tighten it to the following torque.

: 25.5 N·m (2.6 kg-m, 19 ft-lb)

EM-170
 EXHAUST MANIFOLD
< SERVICE INFORMATION > [YD]
EXHAUST MANIFOLD
A
Component INFOID:0000000007042380

EM

I
E1BIA0271GB

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

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

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

Removal and Installation INFOID:0000000007042381 M

REMOVAL
1. Drain engine coolant. Refer to CO-38, "Changing Engine Coolant". N
2. Remove exhaust manifold cover.
3. Remove turbocharger. Refer to EM-167, "Component".
O
4. Remove EGR cooler. Refer to EM-159, "Exploded View".

EM-171
 EXHAUST MANIFOLD
< SERVICE INFORMATION > [YD]
5. Loosen exhaust manifold mounting nuts in the reverse order in
the figure.

: Vehicle front

E1BIA0272ZZ

6. Remove exhaust temperature sensor.

7. Remove exhaust manifold.
INSPECTION AFTER REMOVAL
Surface Distortion
• Use a reliable straight edge and feeler gauge to check the flatness
of exhaust manifold fitting surface.

Limit : 0.3 mm (0.012 in)

• If it exceeds the limit, replace exhaust manifold.

PBIC2210E

INSTALLATION
• If stud bolts were removed, replace them with new ones, and tighten them to the specified torque:

: 14.7 N·m (1.5 kg-m, 11 ft-lb)

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

: Vehicle front

3. Re-tighten the nuts 1 to 8.

4. Install in the reverse order of removal.

E1BIA0272ZZ

INSPECTION AFTER INSTALLATION

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

EM-172
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
OIL PAN AND OIL STRAINER
A
Component INFOID:0000000007042382

EM

J
PBIC3424E

1. Oil level gauge 2. Oil level gauge guide 3. Oil level sensor K
4. O-ring 5. O-ring 6. O-ring
7. Oil pan upper 8. Crankshaft position sensor 9. O-ring
10. Rear plate 11. Rear plate cover 12. Oil strainer L
13. Oil pan drain plug 14. Drain plug washer 15. Oil pan lower

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

Removal and Installation INFOID:0000000007042383

REMOVAL N
WARNING:
To avoid the danger of being scalded, never drain engine oil when engine is hot.
1. Remove engine undercover front and engine undercover middle. Refer to EI-12, "Removal and Installa- O
tion"
2. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
P

EM-173
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
3. Remove oil pan lower bolts. Loosen bolts in the reverse order of
that shown in the figure.

: Vehicle front

PBIC3425E

4. Remove oil pan lower.

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

SEM365EA

5. Remove oil strainer.

6. Remove radiator lower shroud. Refer to CO-41, "Component"
7. Remove power steering oil pump belt. Refer to EM-153.
8. Remove power steering oil pump bracket and move power steering oil pump aside with its piping con-
nected. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to PS-24.
9. Disconnect oil return hose (vacuum pump) from oil pan upper. Refer to EM-179.
10. Remove the oil level gauge guide. Refer to EM-248, "Component"

11. Remove A/C compressor bracket mounting bolts (A).

1 : Oil pan upper

2 : A/C compressor bracket
: Vehicle front

PBIC3426E

12. Remove the drive belt. Refer to EM-156, "Removal and Installation"
13. Remove the crankshaft pulley. Refer to EM-219, "Component".
14. Remove the front cross member. Refer to MT-19, "Removal and Installation from Vehicle" (M/T models),
Refer to AT-259, "Removal and Installation (YD25DDTi Models)" (A/T models).
15. Remove the oil level sensor.
CAUTION:
• Avoid impacts such as a dropping.
• Never disassemble.
• Keep it away from metal particles.
• Never place sensor close to magnetic materials.
16. Remove front propeller shaft. Refer to PR-3.

EM-174
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
17. Remove RH and LH front drive shaft. Refer to FAX-7.
18. Remove front final drive assembly. Refer to FFD-16. A
19. Remove rear plate cover and transmission joint bolts.
20. Loosen bolts in the reverse order of illustration to remove oil pan
upper. EM

: Vehicle front
C

PBIC3431E
E
21. Remove oil pan upper.
• Insert the seal cutter (SST) between oil pan upper and cylinder
block. Slide the seal cutter by tapping on the side of the seal F
cutter with a hammer. Remove oil pan upper.
CAUTION:
• Be careful not to damage aluminum mating surface.
G
• Never insert screwdriver, or oil pan flange will be
deformed.

SEM365EA

I
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
J
INSTALLATION
Note the following, and install in the reverse order of removal.
• Install oil pan upper with the following procedure.
- Use the scraper (A) to remove old liquid gasket from mating sur- K
face of oil pan upper (1).
CAUTION:
• Also remove old liquid gasket from mating surface of cylin- L
der block and rear chain case.
• Remove old liquid gasket from the bolt hole and thread.
M

PBIC3432E
N

- Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) to areas shown in the figure. O

: Vehicle front
P
Use Genuine Liquid Gasket or equivalent.
CAUTION:
• At the 2 bolt holes marked , liquid gasket should be
applied outside holes.
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in) or
4.5 to 5.5 mm (0.177 to 0.217 in) wide. (Be careful that the
PBIC3433E
diameter of the liquid gasket bead is different around the
front.)
EM-175
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
• Attaching should be done within 5 minutes after coating.
- Install oil pan upper.
CAUTION:
Install avoiding misalignment of O-ring.
• Tighten bolts in numerical order to the specified torque.

: Vehicle front

• Bolt dimensions vary depending on the installation location. Refer

to the following and use appropriate bolts.

M6 x 30 mm (1.18 in) : Bolt No. 15, 16

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

PBIC3430E

- Apply a continuous bead of liquid gasket with the tube presser

(commercial service tool) as shown in the figure.

: Vehicle front

Use Genuine Liquid Gasket or equivalent.

CAUTION:
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
wide.
• Attaching should be done within 5 minutes after coating.
PBIC3434E

SEM159F

- Install oil pan lower.

EM-176
 OIL PAN AND OIL STRAINER
< SERVICE INFORMATION > [YD]
• Tighten bolts in numerical order to the specified torque.
A
: Vehicle front

NOTE:
Pour engine oil or start engine at least 30 minutes after oil pan is EM
installed.

PBIC3425E

D
INSPECTION AFTER INSTALLATION
1. Check engine oil level and add engine oil. Refer to LU-19.
2. Check for leakage of engine oil when engine is warmed. E
3. Stop engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-19.
F

EM-177
 GLOW PLUG
< SERVICE INFORMATION > [YD]
GLOW PLUG
Component INFOID:0000000007042384

JPBIA3689GB

1. Glow plug
: Engine front
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000007042385

REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken.
1. Remove extension cowl top. Refer to EI-18, "Removal and Installation".
2. Remove engine cover.
3. Disconnect air inlet hose from electric throttle control actuator.
4. Disconnect glow plug connector.
5. Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from
height of 10 cm (3.94 in) or higher, always replace it.]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Install remaining parts in the reverse order of removal.

EM-178
 VACUUM PUMP
< SERVICE INFORMATION > [YD]
VACUUM PUMP
A
Component INFOID:0000000007042386

EM

I
PBIC3435E

1. O-ring 2. Vacuum pump 3. Bracket J

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

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

Removal and Installation INFOID:0000000007042387 L

INSPECTION BEFORE REMOVAL

1. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector. M
• Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connec-
tor.
2. Start engine and measure generated vacuum at idle speed. N

Standard:
–94.0 to –96.1 kPa (–940 to –961 mbar, –705 to –721 mmHg, –27.76 to –28.38 inHg) O
• If out of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump.
P
REMOVAL
1. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
2. Remove primary timing chain. Refer to EM-220, "Removal and Installation".
3. Disconnect vacuum hose from vacuum pump side.
4. Remove oil feed tube and oil return hose.
5. Remove bracket.

EM-179
 VACUUM PUMP
< SERVICE INFORMATION > [YD]
6. Remove vacuum pump and O-ring.
INSTALLATION
Note the following, and install in the reverse order of removal.
Bracket
Tighten fixing bolts in numerical order as shown in the figure.

: Cylinder block side

PBIC4907E

EM-180
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
INJECTION TUBE AND FUEL INJECTOR
A
Exploded View INFOID:0000000007042388

EM

L
JPBIA3691GB

1. Nozzle oil seal 2. Injection tube No. 1 - 4 3. Protector M

4. Cooper washer 5. Eye-bolt 6. Spill tube
7. Gasket 8. Fuel rail 9. Connector tube
10. Gasket 11. Clamp 12. Return hose N
13. Injection tube 14. Clip 15. Spill hose
16. Clamp 17. Spill tube retaining bolt 18. Clamp
19. Fuel feed hose 20. Fuel pump 21. Clamp O
22. Spill hose 23. Fuel gallery 24. Clamp
25. Air bleed hose 26. Air bleed tube 27. Quick connector
28. Nozzle gasket 29. O-ring 30. Nozzle support P
31. Fuel injector 32. Rocker cover
A. To fuel filter
: Engine front
Refer to GI-9, "Component" for symbols in the figure.

EM-181
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042389

REMOVAL
1. Remove engine cover
2. Remove injection tube. Refer to EM-181, "Exploded View".
CAUTION:
Be careful not to spill fuel in the engine component.
3. Disconnect harness connector from fuel injector.
4. Remove spill hose.
5. Following steps below, remove injection tubes.
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method.
b. Remove injection tubes in order of 3-2-1-4 individually.
CAUTION:
Be careful not to allow leaked fuel to contaminate engine
room. Especially, ensure to keep engine mounting insulator
clear of fuel.

: Engine front

JPBIA3753ZZ

6. Remove nozzle oil seal.

• Using the flat-bladed screwdriver, pry flange to remove oil
seal.
NOTE:
Nozzle oil seal seals between fuel injector and rocker cover. If
only injection tube shall be removed and installed, nozzle oil
seal replacement is not required.

PBIC0944E

7. Remove rocker cover. Refer to EM-196, "Component".

EM-182
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
8. Remove spill tube mounting bolts and nut.
• Loosen bolts and nut to the reverse order in the figure and A
remove them.
CAUTION:
When loosening nut, fix spill tube retaining bolt with span-
EM
ner.

B : Gasket position
C : Spill tube retaining bolt C
: Engine front

G
JPBIA3889ZZ

9. Remove fuel injector as follows.

H
1 : Fuel injector
2 : O-ring
3 : Nozzle gasket I
4 : Nozzle support
a. Remove nozzle support.
b. Remove fuel injector. While rotating it to left and right, raise it to J
remove.
CAUTION: PBIC4852E
• Handle fuel injector carefully without giving any impact. K
• Never disassemble fuel injector.
c. If nozzle gasket remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
d. Remove O-ring from fuel injector. L
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface when replacing fuel injector.
• Refer to EC-1040, "Description" . M

JPBIA3754ZZ
P
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6
2. Following steps below, install fuel injector.
a. Install O-ring and nozzle gasket to fuel injector, and insert them into cylinder head.
b. Tighten injection tubes temporarily in the order of 1-2-3-4.
c. Be sure to fit nozzle support and pin without looseness.
d. Tighten nozzle support bolts.

EM-183
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
e. Loosen injection tubes in the order of 3-2-1-4.
3. Connect spill tube.
• Tighten fixing bolts and nut in numerical order shown in the fig-
ure.
CAUTION:
When tightening nut, fix spill tube retaining bolt with
spanner.
NOTE:
Connection of spill tube gasket may be broken, even if it is
tighten to the specified torque. It does not affect performance.

B : Gasket position
C : Spill tube retaining bolt
: Engine front

JPBIA3889ZZ

4. Perform air tightness test for spill tube.

• Connect a handy vacuum pump to spill connector. Check that
vacuum is retained while applying following vacuum.

Standard:
–53.3 to –66.7 kPa (–533 to –667 mbar, –400 to –
500 mmHg, –15.75 to –19.69 inHg)
• If outside of standard, reconnect spill tube. (Replace gasket in
this case.)
5. Install rocker cover. Refer to EM-196, "Removal and Installa- JEF250Z
tion".
6. Install nozzle oil seal.
• Apply engine oil to the rocker cover nozzle oil seal contact surface and the nozzle oil seal fuel injector
contact surface before installation.
• Insert it straight until its flange fully contacts rocker cover.
CAUTION:
• Check gutter spring in nozzle oil seal on fuel injector for missing.
7. Connect injection tubes individually to each cylinder in order of
1-2-3-4.

: Engine front

JPBIA3753ZZ

8. Install in the reverse order of removal after this step.

EM-184
 INJECTION TUBE AND FUEL INJECTOR
< SERVICE INFORMATION > [YD]
Inspection INFOID:0000000007042390

A
INSPECTION AFTER INSTALLATION
• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing to the vehicle when replacing fuel injector.
Refer to EC-1040, "Description". EM

JPBIA3754ZZ E
Example: Injector Adjustment value = D021ABCD1A061234000000000000E6
• Start engine and increase engine speed to check for fuel leak.
CAUTION:
Never touch engine immediately after stopped as engine becomes extremely hot. F

EM-185
 FUEL PUMP
< SERVICE INFORMATION > [YD]
FUEL PUMP
Component INFOID:0000000007042395

E1BIA0274GB

1. Washer 2. Fuel pump sprocket 3. Seal washer

4. O-ring 5. Adjusting shim 6. Sprocket nut
7. Coupling 8. Oil seal 9. Spacer
10. Key 11. Fuel pump 12. Fuel pump bracket
13. Fuel pump bracket
: Engine front

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

Removal and Installation INFOID:0000000007042396

CAUTION:
• Before removing and installing fuel pump, be sure to remove sprocket. Never loosen or remove
installation nut in the center of fuel pump. If loosened or removed, replace fuel pump.
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis-
ton heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil.
• When fuel pump is replaced with new one or another one, perform fuel pump learning value clearing
before starting engine. Refer to EC-1043, "Description" .
REMOVAL
1. Remove engine cover, vacuum gallery and heater feed pipe. Refer to EM-163, "Component" .
2. Remove fuel hose and spill hose from fuel pump. Refer to EM-193, "Component".
CAUTION:
Be careful not to spill fuel in the engine component.
3. Disconnect harness connectors from fuel pump.
4. Remove injection tube center, clip and insert rubber. Refer to EM-182, "Removal and Installation".

EM-186
 FUEL PUMP
< SERVICE INFORMATION > [YD]
CAUTION:
Be careful not to spill fuel in the engine component. A

5. Remove secondary timing chain. Refer to EM-213, "Component".

6. Hold fuel pump sprocket and remove bolt. EM
a. Insert the positioning stopper pin (SST) into the hole 6 mm (0.24
in) in the diameter on the fuel pump sprocket.
b. Using the TORX wrench (SST), turn pump shaft little by little to C
adjust the position of fuel pump sprocket so that the holes align.
c. Push the positioning stopper pin (SST) through fuel pump
sprocket to fuel pump body to hold fuel pump sprocket. D

MBIA0049E E

• Insert the positioning stopper pin until its flange contacts the fuel
pump sprocket.
F

PBIC2535E

I
7. Using the hexagon wrench (SST) remove tightening bolts of fuel
pump sprocket.
J

L
PBIC2404E

MBIA0074E P

EM-187
 FUEL PUMP
< SERVICE INFORMATION > [YD]
8. Using the sprocket holder (SST), hold fuel pump sprocket to pre-
vent falling.
• Rework sprocket holder (SST) to use, as shown in the figure.

SBIA0217E

• When the sprocket holder is installed, if the positioning stopper

pin (SST) interferes, pull out the positioning stopper pin
approximately 10 mm (0.39 in), then install it.
• After the sprocket holder is installed temporarily, tighten the
sprocket holder after making extension bar and TORX socket
(size: E10) (commercial service tool) insert into the machined
bore.
• The length of the sprocket holder mounting bolts should be
approximately 15 mm (0.59 in) (M6 thread length).
• Check that the a- and b-faces of the sprocket holder contact
the bottom side of the sprocket (small diameter side).
PBIC2534E
CAUTION:
Never remove the sprocket holder (SST) until fuel pump is installed.
• After the sprocket holder is installed, pull out the positioning
stopper pin from fuel pump sprocket.

MBIA0075E

9. Using the extension bar and the TORX socket (size: E10) (com-
mercial service tool), remove the tightening bolts.
CAUTION:
Never disassemble or adjust fuel pump.

PBIC2405E

10. Remove the fuel pump toward the rear of engine.

CAUTION:
For removal, be careful not to drop the seal washer into the engine.
NOTE:
The seal washer of the tightening bolts cannot be reused.
11. Remove adjusting shim.
12. Attach a suitable tool in the M8 bolt hole on coupling.

EM-188
 FUEL PUMP
< SERVICE INFORMATION > [YD]
13. Loosen sprocket nut with the TORX wrench (SST).
A

EM

MBIA0013E

D
14. Remove coupling with a suitable puller.

G
MBIA0014E

15. Remove spacer from fuel pump. H

16. Remove oil seal from spacer.
INSPECTION AFTER REMOVAL
I
Timing Chain
Check for cracks and excessive wear at roller links. Replace
timing chain if necessary.
J

SEM984C

INSTALLATION M
1. Install new oil seal to spacer.

P
MBIA0045E

2. Install spacer to fuel pump.

EM-189
 FUEL PUMP
< SERVICE INFORMATION > [YD]
3. Install coupling to fuel pump of spacer.
• Using the TORX wrench (SST), tighten the sprocket nut to fix
the coupling.

MBIA0013E

4. Install adjusting shim.

• For shim adjustment, measure dimension L [Distance between
front surface of coupling and the fuel pump flange (spacer)] at
two opposing points near the coupling bolt center. Use the
average of these two measurements to select the shim grade
that marked on adjusting shim.

MBIA0077E

• The shim adjustment is required only when the fuel pump is

replaced.

PBIC3439E

Part No. of adjusting shim Grade number Measuring dimension L mm (in) Type
16614 8H800 0.5 t 39.23 - 39.77 (1.5445 - 1.5657) A
16614 8H810 1.0 t 38.76 - 39.23 (1.5260 - 1.5445) B
16614 8H860 1.2 t 38.57 - 38.76 (1.5185 - 1.5260) C
16614 8H820 1.6 t 38.18 - 38.57 (1.5031 - 1.5185) D
16614 8H800 + 16614 8H860 0.5 t + 1.2 t 38.09 - 38.18 (1.4996 - 1.5031) A+C
16614 8H810 + 16614 8H810 1.0 t + 1.0 t 37.80 - 38.09 (1.4882 - 1.4996) B+B
16614 8H860 + 16614 8H810 1.2 t + 1.0 t 37.60 - 37.80 (1.4803 - 1.4882) C+B
16614 8H820 + 16614 8H810 1.6 t + 1.0 t 37.21 - 37.60 (1.4650 - 1.4803) D+B

EM-190
 FUEL PUMP
< SERVICE INFORMATION > [YD]
5. Before fuel pump is installed, check that spacer and the 6 mm
(0.24 in) dia. hole on coupling are aligned. A

EM

MBIA0016E

D
6. Insert fuel pump to the mounting position from the rear side of
the engine, and install the tightening bolts with seal washer.
CAUTION:
E
Be careful not to drop the seal washer into engine.

G
PBIC2438E

7. Using the extension bar and the TORX socket (size: E10) (com-
H
mercial service tool), tighten the tightening bolts of fuel pump.
8. Remove the sprocket holder (SST).
I

PBIC2405E
K
9. Using the TORX wrench (SST), turn the pump shaft gradually to
adjust the position of fuel pump sprocket. Then, insert the posi-
tioning stopper pin (SST) to the 6 mm (0.24 in) dia. hole of the L
fuel pump sprocket through the pump body.
10. Remove the TORX wrench (SST).
M

N
MBIA0049E

11. Using the hexagon wrench (SST), tighten the sprocket tighten- O
ing bolt.
• When the washer of the fuel pump sprocket is removed, install
it with the marking “F” (front) facing the front of the engine. P
12. Pull out the positioning stopper pin (SST).

PBIC2404E

EM-191
 FUEL PUMP
< SERVICE INFORMATION > [YD]
13. Install secondary timing chain. Refer to EM-213, "Removal and Installation".
14. Following steps below, install injection tube center. Refer to EM-185, "Inspection".
a. Pre-set clip and insert rubber to injection tube center.
b. Pre-tight nut of injection tube center to fuel pump and fuel rail by hand. (until seal surface touched)
c. Adjust clip dimension and tight bolt for clip to intake manifold by tool.
d. Tight nut of injection tube center to fuel pump by tool.
e. Tight nut of injection tube center to fuel rail by tool.
15. Connect the harness connector to fuel pump.
16. Install fuel hoses. Refer to EM-181, "Exploded View".
17. Hereafter, install in the reverse order of removal.
CAUTION:
When fuel pump is replaced with new one or another one, perform fuel pump learning value clear-
ing before starting engine. Refer to EC-1043, "Description" .

EM-192
 FUEL PUMP SUCTION CONTROL VALVE
< SERVICE INFORMATION > [YD]
FUEL PUMP SUCTION CONTROL VALVE
A
Component INFOID:0000000007042393

EM

E1BIA0296GB

1. Suction control valve 2. Bolt 3. Small O-ring G

4. Gasket 5. O-ring

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

Removal and Installation INFOID:0000000007042394

REMOVAL I
1. Disconnect wiring harness from Fuel pump suction control valve.
J
1 : Fuel pump suction control valve

E1BIA0297ZZ
M
2. Take note of the connector's orientation. The new valve will have to be fitted in the same way as the old
one.
N
3. Clean the pump with brake cleaner around fuel pump suction control valve contact surface.
4. Remove fixating bolt of the suction valve and remove the suction valve.
NOTE:
O
• The large O-ring says inside. Do not pull the valve with twisting or try pying it out with any tool. Carefully pull
the valve straight up.
• Do not use work gloves to prevent foreign substances entering the fuel injection pump.
NOTE: P
The seal washer of the tightening bolts cannot be reused.
INSTALLATION
1. Remove large O-ring.

EM-193
 FUEL PUMP SUCTION CONTROL VALVE
< SERVICE INFORMATION > [YD]

1 : Large O-ring
NOTE:
• Do not use any tool to remove the O-ring.
• Do not allow any foreign substances to enter into the fuel
injection pump.

E1BIA0298ZZ

2. Ensure that the groove of the pump side housing is contamination free, then place the large new O-ring
into the groove.

1 : Large O-ring
NOTE:
• Apply clean engine oil around the small O-ring, then fit it to the
groove. Otherwise the O-ring may fall off.

E1BIA0299ZZ

3. Insert the new gasket.

4. Apply clean engine oil around the small O-ring on the new suction control valve for sealing.

1 : Small O-ring
NOTE:
• Make sure the suction control valve is clean and no debris
sticks to the O-Ring.Any contamination or damage to the O-
ring will cause the fuel injection pump not to work properly.

E1BIA0300ZZ

5. Insert the new suction control valve by hand until you feel a click. Make sure the connector faces into the
same direction as before removal.

NOTE:
• Do not try to twist the suction control valve in, just push it straight.

E1BIA0301ZZ

6. Tighten bolt by hand and then use the torque wrench. Refer to EM-193, "Component".
7. Connect the suction control valve to the wiring harness.

EM-194
 FUEL PUMP SUCTION CONTROL VALVE
< SERVICE INFORMATION > [YD]
8. Clean the suction control valve fitting area with a degreasing spray.
9. Bleed the air from fuel lines. Refer to FL-17, "Air Bleeding". A
10. Start engine and check there is no fuel leakage.

EM

EM-195
 ROCKER COVER
< SERVICE INFORMATION > [YD]
ROCKER COVER
Component INFOID:0000000007042397

E1BIA0358ZZ

1. Nozzle oil seal 2. Oil filler cap 3. Rocker cover

4. Gasket
A. Refer to EM-196, "Removal and Installation" B. To Intake air duct

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

Removal and Installation INFOID:0000000007042398

REMOVAL
1. Remove engine cover.
2. Remove vacuum gallery and engine cover bracket on rocker cover and ventilation hose.
3. Disconnect harness connector from fuel injector. Refer to EM-181, "Exploded View".
4. Following steps below, remove injection tube. Refer to EM-182, "Removal and Installation".
a. Put a paint mark or tag on injection tubes to identify each cylinder.
• Use a fuel-resistant method.
b. Remove injection tubes in order of 2-1-4-3 individually.

JPBIA3753ZZ

EM-196
 ROCKER COVER
< SERVICE INFORMATION > [YD]

CAUTION: A
Be careful not to allow leaked fuel to contaminate engine room. Especially, ensure to keep engine
mounting insulator clear of fuel.
5. Remove injection nozzle oil seal.
• Using the flat-bladed screwdriver, pry flange to remove nozzle EM
oil seal.

E
PBIC0944E

6. Remove rocker cover.

• Loosen holding bolts in the reverse order of that shown in the F
figure and remove.

: Engine front G

JPBIA3760ZZ I

7. Remove gasket from rocker cover.

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

1 : Cylinder head
2 : Cylinder head rear cover L
a : 10 mm (0.394 in)
b : φ 3.0 mm (0.118 in)
M
: Engine front

• Use Genuine Liquid Gasket or equivalent.

JPBIA3761ZZ
N
3. Tighten holding bolts.
• Tighten all bolts in numerical order as shown in the figure.
O
: Engine front

P
: 7.8 N·m (0.8 kg-m, 69 in-lb)
• Re-tighten to the same torque in the same order as above.

JPBIA3760ZZ

EM-197
 ROCKER COVER
< SERVICE INFORMATION > [YD]
4. Install nozzle oil seal.
• Insert it straight until flange fully contacts rocker cover.
5. Install remaining parts in the reverse order of removal.
6. Before starting engine, bleed air from fuel piping. Refer to FL-17, "Air Bleeding".
INSPECTION AFTER INSTALLATION
Start engine and increase engine speed to check for fuel leak and engine oil leak.
CAUTION:
Never touch the engine immediately after stopped as engine becomes extremely hot.

EM-198
 CAMSHAFT
< SERVICE INFORMATION > [YD]
CAMSHAFT
A
Component INFOID:0000000007042399

EM

J
JPBIA3695GB

1. Camshaft bracket 2. Intake camshaft 3. Exhaust camshaft K

4. Adjusting shim 5. Valve lifter 6. Knock pin
7. Camshaft sprocket 8. Cylinder head 9. O-ring
10. Camshaft position sensor 11. Bracket 12. Cylinder head rear cover L
13. Rubber washer 14. Signal plate
A. Comply with the installation proce-
dure when tightening. Refer to EM- M
199, "Removal and Installation"
Refer to GI-9, "Component" for symbols in the figure.
N
Removal and Installation INFOID:0000000007042400

REMOVAL
O
1. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
2. Remove the following parts:
• Collector (upper and lower). Refer toEM-157, "Component".
P
• Vacuum pump. Refer to EM-179, "Component".
• Fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
3. Remove cylinder head rear cover, camshaft position sensor and rubber washer.

EM-199
 CAMSHAFT
< SERVICE INFORMATION > [YD]
Loosen cylinder head rear cover mounting bolts in the reverse
order shown in the figure.

JPBIA3893ZZ

4. Remove camshaft sprockets and signal plate.

• Loosen the camshaft sprocket mounting bolts and signal plate
mounting bolt by fixing the hexagonal portion of camshaft.

JEM159G

5. Remove camshaft.
• Place distinguishing marks on the right and left sides with paint.
• Loosen and remove the camshaft sprocket bolts in the reverse
order shown in the figure.

: Engine front

JPBIA3771ZZ

6. Remove adjusting shim and valve lifter.

• Remove by taking notice of the installation position, and place outside engine in order to prevent confu-
sion.
INSPECTION AFTER REMOVAL
Visual Check of Camshaft
• Check the camshaft for one sided wear or scratches.
• Replace the camshaft if there are abnormalities.
Camshaft Runout
• Prepare V-block on a flat surface and secure camshaft journals No.
2 and No. 5.
• Set the dial gauge (A) vertically on journal No. 3.
• Rotate camshaft in one direction by hand, then read needle move-
ment on dial gauge. (Total indicator reading)

Limit : Refer to EM-271, "Standard and Limit".

• If it exceeds the limit, replace camshaft.

JPBIA3895ZZ

EM-200
 CAMSHAFT
< SERVICE INFORMATION > [YD]
Height of Cam Nose
• Measure the height of cam nose using the micrometer. A

Standard : Refer to EM-271, "Standard

and Limit". EM
• If out of the standard, replace camshaft.

SEM549A D
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL OUTER DIAMETER E

• Measure outer diameter of camshaft journal with micrometer.

Standard : Refer to EM-271, "Standard

F
and Limit".

H
SEM012A

CAMSHAFT BRACKET INNER DIAMETER I

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

Standard : Refer to EM-271, "Standard

and Limit". K

JEM162G
M
CAMSHAFT OIL CLEARANCE CALCULATIONS
• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter)
N
Standard : Refer to EM-271, "Standard
and Limit".
• If out of standard, refer to the standard value of each unit, then replace the camshaft and/or cylinder head. O
NOTE:
As the camshaft bracket is manufactured with the cylinder head, it is impossible to replace only the camshaft
bracket.
P
Camshaft End Play

EM-201
 CAMSHAFT
< SERVICE INFORMATION > [YD]
• Install dial gauge in thrust direction on front end of camshaft. Mea-
sure end play of dial gauge when camshaft is moved forward/back-
ward (in direction to axis).

Standard : Refer to EM-271, "Standard

and limit and Limit".

PBIC0366E

• Measure the following parts if out of the standard.

- Dimension “A” for camshaft

Standard : 6.882 - 6.930 mm (0.2709 - 0.2728 in)

- Dimension “B” for cylinder head

Standard : 7.000 - 7.030 mm (0.2756 - 0.2768 in)

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

Camshaft Sprocket Runout

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

Limit : Refer to EM-271, "Standard

and Limit".
• If it exceeds the limit, replace camshaft sprocket.

JEM164G

Visual Inspection of Valve Lifter and Adjusting Shim

Check if surface of valve lifter and adjusting shim has any wear or
cracks.
• If anything above is found, replace valve lifter or adjusting shim.

SEM160D

Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER

EM-202
 CAMSHAFT
< SERVICE INFORMATION > [YD]
• Measure the outer diameter of the valve lifter with the micrometer.
A
Standard : Refer to EM-271, "Standard
and Limit".
EM

SEM961E

D
VALVE LIFTER BORE DIAMETER
• Measure the bore diameter of the cylinder head valve lifter with the
inside micrometer. E

Standard : Refer to EM-271, "Standard

and Limit".
F

PBIC0367E

H
VALVE LIFTER CLEARANCE CALCULATIONS
• (Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)

Standard : Refer to EM-271, "Standard I

and Limit".
• If out of standard, refer to the outer diameter and bore diameter standard values and replace valve lifter and/ J
or cylinder head.
INSTALLATION
1. Install valve lifter and adjusting shim. K
• Check that these are installed in the same position as before the removal process.
2. Install camshaft.
L
1 : Intake camshaft
2 : Exhaust camshaft
: Engine front M
• Identify camshafts by the paint position.

A : White N
B : Green
JPBIA3894ZZ

EM-203
 CAMSHAFT
< SERVICE INFORMATION > [YD]
• Install so that knock pins (A) are positioned in the directions
shown in the figure.

B : Intake camshaft
C : Exhaust camshaft
d : Approx. 65°
: Up

JPBIA3909ZZ

3. Install camshaft brackets.

• Completely remove any foreign material on back surfaces of camshaft brackets and top surface of cylin-
der head.
• Install correctly, identifying brackets by the journal No. and
front mark on top surface.

JEM175G

4. Tighten camshaft bolts in numerical order as shown in the figure

according to the following procedure:

: Engine front

a. Tighten No. 13 to 15.

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

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

: 1.96 N·m (0.20 kg-m, 1 ft-lb)

c. Tighten all bolts.

: 5.88 N·m (0.60 kg-m, 4 ft-lb)

d. Tighten all bolts.

: 12.8 N·m (1.3 kg-m, 9 ft-lb)

5. Install camshaft sprockets and signal plate.
• Camshaft sprockets are commonly used for right side and left side.
• Align camshaft sprocket and knock pin on camshaft, and install.
• Holding the hexagonal part of camshaft with a wrench, tighten bolt securing camshaft sprockets and sig-
nal plate.
6. Install rubber washer to cylinder head rear side.

EM-204
 CAMSHAFT
< SERVICE INFORMATION > [YD]
7. Apply liquid gasket to cylinder head rear cover as shown in the
figure. A
Use Genuine Liquid Gasket or Equivalent.

a : 4.0 - 5.6 mm (0.157 - 0.220 in)

EM
b : φ 3.4 - 4.4 mm (0.134 - 0.173 in)

JPBIA3772ZZ

D
8. Install cylinder head rear cover and tighten mounting bolts in
numerical order shown in the figure.

M8 × 50 mm (1.97 in) : Bolt No. 1 E

M8 × 20 mm (0.79 in) : Bolt No. 2 - 6
F

G
JPBIA3893ZZ

9. Before installing spill tube after installing secondary timing chain, check and adjust valve clearance. Refer
to EM-206, "Valve Clearance". H
10. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
I
Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the J
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, K
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE: L
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises. M
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
N
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
O

Engine coolant Level Leakage Level

Engine oil Level Leakage Level P
Transmission / AT Models Leakage Level / Leakage Leakage
transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-205
 CAMSHAFT
< SERVICE INFORMATION > [YD]
Valve Clearance INFOID:0000000007042401

INSPECTION
• When the camshaft or parts in connection with valves are removed or replaced, and a malfunction has
occurred (poor starting, idling, or other malfunction) due to the miss adjustment of the valve clearance,
inspect as follows.
• Inspect and adjust when the engine is cool (at normal temperature).

1. Remove rocker cover. Refer to EM-196, "Component".

2. Remove fuel injector. Refer to EM-181, "Exploded View".
3. Set the No. 1 piston to TDC on its compression stroke.
• Turn crankshaft pulley clockwise so that the cam nose (A) on
exhaust camshaft (1) faces straight above ( ). (No position
indicator, etc. is provided on the crankshaft pulley.)

JPBIA4521ZZ

4. While referring to the figure, measure the valve clearance

marked in the table below.

: Vehicle front

Measuring position No.1 No.2 No.3 No.4

No. 1 cylinder at compression INT (A) (D)

TDC EXH (B) (C)

JPBIA3758ZZ

NOTE:
Use a feeler gauge (A), measure the clearance between valve
lifter and camshaft.

JPBIA3759ZZ

5. Set the No. 4 cylinder at TDC by rotating the crankshaft clockwise once. (360 degrees)

EM-206
 CAMSHAFT
< SERVICE INFORMATION > [YD]
6. While referring to the figure, measure the valve clearance
marked in the table below. A

: Vehicle front
EM
Measuring position No.1 No.2 No.3 No.4

No. 4 cylinder at compression INT (A) (D)

C
TDC EXH (B) (C)

JPBIA3787ZZ

D
7. If the valve clearance is outside the specification, adjust as follows.
ADJUSTMENTS
• Remove adjusting shim for parts which are outside the specified valve clearance. E
1. Extract engine oil on the upper side of the cylinder head (for the air blowing in step 6).
2. Rotate crankshaft to face the camshaft for adjusting shims that
are to be removed upward. F

1 : Round hole
: Facing straight above G

JPBIA3883ZZ

I
3. Grip camshaft with the camshaft pliers (A) [SST: KV10115110],
then using camshaft as a support point, push adjusting shim
downward to compress valve spring. Then move the camshaft
J
pliers handle in the direction of arrow ( ).
CAUTION:
Never damage camshaft, cylinder head and the outer cir-
cumference of valve lifter. K

L
JPBIA3884ZZ

4. With valve spring in a compressed state, remove the camshaft

pliers (A) [SST: KV10115110] by securely setting the outer cir- M
cumference of the valve lifter with the end of the lifter stopper (B)
[SST: KV10115120].
• Hold the lifter stopper by hand until the shim is removed. N
CAUTION:
Never retrieve the camshaft pliers forcefully, as camshaft
will be damaged.
O

JPBIA3885ZZ
P
5. Move the round hole of adjusting shim to the front with the very thin screwdriver or like that.
• When adjusting shim on valve lifter will not rotate smoothly, restart from step 3 to release the end of the
lifter stopper [SST: KV10115120] from touching adjusting shim.

EM-207
 CAMSHAFT
< SERVICE INFORMATION > [YD]
6. Remove adjusting shim from valve lifter by blowing air through
the round hole (1) of the adjusting shim with the air gun (B).

A : Lifter stopper
CAUTION:
To prevent any remaining engine oil from being blown
around, thoroughly wipe the area clean and wear protective
goggles.

JPBIA3886ZZ

7. Remove adjusting shim (1) by using the magnet hand (B).

A : Lifter stopper

JPBIA3887ZZ

8. Measure the thickness of adjusting shim using the micrometer.

• Measure near the center of the shim (the part that touches
camshaft).

FEM032

9. Select the new adjusting shim from the following methods.

Calculation method of the adjusting shim thickness:

R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake
N = R + [M - 0.28 mm (0.0110 in)]
Exhaust
N = R + [M - 0.30 mm (0.0118 in)]
• New adjusting shims have the thickness stamped (A) on the
rear side.
• Shims are available in 33 size from 2.10 mm (0.0827 in) to
2.74 mm (0.1079 in), in steps of 0.02 mm (0.0008 in). Refer to
EM-271, "Standard and Limit".

B : Thickness

JPBIA3912ZZ

EM-208
 CAMSHAFT
< SERVICE INFORMATION > [YD]

10. Fit the selected adjusting shim to valve lifter. A

A : Lifter stopper
B : Suitable tool
EM
CAUTION:
Place the stamped side of adjusting shim to valve lifter.
C

JPBIA3888ZZ
D
11. Compress valve spring using the camshaft pliers [SST: KV10115110] and remove the lifter stopper [SST:
KV10115120].
E
12. Rotate crankshaft 2 to 3 turns by hand.
13. Confirm that the valve clearance is within the specification.
14. Install remaining parts in the reverse order of removal.
F
15. Warm up engine, and check for unusual noise and vibration.

EM-209
 OIL SEAL
< SERVICE INFORMATION > [YD]
OIL SEAL
Removal and Installation of Valve Oil Seal INFOID:0000000007042402

REMOVAL
1. Turn crankshaft until the cylinder requiring new valve oil seals is at TDC. This will prevent valve from drop-
ping into cylinder.
2. Remove camshafts. Refer to EM-199.
3. Remove adjusting shims and valve lifters. Refer to EM-199.
• Check the installation positions, and keep them to avoid being confused.
4. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
5. Remove valve collet.
• Compress the valve spring with valve spring compressor,
attachment and adapter (SST). Remove valve collet with a
magnet hand.
CAUTION:
When working, be careful not to damage valve lifter holes.

PBIC2388E

6. Remove valve spring retainer and valve spring.

7. Remove valve oil seal with the valve oil seal puller (SST).

JEM153G

INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Using the valve oil seal drift (SST), install valve oil seals refer-
ring to the dimension shown in the figure.

JEM165G

3. Install in the reverse order of removal.

Removal and Installation of Front Oil Seal INFOID:0000000007042403

REMOVAL

EM-210
 OIL SEAL
< SERVICE INFORMATION > [YD]
1. Remove the following parts.
• Splash guard (RH). Refer to EI-25, "Removal and Installation". A
• Drive belt. Refer to EM-161, "Component".
• Crankshaft pulley. Refer to EM-248, "Component".
2. Remove front oil seal with a suitable tool. EM
CAUTION:
Be careful not to damage oil pump housing and crankshaft.
C

JPBIA3762ZZ E

INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip. F
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
G
A : Oil seal lip
B : Dust seal lip
: Engine inside H
: Engine outside

I
JPBIA0054ZZ

• Using the suitable drift [60 mm (2.36 in) dia.] (A), press fit the J
oil seal (2) so that the dimension is as specified in the figure.

1 : Oil pump housing

K

b : 0 - 0.5 mm (0 - 0.020 in)

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

JPBIA3763ZZ

3. Install in the reverse order of removal.

Removal and Installation of Rear Oil Seal INFOID:0000000007042404

REMOVAL
EM-211
 OIL SEAL
< SERVICE INFORMATION > [YD]
1. Remove engine and transaxle from vehicle. Refer to EM-244, "Component".
2. Remove transaxle.
3. Remove drive plate.
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.

A : Oil seal lip

B : Dust seal lip
: Engine inside
: Engine outside

JPBIA0054ZZ

• Press in rear oil seal (2) to rear oil seal retainer (1) as shown in
the figure.

b : 0 - 0.5 mm (0 - 0.020 in)

• Using the drift [100 mm (3.94 in) dia.] (A), press fit so that the
dimension is as specified in the figure.
• Avoid inclined fitting. Force fit perpendicularly.

JPBIA3764ZZ

3. Install in the reverse order of removal after this step.

EM-212
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
SECONDARY TIMING CHAIN
A
Component INFOID:0000000007042405

EM

I
JPBIA3694GB

1. Chain tensioner 2. Slack guide 3. Front chain case J

4. Tension guide 5. Gasket 6. Secondary timing chain
7. Tension guide
A. Oil pump housing side B. Comply with the installation proce- K
dure when tightening. Refer to EM-
213, "Removal and Installation"
Refer to GI-9, "Component" for symbols in the figure.
L
Removal and Installation INFOID:0000000007042406

CAUTION: M
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis-
ton heads.
• When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting
surfaces with new engine oil. N

REMOVAL
1. Remove RH engine mounting bracket (lower). Refer to EM-244, "Component". O
2. Remove front chain case.

EM-213
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• Loosen fixing bolts in reverse order of that shown in the figure
and remove them.
CAUTION:
• While front chain case is removed, cover openings to
prevent entry of foreign material into engine.

JPBIA3769ZZ

• Never remove mass damper (2) on the back of cover.

1 : Tension guide

JPBIA3892ZZ

3. Set the No. 1 piston to TDC on its compression stroke.

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

SEM515G

4. Remove chain tensioner.

a. Push the plunger of chain tensioner and keep it pressed with a
push pin.

JEM124G

EM-214
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
b. Using the hexagon wrench [SST: KV11106010], remove bolts to
remove chain tensioner. A

EM

SBIA0227E

D
5. Remove slack guide.
• Using the hexagon wrench [SST: KV11106020], remove bolt to
remove slack guide.
E

SBIA0228E

H
6. Remove tension guide.
7. Remove secondary timing chain.
• Timing chain alone can be removed without removing sprock-
ets. I

K
JEM127G

INSTALLATION
1. Install secondary timing chain. L

EM-215
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on the timing
chain.

1 : Secondary timing chain

2 : Chain tensioner
3 : Slack guide
4 : Fuel pump sprocket
5 : Tension guide
6 : Camshaft sprocket
A : Alignment mark (dark blue link)
B : Alignment mark (punched mark)
C : Alignment mark (yellow link)
2. Install tension guide.
• The upper bolt has a longer shank than the lower bolt.

PBIC4048E

3. Using the hexagon wrench [SST: KV11106020], install slack

guide.

SBIA0228E

4. Install chain tensioner.

a. Push the plunger of chain tensioner. While holding it with a push
pin, install chain tensioner.
b. Using the hexagon wrench [SST: KV11106010], tighten bolts.
c. Pull out the push pin, etc. holding the plunger.
• Check again that the alignment marks on the sprockets
and the colored alignment marks on the timing chain are
aligned.

SBIA0227E

5. Install front chain case.

EM-216
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
a. Install tension guide (1) on the back surface of front chain case.
A
2 : Mass damper
• Hold front chain case vertically when installing. Tension guide
may come off if front chain case is tilted. EM

JPBIA3892ZZ

D
b. Apply a continuous bead of liquid gasket on both ends of arched area (locations where rear chain case is
adjoined) as shown in the figure.
E

I
JPBIA3770ZZ

1. Oil pump housing 2. Rear chain case J

b. φ 19 mm (0.75 in) c. 10 mm (0.39 in) e. φ 3.4 - 4.4 mm (0.13 - 0.17 in)
f. 5 mm (0.20 in)
K
CAUTION:
• For (A), the overlap of the liquid gasket starting point and end-point must be minimized and
faced outward.
Use Genuine Liquid Gasket or equivalent. L

c. Install front chain case.

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

JPBIA3769ZZ

6. Install in the reverse order of removal after this step.

EM-217
 SECONDARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
Inspection INFOID:0000000007042407

INSPECTION AFTER REMOVAL

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

SEM984C

INSPECTION AFTER INSTALLATION

Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level

Transmission / AT & CVT Models Leakage Level / Leakage Leakage

transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-218
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
PRIMARY TIMING CHAIN
A
Component INFOID:0000000007042408

EM

JPBIA3696GB

N
1. Fuel pump 2. O-ring 3. Rear chain case
4. O-ring 5. Fuel pump sprocket 6. Washer
7. Tension guide 8. Primary timing chain 9. Chain tensioner O
10. Slack guide 11. Crankshaft sprocket 12. Crankshaft pulley
13. Front oil seal 14. Oil pump housing 15. Crankshaft gear
16. Key 17. Balancer unit 18. Seal washer P
A. Comply with the installation proce- B. Comply with the installation proce-
dure when tightening. Refer to EM- dure when tightening. Refer to EM-
220, "Removal and Installation". 220, "Removal and Installation".
Refer to GI-9, "Component" for symbols in the figure.

EM-219
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042409

CAUTION:
• After removing timing chain, never turn crankshaft and camshaft separately, or valves will strike pis-
ton heads.
• When installing camshafts, chain tensioners, oil seals or other sliding parts, lubricate contacting
surfaces with new engine oil.
REMOVAL
1. Drain engine oil. Refer to LU-20, "Changing Engine Oil".
2. Remove the following parts:
• Drive belt auto-tensioner and idler pulley. Refer to EM-156, "Removal and Installation".
• Collector (upper and lower). Refer to EM-157, "Component".
• Vacuum pump. Refer to EM-179, "Component".
• Fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
• Oil pan (upper and lower). Refer to EM-173, "Component".
3. Remove crankshaft pulley.
a. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool).
b. Loosen crankshaft pulley fixing bolt and pull out the bolt approx-
imately 10 mm (0.39 in).

PBIC3469E

c. Using the pulley puller [SST: KV11103000], remove crankshaft

pulley.
• Use two M6 bolts with approx. 60 mm (2.36 in) shank length
for securing crankshaft pulley.

JEM132G

4. Remove oil pump housing.

• Loosen bolts in reverse order of that shown in the figure and
remove them.
• Use the seal cutter [SST: KV10111100] etc. for removal.

JPBIA3773ZZ

EM-220
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
5. Remove crankshaft gear (1) with the following procedure.
a. Check that No.1 piston is TDC on its compression stroke. A
b. Turn the idler sub gear (3) counterclockwise with snap ring plier
(B) or suitable tool for aligning idler sub gear and idler main gear
(2). EM
• If idler gear rotates, hold the flat faces on balancer drive shaft
front end (4).
c. Install internal mechanism securing bolt and plate (Service part: C
13012 EB30A and 13013 EB30A) (A) and tighten to the speci-
fied torque.
D
: 4.0 N·m (0.41 kg-m, 35 in-lb)

CAUTION:
• Never loosen idler gear mounting bolt (5). E
• Only use the genuine internal mechanism securing bolt
and plate, or the idler gear and will be damaged.
• Never remove internal mechanism securing bolt and plate
F
from idler gear and until crankshaft gear and all of the
parts in connection have been installed.
• If internal mechanism securing bolt and plate is not
installed, internal mechanism of idler gear and will disen- G
gage after crankshaft gear is removed. This will prohibit JPBIA3914ZZ

the balancer unit from being reusable.

d. Apply mating marks (C) to crankshaft gear and idler sub gear. H
e. Remove crankshaft gear.
6. Remove front oil seal from oil pump housing.
• Punch out the seal off from the back surface of the oil pump housing using a flat-bladed screwdriver. I
CAUTION:
Be careful not to damage oil pump housing.
J
7. Remove chain tensioner (1).
• When removing chain tensioner, push the plunger of chain
tensioner and keep it pressed with a push pin (2).
8. Remove slack guide (3). K

M
JPBIA3774ZZ

9. Hold fuel pump sprocket (1) and remove bolt.

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

c : φ 6 mm (0.24 in) O
d : 80 mm (3.15 in)
b. Using the TORX wrench (B) [SST: KV11106040], turn pump
shaft little by little to adjust the position of fuel pump sprocket so P
that the holes align.
JPBIA3775ZZ

e : 26 mm (1.02 in)
c. Push positioning stopper pin through fuel pump sprocket to fuel pump body to hold fuel pump sprocket.

EM-221
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• Insert the positioning stopper pin [SST: KV11106030] until its
flange contacts fuel pump sprocket.

PBIC2535E

10. Using the hexagon wrench [SST: KV11106050] remove tighten-

ing bolts to fuel pump sprocket.

PBIC2404E

MBIA0074E

11. Remove primary timing chain (2) with fuel pump sprocket (1)
and crankshaft sprocket (3).

JPBIA3776ZZ

EM-222
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
12. Remove tension guide (1).
A

EM

JPBIA3777ZZ

D
13. Remove fuel pump. Refer to EM-186, "Component".
14. Remove camshaft sprockets. Refer to EM-199, "Component".
15. Remove rear chain case. E
• Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
• Use the seal cutter [SST: KV10111100] for removal.
F

JPBIA3778ZZ

L
16. Remove balancer unit.
• Loosen mounting bolts in the reverse order as shown in the
figure.
M
: Engine front

PBIC4049E

INSTALLATION P
NOTE:
The figure shows the relationship between the mating mark on each timing chain and that on the correspond-
ing sprocket, with the components installed.

EM-223
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]

JPBIA3779ZZ

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

4. Fuel pump sprocket 5. Chain tensioner 6. Slack guide
7. Primary timing chain 8. Crankshaft sprocket 9. Tension guide
10. Tension guide 11. Camshaft sprocket 12. Tension guide
13. Front chain case
A. Alignment mark (dark blue link) B. Alignment mark (yellow link) C. Alignment mark (punched mark)
D. Alignment mark (punched mark) E. Alignment mark (punched mark)

CAUTION:
Before starting work, check that No. 1 piston is on its compression stroke.
1. Install balancer unit, and tighten mounting bolts in numerical
order as shown in the figure.

: Engine front

CAUTION:
If mounting bolts are re-used, check their outer diameter
before installation. Refer to "Balancer Unit Mounting Bolt
Outer Diameter".
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
PBIC4049E
b. Tighten all bolts.

: 29.4 N·m (3.0 kg-m, 22 ft-lb)

c. Turn all bolts 65 degrees clockwise (angle tightening).

1 : Balancer unit
CAUTION:
Check tightening angle with an angle wrench [SST:
KV10112100] (A) or a protract. Never make judgement by
visual check alone.
d. Completely loosen.

: 0 N·m (0 kg-m, 0 ft-lb) PBIC3474E

CAUTION:
In this step, loosen bolts in the reverse order as shown in the figure.
e. Tighten all bolts.

EM-224
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]

: 29.4 N·m (3.0 kg-m, 22 ft-lb) A

f. Turn them another 65 degrees clockwise (angle tightening).

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

JPBIA3780ZZ

J
b. Install new O-ring (1) to the grooves of fuel pump bracket.

M
JPBIA3781ZZ

c. Install rear chain case.

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

EM-225
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
d. Tighten bolts in numerical order shown in the figure.
• Install the following two types of bolts, referring to the figure.

M8 × 16 mm (0.63 in) : Bolt No. 1, 2, 8, 9, 10, 11, 12, 13,

17, 18
M8 × 20 mm (0.79 in) : Bolt No. 3, 4, 5, 6, 7, 14, 15, 16,
19, 20
• The shank length under the bolt neck above is the length of
threaded part (pilot portion not included).
e. After tightening all the bolts, re-tighten in the same order.

JPBIA3778ZZ

3. Install fuel pump. Refer to EM-186, "Component".

• Before installing, check that spacer and the hole 6 mm (0.24 in) in diameter on coupling are aligned.
4. Install tension guide (1).

JPBIA3777ZZ

5. Install crankshaft sprocket (3), aligning it with crankshaft key on

the far side.
6. Install primary timing chain (2) with fuel pump sprocket (1).
• When installing, match the alignment marks on sprockets with
color coded alignment marks (colored links) on primary timing
chain.
• Install fuel pump sprocket washer with the surface marked “F”
(front mark) facing the front of the engine.

JPBIA3776ZZ

EM-226
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
7. Use the positioning stopper pin (A) [SST: KV11106030] to hold
the fuel pump sprocket (1) and install the bolt. A

c : φ 6 mm (0.24 in)
d : 80 mm (3.15 in) EM
• Using the TORX wrench (B) [SST: KV11106040], turn the fuel
pump shaft little by little to adjust the position of the fuel pump
sprocket. Insert positioning stopper pin into the hole 6 mm C
(0.24 in) in diameter on fuel pump sprocket so that the stopper
pin goes through the fuel pump body. While the stopper pin is
in place, install the bolt. JPBIA3775ZZ

D
e : 26 mm (1.02 in)

PBIC2404E
H

8. Install timing chain slack guide (3).

9. Install chain tensioner (1). I
• Push the plunger of the chain tensioner. While keeping
plunger pressed down with a push pin (2), install chain ten-
sioner.
• After installation, pull out the push pin holding the plunger. J
CAUTION:
Check again that the alignment marks on sprockets and the
colored alignment marks on timing chain are aligned. K

JPBIA3774ZZ

10. Install front oil seal (1) to oil pump housing (2). L
• Using the suitable drift (A) [62 mm (2.44 in) dia.], force fit the
seal until it hits the bottom.
CAUTION: M
Never touch lips of oil seal. Check seal surfaces are free of
foreign materials.
N

O
PBIC3448E

11. Install crankshaft gear.

P

EM-227
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
• Align crankshaft gear (1) mating mark and idler sub gear (3)
mating mark (C).

2 : Idler main gear

4 : Balancer drive shaft front end
5 : Idler gear mounting bolt (do not loosen)
B : Snap ring plier
• Remove internal mechanism securing bolt and plate (Service
part: 13012 EB30A and 13013 EB30A) (A).

JPBIA3914ZZ

- If new balancer unit (2) is used, align matching marks (B) of

each gear as shown in the figure.
- Remove securing-bolt-and-plate (A) and securing pin (C) after
installing crankshaft gear (1).

PBIC3475E

12. Install oil pump housing.

EM-228
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure. A
• Leave the start and end areas (A) of the bead slightly protrud-
ing from the surface.
• Apply liquid gasket along upper end surface of oil pump hous-
EM
ing.

b : φ3.4 - 4.4 mm (0.13 - 0.17 in)

c : 4.0 - 5.6 mm (0.16 - 0.22 in) C
d : 0.5 - 2.1 mm (0.02 - 0.08 in)

G
JPBIA3782ZZ

b. Install new O-rings into the groove of rear chain case.

H
c. Install oil pump housing.
• When installing, align the inner rotor in the direction of the two facing flats of oil pump drive spacer.
• When installing, align the dowel pin with the pin hole.
I
d. Tighten fixing bolts in numerical order shown in the figure.
e. After tightening all the bolts, re-tighten in the same order.
J

L
JPBIA3773ZZ

13. Check gaps on upper oil pan mounting surface.

• Using straightedge and feeler gauge, measure gaps between M
the locations of the following parts:

Oil pump housing and rear chain case: N

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

14. Install crankshaft pulley, refer to the following:

CAUTION:
Be careful not to damage front oil seal.
a. Install crankshaft pulley to crankshaft.
b. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.

EM-229
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
c. Hold crankshaft pulley with the pulley holder (commercial ser-
vice tool).
d. Tighten crankshaft pulley fixing bolt.

: 75.0 N·m (7.7 kg-m, 55 ft-lb)

e. Completely loosen.

: 0 N·m (0 kg-m, 0 ft-lb)

PBIC3469E
f. Tighten crankshaft pulley bolt.

: 75.0 N·m (7.7 kg-m, 55 ft-lb)

g. Put an alignment mark on crankshaft pulley that aligns with one of the punched marks on the bolt.

h. Tighten fixing bolt another 120 degrees (angle tightening) (turn

by 2 notch).

A : Indicate embossments
B : Alignment mark

PBIC3476E

15. Install in the reverse order of removal.

Inspection INFOID:0000000007042410

INSPECTION AFTER REMOVAL

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

SEM984C

Balancer Unit Mounting Bolt Outer Diameter

• Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
• If reduction appears in “A” range, regard it as “d2”.

Limit (“d1” - “d2”) : 0.15 mm (0.0059 in)

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

PBIC1137E

EM-230
 PRIMARY TIMING CHAIN
< SERVICE INFORMATION > [YD]
INSPECTION AFTER INSTALLATION
A
Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the EM
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping,
check for fuel leakage at connection points. C
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE: D
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises.
E
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to F
the specified level, if necessary.
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped G
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
H
Transmission / AT & CVT Models Leakage Level / Leakage Leakage
transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
Other oils and fluids* Level Leakage Level I
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
J
*: Power steering fluid, brake fluid, etc.

EM-231
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
CYLINDER HEAD
On-Vehicle Service INFOID:0000000007042411

CHECKING COMPRESSION PRESSURE

1. Warm up engine thoroughly. Then, stop it.
2. Using CONSULT, check no error codes are indicated for self-diagnosis items. Refer to EC-1036, "Work
Procedure".
• Do not disconnect CONSULT until the end of this operation, it will be used to check engine rpm and for
error detection at the end of this operation.
3. Disconnect the battery cable from the negative terminal.
4. Remove the engine cover and bracket. Refer to EM-157, "Component"
5. To prevent fuel from being injected during inspection, disconnect
all the connectors of the fuel injector.

A : Connector
B : Injector

JPBIA3881ZZ

6. Wind the insulating tape around the electrode of the discon-

nected connectors. Tie them together and fix them on the har-
ness side.

A : Connector

PBIC4772E

7. Remove glow plugs from all the cylinders. Refer to EM-178, "Component".
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs.

8. Install compression gauge adapter [SST: ED19600610] to instal-

lation holes of glow plugs and connect compression gauge for
diesel engine.

: 20.0 N·m (2.0 kg-m, 15 ft-lb)

9. Connect the battery cable to the negative terminal.
10. Turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and engine
rpm. Perform these steps to check each cylinder.
• Always use a fully-charged battery to obtain specified engine SEM112G
speed.

Compression pressure : Refer to EM-271, "Standard and Limit".

EM-232
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions. A
• If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
EM
• If compression pressure is low in some cylinders, apply engine oil from glow plug installation hole. Then
check pressure again.
- If compression pressure becomes normal after applying engine oil, piston ring may be worn or dam-
aged. Check piston ring for malfunction. If any, replace piston ring. C
- If compression pressure is still low after applying engine oil, valve may be malfunctioning. Check valve
for malfunction. If contact malfunction is found, replace valve or valve seat.
• If compression pressure in adjacent two cylinders is low after applying engine oil, pressure may be leak- D
ing from gasket. In this case, replace cylinder head gasket.
11. Complete this operation as follows:
a. Turn the ignition switch to “OFF”. E
b. Disconnect the battery cable from the negative terminal.
c. Install glow plug and install all the parts removed in step 4.
d. Connect all the connectors of the fuel injector. F
e. Connect the battery cable to the negative terminal.
f. Check DTC. If DTC is displayed, erase it. Refer to EC-1034, "Diagnostic Work Sheet".
G
Exploded View INFOID:0000000007042412

REMOVAL H

JPBIA3698GB

P
1. Bracket 2. Slinger bracket 3. Cylinder head assembly
4. Gasket 5. Dowel pin
A. Comply with the installation proce-
dure when tightening. Refer to EM-
234, "Removal and Installation".
Refer to GI-9, "Component" for symbols in the figure.

EM-233
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
DISASSEMBLY

JPBIA3699GB

1. Adjusting shim 2. Valve lifter 3. Valve collet

4. Valve spring retainer 5. Valve spring (intake) 6. Valve oil seal
7. Valve spring seat 8. Valve guide 9. Cylinder head
10. Valve seat 11. Valve (intake) 12. Valve (exhaust)
13. Valve spring (exhaust)
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000007042413

REMOVAL
1. Drain engine coolant from radiator and cylinder block. Refer to CO-38, "Changing Engine Coolant" and
CO-38, "Inspection".
2. Remove the following parts:
• EGR system. Refer to EM-159, "Exploded View".
• Turbocharger. Refer to EM-167, "Component".
• Exhaust manifold. Refer to EM-171, "Component".
• Intake manifold. Refer to EM-163, "Component".
• Vacuum pump. Refer to EM-179, "Component".
• Glow plug. Refer to EM-178, "Component".
• Injection tube and fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
• Camshaft. Refer to EM-199, "Component".
3. Remove cylinder head assembly.
• Remove bolts between rear chain case and cylinder head. Refer to EM-233, "Exploded View".

EM-234
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• Remove cylinder head bolts in the reverse order as shown in
the figure with the cylinder head bolt wrench (commercial ser- A
vice tool).

: Engine front
EM
• Lift up cylinder head assembly to avoid interference with dowel
pins located between the cylinder block and cylinder head,
and remove cylinder head assembly. C
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of cylinder JPBIA3785ZZ

head, or, place wood blocks beneath both ends of cylin- D

der head to keep the cylinder bottom from any contact.
• For glow plug removal, the following shall be noted.
CAUTION: E
• To avoid breakage, never remove glow plug unless necessary.
• Perform continuity test with glow plug installed.
• Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
• Never use air impact wrench. F

INSTALLATION
Before installation, remove old liquid gasket from mating surface of all liquid gasket applied parts. G
1. Install cylinder head gasket.
• Cylinder head gasket to be installed is selected by its thickness through the following procedure.
- When replacing gasket alone:
H
• Install a gasket with same thickness as that of the one removed.
• Identify the thickness of gasket by the number of ID marks on
the front LH side.
I
: Engine front

J
Gasket thickness* mm (in) Number of grade Number of ID marks
0.900 (0.0354) 1 0
0.925 (0.0364) 2 1 K
0.950 (0.0374) 3 1+2
JPBIA3786ZZ

0.975 (0.0384) 4 1+2+3

1.000 (0.0394) 5 1+2+3+4
L

1.025 (0.0404) 6 1+2+3+4+5

*: Measured with head bolts tightened
M

• Heater return tube is omitted for explanation.

NOTE: N
Use mirrors for checking at points out of clear sight.
- When the following parts have been repaired/replaced:
• With cylinder block upper surface and/or crankshaft pin journal ground.
• With cylinder block, pistons, connecting rods, and/or crankshaft replaced. O
a. Set piston at a point close to TDC.

EM-235
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
b. Set the dial gauge at the location as shown in the figure. Turning
crankshaft gradually, set the gauge scale to “0” where the piston
protrusion is maximized.
c. Move the dial gauge stand so that the tip of dial gauge can con-
tact cylinder block. Read the difference.
d. Measure two points from each cylinder in order to obtain each
mean value of them. Choose a properly thick gasket corre-
sponding the highest number of the four values.

SEM507G

Identification
Piston protrusion mm (in) Gasket thickness* mm (in)
Number of ID marks
0.161 - 0.186 (0.0063 - 0.0073) 0.900 (0.0354) 0
0.186 - 0.211 (0.0073 - 0.0083) 0.925 (0.0364) 1
0.211 - 0.236 (0.0083 - 0.0093) 0.950 (0.0374) 1+2
0.236 - 0.261 (0.0093 - 0.0103) 0.975 (0.0384) 1+2+3
0.261 - 0.286 (0.0103 - 0.0113) 1.000 (0.0394) 1+2+3+4
0.286 - 0.331 (0.0113 - 0.0130) 1.025 (0.0404) 1+2+3+4+5
*: Measured with head bolts tightened
e. If out of above protrusion, check replaced parts.
2. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure.
A: Apply bead so that it does not protrude into oil passage.
B: Minimize the overlapping area of the bead, with start and end
areas of bead as shown in the figure.
Apply so that the portion marked * comes at an external loca-
tion but cannot be viewed externally after engine is assembled.

PBIC1256E

3. Install cylinder head assembly.

• Tighten bolts in numerical order as shown in the figure accord-
ing to the following procedure:

: Engine front

a. Apply engine oil to bolt threads and seat surfaces.

b. Tighten all bolts.

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

JPBIA3785ZZ

EM-236
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
c. Tighten all cylinder head bolts (clockwise).
A
Angle tightening : 180 degrees
CAUTION:
• When the angle wrench [SST: KV10112100] is not used, EM
paint an alignment mark on the head of cylinder head bolt
and cylinder head surface before tightening. Check the
angle with a protractor. C
d. Loosen completely in the reverse order of that shown in the fig-
ure.
JEM166G

D
: 0 N·m (0 kg-m, 0 ft-lb)
e. Tighten all bolts.
E

: 39.2 N·m (4.0 kg-m, 29 ft-lb)

f. Tighten all cylinder head bolts (clockwise). F

Angle tightening : 90 degrees

G
g. Tighten all cylinder head bolts (clockwise).

Angle tightening : 90 degrees

H
CAUTION:
• When the angle wrench [SST: KV10112100] is not used, paint an alignment mark on the head of
cylinder head bolt and cylinder head surface before tightening. Check the angle with a protrac-
tor. I
4. Tighten bolts between rear chain case and cylinder head. Refer to EM-233, "Exploded View".
5. After installing cylinder head, measure dimension from the front
J
end surface of cylinder block to that of cylinder head (If rear
chain case is removed).

Standard : 23.53 - 24.07 mm (0.9264 - 0.9476 in) K

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

JEM172G
M
6. Install glow plug.
CAUTION:
• To avoid damage, glow plugs should be removed only when required. N
• Handle with care to avoid applying shock. When dropped from approx. 10 cm (3.94 in) or higher,
always replace with a new one.
• Before installing, remove carbon depositing on mounting hole of glow plug with a reamer. O
7. Install engine coolant temperature sensor. Refer to EM-233, "Exploded View".
8. Install in the reverse order of removal.
Disassembly and Assembly INFOID:0000000007042414
P

DISASSEMBLY
1. Remove adjusting shims and valve lifters.
• Check the installation positions, and keep them to avoid being confused.

EM-237
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
2. Remove valve collet.
• Using the valve spring compressor [SST: KV10116200], com-
press valve spring. Using magnet hand, remove valve collets.

PBIC2388E

3. Remove valve spring retainers and valve springs.

4. Remove valves as pressing valve stems toward combustion chamber.
• Before removing valve, check the valve guide clearance. Refer to EM-239, "Inspection".

5. Remove valve oil seals using the valve oil seal puller [SST:
KV10107902].
6. Remove valve spring seats.
7. Remove valve seats.
• Before removing valve seats, perform valve seat contact
check. Refer to EM-239, "Inspection".
8. Remove valve guides.

JEM153G

ASSEMBLY
1. Install valve guides. Refer to EM-239, "Inspection".
2. Install valve seats. Refer to EM-239, "Inspection".
3. Using the valve oil seal drift [SST: KV10115600], install valve oil
seals referring to the dimension shown in the figure.
4. Install valve spring seats.

JEM165G

5. Install valves.
• Install the valves with bigger outer diameter to intake valve side.

6. Install valve spring.

7. Install valve spring retainers.

EM-238
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
8. Using the valve spring compressor [SST: KV10116200], com-
press valve springs. A
Then install valve collets using magnet hand.
• After installing valve collets, tap the stem end using the plastic
hammer, and check the installation status.
EM

PBIC2388E

D
9. Install valve lifters and adjusting shims to the same positions as before.
Inspection INFOID:0000000007042415
E
INSPECTION AFTER REMOVAL
Cylinder Head Bolt Deformation F
• Using micrometer, measure the outer diameters “d1” and “d2” of
bolt thread as shown in the figure.
• If the necking point can be identified, set it as measuring point d1.
• Calculate the difference between “d1” and “d2”. G

Limit : 0.15 mm (0.0059 in)

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

I
JEM171G

Cylinder Head Distortion

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

Limit : Refer to EM-271, "Standard and Lim- L

it".
• If it exceeds the limit, replace cylinder head.
M

JPBIA0176ZZ N
INSPECTION AFTER DISASSEMBLY
Valve Dimension O
• Check dimensions of each valve. For dimensions, refer to EM-271,
"Standard and Limit".
• If dimensions are out of the standard, replace valve.
P

SEM188A

EM-239
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
Valve Guide Clearance

Valve Stem Diameter

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

Standard : Refer to EM-271, "Standard and

Limit".

JPBIA0183ZZ

Valve Guide Inner Diameter

• Measure inner diameter of valve guide with inside micrometer.

Standard : Refer to EM-271, "Standard and

Limit" .

Valve Guide Clearance

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

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If it exceeds the limit, replace valve and/or valve guide.
Valve Guide Replacement
When removing valve guide, replace it with oversized [0.2 mm (0.008 in)] valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).

JPBIA0184ZZ

2. Using the valve guide drift (commercial service tool), tap valve
guides out from the combustion chamber side.
WARNING:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.

SEM931C

EM-240
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
3. Ream cylinder head valve guide hole with the valve guide
reamer (commercial service tool) (A). A

Valve guide hole diameter : Refer to EM-271, "Standard

(for service parts) and Limit". EM

JPBIA0185ZZ

D
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
E

G
JPBIA0184ZZ

5. Using the valve guide drift (commercial service tool), press fit
valve guides from camshaft side, referring to the dimension H
shown in the figure.

Projection (L) : Refer to EM-271, "Standard and Lim- I

it".
WARNING:
Cylinder head contains heat, when working, wear protective J
equipment to avoid getting burned.
PBIC2497E
K
6. Using the valve guide reamer (commercial service tool), perform
reaming to the press-fitted valve guides.
L
Reaming specifications : Refer to EM-271, "Stan-
dard and Limit".
M

N
JPBIA0185ZZ

Valve Seat Contact

O
• Before starting this check, confirm that the dimension of valve
guide and valves are as specified.

A : OK P
B : NG
• Apply red lead primer on contacting surfaces of valves seat and of
valve face to examine the conditions of contacting surfaces.
• Check that the paint on contacting surfaces is continuous along the
entire circumference.

JPBIA0187ZZ

EM-241
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• If there are abnormal indications, grind the valve and check the contact again. If malfunction indications still
persist, replace valve seat.
Valve Seat Replacement
When removing valve seat, replace it with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-271, "Standard and Limit".
2. Ream cylinder head recess diameter (a) for service valve seat.

Oversize [0.5 mm : Refer to EM-271, "Standard and

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

JPBIA0188ZZ

3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
4. After cooling valve seats sufficiently with dry ice, press fit it to
cylinder head.
WARNING:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
CAUTION:
Never touch the cooled valve seats directly by hand.

JPBIA0184ZZ

5. Using the valve seat cutter set (commercial service tool), finish
processing referring to the dimensions shown in the figure.
Refer to EM-271, "Standard and Limit".
CAUTION:
When using the valve seat cutter set, grasp cutter handle
with both hands, press cutter onto contacting face all
around, and cut thoroughly. If cutter is pressed unevenly or
repeatedly, the valve seat surface may be damaged.

SEM934C

6. Using compound, perform valve fitting.

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

8. Use the depth gauge to measure the distance between the

mounting surface of cylinder head spring seat and the valve
stem end. If the distance is shorter than specified, repeat step 5
above to adjust it. If it is longer, replace valve seat with a new
one.

Valve seat resurface : Refer to EM-271, "Standard and

limit (L) Limit".

JEM253G

Valve Spring Square

EM-242
 CYLINDER HEAD
< SERVICE INFORMATION > [YD]
• Position the try square to valve spring, turn the spring, and mea-
sure the maximum clearance value between top surface of spring A
and the try square.

Limit : Refer to EM-271, "Standard and Limit". EM

• If it exceeds the limit, replace valve spring.

PBIC0080E

D
Valve Spring Dimensions and Valve Spring Pressure Load
• Using intake valve spring tester, check the following.

Standard : Refer to EM-271, "Standard and E

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

G
SEM113

INSPECTION AFTER INSTALLATION H

Inspection for Leakage

The following are procedures for checking fluid leakage, lubricant leakage. I
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If any are less than the
required quantity, fill them to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Follow the procedure below to check for fuel leakage.
- Turn ignition switch to the “ON” position (with engine stopped). With fuel pressure applied to fuel piping, J
check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. K
NOTE:
If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a
pounding noise during and just after the engine start. However, this does not indicate a malfunction. The
noise will stop after hydraulic pressure rises. L
• Warm up engine thoroughly to check that there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system. M
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill them to
the specified level, if necessary.
Summary of the inspection items: N
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level O
Transmission / AT & CVT Models Leakage Level / Leakage Leakage
transaxle fluid MT Models Level / Leakage Leakage Level / Leakage
P
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-243
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
ENGINE ASSEMBLY
Component INFOID:0000000007042416

JPBIA1398GB

1. Vacuum hose 2. Vacuum gallery 3. Vacuum hose

4. Vacuum hose 5. RH engine mounting insulator 6. RH engine mounting bracket
7. Engine mount control solenoid valve 8. Vacuum gallery 9. LH engine mounting bracket
10. Heat insulator 11. Vacuum hose 12. LH engine mounting insulator
13. Transmission cross member 14. Engine mounting insulator (rear) 15. RH engine mounting insulator
16. RH engine mounting bracket 17. LH engine mounting bracket 18. Heat insulator
19. LH engine mounting insulator
Models with electronic controlled en- Models without electronic controlled
A. B.
gine mount engine mount

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

EM-244
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
Removal and Installation INFOID:0000000007042417

A
WARNING:
• Situate vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels. EM
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations. C
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine main body section, refer to the applicable
sections. D
• 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 transmission jack or similar tool before
E
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-42, "Pantograph Jack,
Garage Jack and Safety Stand".
F
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or openings to prevent fluid from spilling.
G
REMOVAL
Description of work
Remove transmission assembly from vehicle downward. Then hoist the engine from vehicle upward. H
Preparation
1. Disconnect battery cable from negative terminal. Refer to SC-11.
2. Drain engine coolant from radiator. Refer to CO-38, "Changing Engine Coolant". I
3. Remove the following parts.
• Engine undercover front, engine undercover middle, engine undercover rear: Refer to EI-12.
• Hood assembly: Refer to BL-14, "Removal and Installation of Hood Assembly". J
• Engine cover: Refer to EM-159, "Exploded View".
• Drive belts: Refer to EM-153.
• Cooling fan, fan coupling and water pump pulley: Refer to CO-49. K
• Air duct and air cleaner case: Refer to EM-157, "Component".
• Air inlet tube and air inlet hose: Refer to EM-161.
• Alternator: Refer to SC-25, "Removal and Installation".
• Radiator, radiator shroud (upper and lower) and cooling fan assembly: Refer to CO-41 and CO-45. L
4. Disconnect engine room harness from the engine side and set it aside for easier work.
5. Disconnect all the body-side vacuum hoses and air hoses at engine side.
M
Engine room RH
1. Disconnect fuel feed hose and return hose. Refer to EM-181, "Exploded View".
2. Remove fuel filter. Refer to FL-16. N
3. Disconnect heater hose. Refer to CO-37, "Cooling Circuit".
Engine room LH
O
1. Remove A/C compressor with piping connected from engine. Temporarily secure it on body with a rope to
avoid putting load on it. Refer to ATC-115, "Removal and Installation for Compressor (YD models)".
Vehicle underbody P
1. Remove exhaust front tube. Refer to EX-6, "Component (YD Engine Models without DPF)".
2. Remove front and rear propeller shaft. Refer to PR-3 and PR-7.
3. Remove clutch operating cylinder from transmission, and move it aside (M/T models). Refer to CL-13 and
CL-13, "MODELS WITH YD ENGINE : Component".
4. Disconnect power steering fluid piping at a point between body and engine. Refer to PS-40, "Component
(YD25DDTi Models)".

EM-245
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
5. Remove starter motor. Refer to SC-41, "Removal and Installation".
6. Remove transmission assembly. Refer to MT-19 (M/T models) or AT-259 (A/T models).
Removal
1. Install engine slingers into front right of cylinder head (A) and
rear left of cylinder head (B).

1 : Engine slinger (front)

2 : Engine slinger (rear)
: Engine front

Engine slinger bolts:

: 22.0 N·m (2.2 kg-m, 16 ft-lb)
PBIC3480E

2. Lift with hoist and secure engine in position.

3. Loosen LH and RH engine mounting insulator mounting nuts.
4. Remove engine.
CAUTION:
• During the operation, check that no part interferes with
body side.
• Before and during this lifting, always check if any har-
nesses are left connected.

SEM896G

INSTALLATION
Install in the reverse order of removal.
• Do not allow engine oil to get on mounting insulator. Be careful not to damage mounting insulator.
• When installation directions are specified, install parts according to the direction marks on them referring to
figure of components. Refer to EM-244.
• Check that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
• Insert vacuum hose to vacuum gallery until vacuum hose comes in contact with the stopper when a stopper
is provided at vacuum gallery.
• Insert vacuum hose up to 15 mm (0. 59 in) when a stopper is not provided at vacuum gallery.
INSPECTION AFTER INSTALLATION
Inspection for Leaks

The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• 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-25.
• Use procedure below to check for fuel leakage.
- Before starting engine, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, 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
specified level, if necessary.

EM-246
 ENGINE ASSEMBLY
< SERVICE INFORMATION > [YD]
Summary of the inspection items:
Items A
Before starting engine Engine running After engine stopped

Engine coolant
Level Leakage Level
EM
Engine oil Level Leakage Level

Transmission / transaxle AT & CVT Models Leakage Level / Leakage Leakage

fluid MT Models Level / Leakage Leakage Level / Leakage C
Other oils and fluid (*) Level Leakage Level
Fuel Leakage Leakage Leakage
D
Exhaust gases — Leakage —
* Power steering fluid, brake fluid, etc.
E

EM-247
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
CYLINDER BLOCK
Component INFOID:0000000007042418

JPBIA3700GB

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

4. Alternator bracket 5. Drain plug 6. Top ring
7. Second ring 8. Oil ring 9. Snap ring
10. Piston 11. Piston pin 12. Connecting rod
13. Connecting rod bearing 14. Connecting rod cap 15. Main bearing cap
16. Main bearing lower 17. Drive plate 18. Reinforcement plate
19. Crankshaft 20. Key 21. Main bearing upper
22. Thrust bearing 23. Oil jet 24. Rear oil seal retainer
25. Rear oil seal 26. Rear cover 27. Oil pressure switch
28. Knock sensor

EM-248
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
A. Comply with the installation proce- B. Comply with the installation proce-
dure when tightening. Refer to EM- dure when tightening. Refer to EM- A
249, "Disassembly and Assembly". 249, "Disassembly and Assembly".
Refer to GI-9, "Component" for symbols in the figure.
EM
Disassembly and Assembly INFOID:0000000007042419

DISASSEMBLY
C
1. Remove the following parts:
• EGR system. Refer to EM-159, "Exploded View".
• Turbocharger. Refer to EM-167, "Component".
• Exhaust manifold. Refer to EM-171, "Component". D
• Intake manifold. Refer to EM-163, "Component".
• Vacuum pump. Refer to EM-179, "Component".
• Glow plug. Refer to EM-178, "Component". E
• Injection tube and fuel injector. Refer to EM-181, "Exploded View".
• Rocker cover. Refer to EM-196, "Component".
• Secondary timing chain. Refer to EM-213, "Component".
• Camshaft. Refer to EM-199, "Component". F
• Cylinder head assembly. Refer to EM-233, "Exploded View".
• Oil pan and oil strainer: Refer to EM-173, "Component".
• Water pump. Refer to CO-51, "Removal and Installation". G
• Thermostat. Refer to CO-53, "Component".
• Water piping. Refer to CO-37, "Cooling Circuit".
• Fuel pump and fuel pump bracket. Refer to EM-186, "Component".
H
• Oil cooler. Refer to LU-25, "Component".
• A/C compressor. Refer to ATC-115, "Removal and Installation for Compressor (YD models)" or ATC-
242, "Removal and Installation for Compressor".
• Alternator. Refer to SC-41, "Removal and Installation". I
2. Remove rear oil seal retainer.
• Insert a flat-bladed screwdriver between main bearing cap and rear oil seal retainer to remove retainer.
3. Remove rear oil seal from rear oil seal retainer. Refer to EM-211, "Removal and Installation of Rear Oil J
Seal".
• Punch out with a flat-bladed screwdriver.
CAUTION: K
Be careful not to damage rear oil seal retainer.
4. Remove piston and connecting rod assembly.
• Before removing piston and connecting rod assembly, check
L
connecting rod side clearance. Refer to EM-271, "Standard
and Limit".
a. Move crankshaft pin to be removed to approximately BDC.
M
b. Remove connecting rod caps.
c. Using the grip of a hammer, press the piston and connecting rod
assembly out to cylinder head side.
CAUTION: N
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod JEM195G

big end. O

EM-249
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• When removing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
oil jet (1).

JPBIA3896ZZ

5. Remove connecting rod bearings from connecting rods and caps.

CAUTION:
• Be careful not to drop connecting rod bearing, and to scratch the surface.
• Identify installation positions, and store them without mixing them up.

6. Remove piston rings from pistons using the piston ring expander
(commercial service tool) (A).
CAUTION:
• When removing, prevent pistons from being damaged.
• Never expand piston rings excessively. This may damage
piston rings.

PBIC3233J

7. Remove pistons from connecting rods.

a. Using the snap ring pliers (A), remove snap rings.

PBIC3230J

b. Using the industrial use dryer (A), heat pistons up to 60 to 70°C

(140 to 158°F).

PBIC3231J

EM-250
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
c. Using rod with outer diameter of 26 mm (1.02 in), press piston
pins out. A

EM

EMM0072D

D
8. Loosen and remove main bearing cap bolts in reverse order as
shown in the figure.
E
: Engine front

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

• Before loosening main bearing cap bolts, measure crankshaft F
end play. Refer to EM-256, "Inspection".

G
JPBIA3788ZZ

9. Remove main bearing caps. H

• Insert bolts (1) into bolt holes, and then remove main bearing
cap (2) by lifting up and shaking forward and backward.
10. Remove crankshaft.
I
11. Remove main bearings and thrust bearings from cylinder block
and main bearing caps.
CAUTION:
Check the correct installation locations of removed parts. J
Store them so they never get mixed up.
12. Remove oil jet.
JPBIA2478ZZ
13. Remove oil jet relief valve. K

ASSEMBLY
1. Blow air sufficiently to inside engine coolant passage, engine oil passage, crankcase and cylinder bore to L
remove foreign matter.
CAUTION:
Use a goggles to protect your eye.
M
2. Install drain plug to cylinder block (1).
• Apply liquid gasket to drain plug (2).
Use Genuine Liquid Gasket or equivalent
• Tighten drain plug. N

: 46.6 N·m (4.8 kg-m, 34 ft-lb)

O

P
PBIC3483E

3. Install oil jet relief valve.

EM-251
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
4. Install oil jet.
• Align knock pin on back of oil jet with hole on block when
installing oil jet.

PBIC0389E

5. Install main bearings and thrust bearings.

a. Remove contamination, dust and engine oil from bearing mount-
ing positions on cylinder block and main bearing caps.
b. Install thrust bearings on both sides of No. 3 housing on cylinder
block.
• Install thrust bearings with oil groove facing to crankshaft arm
(outside).

JEM224G

c. Being careful with the direction, install main bearings.

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

JEM225G

9. With the TORX socket (size: E14) (commercial service tool),

tighten the main bearing cap bolts according to the following
procedure:

: Engine front

a. Apply engine oil to the threaded part and seat surface of each
bolt.
b. Tighten all bolts in numerical order shown in the figure.

: 27.0 N·m (2.8 kg-m, 20 ft-lb) JPBIA3788ZZ

EM-252
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
c. Put alignment marks (with paint) on each bolt and the main bearing cap, all in the same direction. (When
using a protractor) A

d. Then, tighten 90 degrees. (angle tightening)

CAUTION:
Always use either the angle wrench [SST: KV10112100] or EM
protractor during angular tightening. Avoid tightening
based on visual checks alone.
• After tightening bolts to specified torque, check that crankshaft C
rotates smoothly.
• Check crankshaft end play. Refer to EM-256, "Inspection".
10. Check the outer diameter of connecting rod bolts. Refer to EM- D
256, "Inspection".
11. Install piston to connecting rod. JEM226G

a. Using the snap ring pliers, install snap rings to groove on piston E
rear side.
• Fit snap ring correctly into grooves.
b. Install pistons to connecting rods. F
• Using the industrial use dryer (A), heat pistons up to approx.
60 to 70°C (140 to 158°F) until piston pin can be pressed
down by finger touch. Then insert piston pin into piston and
connecting rod from front side of piston toward rear. G

I
PBIC3231J

• Assemble piston and connecting rod with front mark of piston J

head and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
c. Install snap ring to front side of piston.
K
• Refer to above step a for precaution on snap ring installation.
• After installation, check connecting rods for smooth move-
ment.
L

MBIA0024E M
12. Use the piston ring expander (commercial service tool) to install piston rings.
CAUTION:
When installing, prevent piston from being damaged. N
• Install top ring and second ring with punched mark surfaces
facing upward.
O
Punched mark:
Top ring : RTOP
Second ring : R2ND P
• Install rings so that three closed gap position 120 degrees
apart one another.
• Closed gaps do not need to face in a specific directions, as
long as each are positioned 120 degrees apart. JEM228G

EM-253
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
13. Install connecting rod bearing to connecting rod and cap.
• While installing connecting rod bearing, apply engine oil to
bearing surfaces (inside). Do not apply engine oil to rear sur-
faces, but clean them completely.
• Align protrusions on connecting rod bearings with connecting
rod cut-outs to install connecting rod bearings.

JEM229G

14. Install piston and connecting rod assembly to crankshaft.

• Move crankshaft pin to be assembled to BDC.
• Align cylinder position with cylinder No. on connecting rod to
install piston and connecting rod assembly.
• Using the piston ring compressor [SST: EM03470000] or suit-
able tool, install piston and connecting rod assembly with front
mark on piston head facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
oil jet.
PBIC1619E

15. Install connecting rod caps and mounting nuts.

• Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
• Check that the front mark on connecting rod cap faces
towards the front of the engine.

MBIA0024E

16. Tighten connecting rod nuts according to the following procedure:

a. Apply engine oil on bolt threads and seat surface of nuts.
b. Tighten bolts.

: 29.4 N·m (3.0 kg-m, 22 ft-lb)

c. Loosen completely.

: 0 N·m (0 kg-m, 0 in-lb)

d. Tighten bolts.

: 19.6 N·m (2.0 kg-m, 14 ft-lb)

e. Tighten bolts.

EM-254
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]

Angle tightening : 120 degrees A

• Always use either the angle wrench [SST: KV10112100] or
protractor during angular tightening. Avoid tightening
based on visual checks alone. EM
• After tightening nuts, check that crankshaft rotates smoothly.
• Check connecting rod side clearance. Refer to EM-256,
"Inspection".
C

JEM231G

D
17. Press fit rear oil seal into rear oil seal retainer.
• Using the drift [105 mm (4.13 in) dia.], press fit so that the
dimension is as specified in the figure.
E
• Avoid inclined fitting. Force fit perpendicularly.

G
JEM232G

18. Install rear oil seal retainer to cylinder block. H

• Apply new engine oil to the oil and dust seal lips.
• Apply liquid gasket to rear oil seal retainer using the tube
presser (commercial service tool) as shown in the figure. I
Use Genuine Liquid Gasket or equivalent.

JEM233G
K

19. Install fuel pump bracket (1).

• Align the bracket with the dowel pins (A) on cylinder block to L
install.

JPBIA3897ZZ

O
20. Assemble in the reverse order of disassembly.
21. Remove engine from engine stand in the reverse order of assembly.
P

EM-255
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
22. Install drive plate (1).

A : Rounded
: Engine front

• When installing drive plate to crankshaft (2), be sure to cor-

rectly align crankshaft side dowel pin and drive plate side
dowel pin hole.
CAUTION:
If these are not aligned correctly, engine runs roughly and
“MI” turns on.
JPBIA3915ZZ
• Install drive plate and reinforcement plate (3) as shown in the
figure.
• Holding ring gear with ring gear stopper [SST: KV10105630], tighten securing bolts with TORX socket
(size: E20) (commercial service tool).
• Tighten bolts uniformly in a crisscross manner.

23. Install in the reverse order of removal.

Inspection INFOID:0000000007042420

CRANKSHAFT END PLAY

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

Standard and limit : Refer to EM-271, "Standard and

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

CONNECTING ROD SIDE CLEARANCE

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

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If measured value exceeds the limit, replace connecting rod and
repeat measurement.
If measured value still exceeds the limit, replace crankshaft.

JEM203G

PISTON TO PISTON PIN CLEARANCE

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

Standard : Refer to EM-271, "Standard and Limit".

JPBIA0217ZZ

EM-256
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A). A

Standard : Refer to EM-271, "Standard and Limit".

EM

JPBIA0218ZZ D
Calculation of Piston to Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) − (Piston pin outer diameter)
E
Standard : Refer to EM-271, "Standard and Limit".
• If out of the standard, replace piston/piston pin assembly.
NOTE: F
Piston is available together with piston pin as assembly.
PISTON RING SIDE CLEARANCE G
• Measure the side clearance of piston ring (1) and piston ring groove with a feeler gauge (C).

A : NG
H
B : OK

Standard and limit : Refer to EM-271, "Standard and

I
Limit".

JPBIA2276ZZ

K
• Align top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of ring
groove.
• If side clearance exceeds the limit, replace piston ring. L
• Check clearance again. If side clearance still exceeds the limit,
replace piston.
M

N
FEM100

PISTON RING END GAP

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

A : Press-fit

Standard and limit : Refer to EM-271, "Standard and

Limit".
JPBIA2277ZZ

EM-257
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder and use oversize piston and piston rings.
CONNECTING ROD BEND AND TORSION
• Check with a connecting rod aligner.

A : Bend
B : Torsion
C : Feeler gauge

Bend limit : Refer to EM-271, "Standard and

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

JPBIA0221ZZ

CONNECTING ROD BIG END DIAMETER

• Install connecting rod bearing cap without installing connecting rod
bearing, and tighten connecting rod bolts to the specified torque.
Refer to EM-249, "Disassembly and Assembly" for the tightening
procedure.

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

Standard : Refer to EM-271, "Standard and Limit".

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).

Standard : Refer to EM-271, "Standard and Limit".

JPBIA0223ZZ

Piston Pin Outer Diameter

EM-258
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
Measure the outer diameter of piston pin with a micrometer (A).
A
Standard : Refer to EM-271, "Standard and Limit".

EM

JPBIA0218ZZ

D
Connecting Rod Bushing Oil Clearance
(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
E
Standard and limit : Refer to EM-271, "Standard and Limit".
• If the calculated value exceeds the limit, replace connecting rod assembly and/or piston and piston pin
assembly. F
• If replacing piston and piston pin assembly, refer to EM-249, "Disassembly and Assembly".
• If replacing connecting rod assembly, refer to EM-271, "Standard and Limit" to select the connecting rod
bearing. G
CYLINDER BLOCK DISTORTION
• Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or
other contamination. H
CAUTION:
Be careful not to allow gasket flakes to enter engine oil or engine coolant passages.
• Measure the distortion on the cylinder block upper face at some I
different points in six directions (C), (D), (E), (F), (G) and (H) with a
straightedge (A) and a feeler gauge (B).

Limit : Refer to EM-271, "Standard and Limit". J

• If it exceeds the limit, replace cylinder block.

K

JPBIA0224ZZ L
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap (2) without installing main bearings, and
tighten main bearing cap bolts to the specified torque. Refer to EM- M
249, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge. N
Standard : Refer to EM-271, "Standard and Limit".
• If out of the standard, replace cylinder block (1) and main bearing O
cap as assembly.
NOTE:
Cylinder block cannot be replaced as a single part, because it is JPBIA0225ZZ

machined together with main bearing cap. P

PISTON TO CYLINDER BORE CLEARANCE

Cylinder Bore Inner Diameter

EM-259
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• Using a bore gauge, measure the cylinder bore for wear, out-of
round and taper at six different points on each cylinder. [(A) and (B)
directions at (C), (D), and (E)] [(A) is in longitudinal direction of
engine]

f : 10 mm (0.39 in)
g : 85 mm (3.35 in)
h : 160 mm (6.30 in)

Standard and limit : Refer to EM-271, "Standard and

JPBIA2059ZZ
Limit".

• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
hone or bore the inner wall.
• Oversize piston is provided. When using oversize piston, hone the cylinder so that the clearance between
piston and cylinder satisfies the standard.
CAUTION:
If oversize piston is used, use it for all cylinders with oversize piston rings.

Oversize (O/S) : Refer to EM-271, "Standard and

Limit".
Piston Outer Diameter
Measure the outer diameter of piston skirt with a micrometer (A).

Measurement position : Refer to EM-271, "Standard

Standard and Limit".

JPBIA0227ZZ

Piston to Cylinder Bore Clearance

• Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].

A : Direction A
C : Position C
E : Position E
f : 10 mm (0.39 in)
g : 85 mm (3.35 in)
h : 160 mm (6.30 in)
(Clearance) = (Cylinder bore inner diameter) − (Piston outer diam- JPBIA2059ZZ
eter)

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If it exceeds the limit, replace piston and piston pin assembly. Refer to EM-249, "Disassembly and Assem-
bly".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.

EM-260
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]

Re-bore size calculation: A

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

Standard : Refer to EM-271, "Standard and Limit".

• If out of the standard, measure the main bearing oil clearance. I
Then use the under size bearing. Refer to EM-265, "How to Select
Piston and Bearing".
J

FEM114
K
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A).
L
Standard : Refer to EM-271, "Standard and Limit".
• If out of the standard, measure the connecting rod bearing oil M
clearance. Then use under size bearing. Refer to EM-265, "How to
Select Piston and Bearing".

JPBIA0228ZZ

CRANKSHAFT OUT-OF-ROUND AND TAPER O

EM-261
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in the dimensions
between (d) and (c) at (a) and (b).
• Taper is indicated by the difference in the dimensions between.

Out-of-round (Difference : Refer to EM-271, "Stan-

between c and d) dard and Limit".
Taper (Difference between
a and b)
JPBIA0229ZZ
• If the measured value exceeds the limit, correct or replace crank-
shaft.
• If corrected, measure the bearing oil clearance of the corrected journal and/or pin. Then select the main
bearing or connecting rod bearing. Refer to EM-265, "How to Select Piston and Bearing" and/or EM-271,
"Standard and Limit".
CRANKSHAFT RUNOUT
• Place V-block on precise flat table, and support the journals on
both ends of crankshaft.
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on a
dial indicator. (Total indicator reading)

Standard and limit : Refer to EM-271, "Standard and

Limit".
• If it exceeds the limit, replace crankshaft.
SEM346D

CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation
• Install connecting rod bearings (1) to connecting rod (2) and con-
necting rod cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-249, "Disassembly and Assembly" for the
tightening procedure.

JPBIA0230ZZ

• Measure the inner diameter of connecting rod bearing with an inside micrometer.
(Oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter)

Standard and limit : Refer to EM-271, "Standard and Limit".

• If the calculated value exceeds the limit, select proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-256, "Inspection".
Method of Using Plastigage
• Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and connecting rod bearing cap, and tighten connecting
rod bolts to the specified torque. Refer to EM-249, "Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:

EM-262
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
Never rotate crankshaft.
• Remove connecting rod bearing cap and bearings, and using the A
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
EM
same as that described in the “Method by Calculation”.

JPBIA0231ZZ D
MAIN BEARING OIL CLEARANCE
Method by Calculation E
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-249, "Disassembly and Assembly" for the tightening
procedure. F
• Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter) G

Standard and limit : Refer to EM-271, "Standard and

Limit". H
• If the calculated value exceeds the limit, select proper main bear- JPBIA0232ZZ

ing according to main bearing inner diameter and crankshaft main

journal diameter to obtain the specified bearing oil clearance. Refer to EM-256, "Inspection". I
Method of Using Plastigage
• Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil J
holes.
• Install main bearing to cylinder block and main bearing cap, and tighten main bearing cap bolts with main
bearing cap to the specified torque. Refer to EM-249, "Disassembly and Assembly" for the tightening proce-
dure. K
CAUTION:
Never rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale on L
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
M
same as that described in the “Method by Calculation”.

JPBIA0231ZZ O
MAIN BEARING CRUSH HEIGHT
P

EM-263
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• 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-237, "Disassembly and
Assembly" for the tightening procedure.

A : Crush height

Standard : There must be crush height.

• If the standard is not met, replace main bearings.
JPBIA0233ZZ

CONNECTING ROD BEARING CRUSH HEIGHT

• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings (1) installed,
the tip end of bearing must protrude. Refer to EM-237, "Disassem-
bly and Assembly" for the tightening procedure.

A : Crush height

Standard : There must be crush height.

• If the standard is not met, replace connecting rod bearings.
JPBIA0233ZZ

MAIN BEARING CAP BOLT DEFORMATION

• Measure the outer diameter of threaded area, “d1” and “d2”, at the
points specified in the figure.
• When the necked point is identified at a point other than where
specified, measure at the point as “d2”.
• Calculate the difference between “d1” and “d2”.

Limit : 0.13 mm (0.0051 in)

• If it exceeds the limit, replace main bearing cap bolt.

JEM219G

CONNECTING ROD BOLT DEFORMATION

• Install nuts to connecting rod bolts. Check that the nut can be
screwed smoothly on bolt threads by hand to the last thread on the
bolt.
• If the nut does not screw in smoothly, measure the outer diameter
of the bolt thread at the point specified in the figure.
• If a necked point is identified, measure at that point.

Standard : 8.90 - 9.00 mm (0.3504 - 0.3543 in) dia.

Limit : 8.75 mm (0. 3445 in) dia.
• If it exceeds the limit, replace connecting rod bolts and nuts.
JEM220G

OIL JET

EM-264
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs. A

Standard : No deformation and no damage.

• If out of the standard, replace oil jet. EM

JEM221G

D
OIL JET RELIEF VALVE
• Using clean plastic stick, press check valve in oil jet relief valve.
Check that valve moves smoothly with proper reaction force.
E
Standard:
Valve moves smoothly with proper reaction force.
F
• If out of the standard, replace oil jet relief valve.

JEM222G

DRIVE PLATE H
• Check drive plate and signal plate for deformation or cracks.
CAUTION:
• Never disassemble drive plate.
I
• Never place drive plate with signal plate facing down.
• When handling signal plate, take care not to damage or
scratch it.
• Handle signal plate in a manner that prevents it from becom- J
ing magnetized.
• If anything is found, replace drive plate.
K
SEM760G

How to Select Piston and Bearing INFOID:0000000007042421

L
DESCRIPTION

Selection points Selection parts Selection items Selection methods M

Determined by match of cylin-
der block bearing housing
Between cylinder block to Main bearing grade (bearing grade (inner diameter of hous- N
Main bearing
crankshaft thickness) ing) and crankshaft journal
grade (outer diameter of jour-
nal)
O
Combining service grades for
connecting rod big end diame-
Between crankshaft to connect- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
ing rod (bearing thickness)
ameter determine connecting P
rod bearing selection.
Piston and piston pin assembly
Between cylinder block to pis- Piston grade (piston outer diam- Piston grade = cylinder bore
The piston is available together
ton eter) grade (inner diameter of bore)
with piston pin as an assembly.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.

EM-265
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON WHEN NEW CYLINDER BLOCK IS USED
1. Identify the cylinder bore grade (No. 1, 2, or 3) on LH surface at
the rear of cylinder block.
2. Select piston of the same grade.
• The part No. of piston is specified together with piston pin as
an assembly.

JEM208G

HOW TO SELECT PISTON WHEN CYLINDER BLOCK IS REUSED

1. Measure cylinder bore inner diameter. Refer to EM-265, "How to Select Piston and Bearing".
2. Referring to “Cylinder bore inner diameter” in “Piston Selection Table”, determine the bore grade.

A : Identification code
B : Front mark
C : Piston grade number
3. Select piston of the same grade.

JPBIA3910ZZ

PISTON SELECTION TABLE

Unit: mm (in)

Grade (punched) 1 2 3
Cylinder bore in-
89.000 - 89.010 (3.5039 - 3.5043) 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
ner diameter
Piston outer di-
88.806 - 88.820 (3.4963 - 3.4968) 88.816 - 88.830 (3.4967 - 3.4972) 88.826 - 88.840 (3.4971 - 3.4976)
ameter

NOTE:
Piston is available together with piston pin as an assembly.
HOW TO SELECT CONNECTING ROD WHEN NEW CONNECTING ROD AND CRANKSHAFT
ARE USED
1. Identify the pin diameter grade on front surface of crankshaft.
2. Select connecting rod bearings of the same grade.
NOTE:
There is no grading for the inner diameter of the big end of the
connecting rod.

JEM215G

HOW TO SELECT CONNECTING ROD WHEN CONNECTING ROD AND CRANKSHAFT ARE RE-

EM-266
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
USED
1. Measure the inner diameter of the big end of connecting rod and check it is within the specified range. A
Refer to EM-256, "Inspection".
2. Measure the outer diameter of the crankshaft pin. Refer to EM-256, "Inspection".
3. Determine the crankshaft pin grade by comparing the measurement with the values under the column EM
“Crankshaft pin outer diameter” in “Selection Table of connecting Rod Bearing”.
4. Choose bearings of the same grade.
C
CONNECTING ROD BEARING SELECTION TABLE

JPBIA3907GB

N
UNDERSIZE BEARING USAGE GUIDE
• If bearing clearance is out of the specifications for connecting rod bearings in standard size, use under size
bearings. O
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank-
shaft pins to adjust clearance to specification.

Connecting rod bearing under size : Refer to EM-271, "Standard and Limit". P

CAUTION:

EM-267
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
When grinding the crankshaft pin to use an under size bearing,
avoid damaging the fillet R.

Standard dimension R : 1.5 - 1.7 mm (0.059 - 0.067 in)

JEM216G

HOW TO SELECT MAIN BEARING WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE
USED
1. Identify the crank journal grade on LH surface at the rear of the
cylinder block, and locate the applicable grade on the “Grade”
row in the “Main Bearing Grade Table”.

JEM208G

2. Identify the journal grade on the front surface of crankshaft, and

locate the applicable grade under the “Grade” column in the
“Main Bearing Grade Table”.

JEM215G

3. The main bearing to be used can be located in the cell where the row and column cross.
HOW TO SELECT MAIN BEARING WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the inner diameter of cylinder block main bearing housing. Refer to EM-256, "Inspection".
2. Locate the applicable cell where the measurement falls, on “Inner diameter of Cylinder block main bearing
housing” row in the “Main Bearing Grade Table”.
3. Measure the outer diameter of crankshaft journal. Refer to EM-256, "Inspection".
4. Locate the applicable cell where the measurement falls, under “Crankshaft journal outer diameter” column
in the “Main Bearing Grade Table”.
5. The main bearing to be used can be located in the cell where the row and column cross.

EM-268
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
MAIN BEARING SELECTION TABLE
A

EM

L
JPBIA3906GB

MAIN BEARING GRADE TABLE (ALL JOURNALS) M

Main bearing grade table (All journals) : Refer to EM-271, "Standard and
Limit". N
UNDERSIZE BEARING USAGE GUIDE
• If bearing clearance is out of the specifications for main bearings in standard size, use under size bearings.
• When using under size bearings, measure bearing inner diameter with bearing installed, and grind crank- O
shaft journals to adjust clearance to the specification.

Main bearing under size : Refer to EM-271, "Standard and P

Limit".
CAUTION:

EM-269
 CYLINDER BLOCK
< SERVICE INFORMATION > [YD]
When grinding crank journals to use under size bearings, keep
corners radius of fillet R. (All journals)

Standard dimension R : 1.5 - 1.7 mm (0.059 - 0.067 in)

JEM216G

EM-270
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
SERVICE DATA AND SPECIFICATIONS (SDS)
A
Standard and Limit INFOID:0000000007042422

GENERAL SPECIFICATIONS EM

Cylinder arrangement In-line 4

Displacement Unit: cm3 (cu in) 2,488 (151.82) C
Bore and stroke Unit: mm (in) 89.0 x 100 (3.504 x 3.937)
Valve arrangement DOHC
D
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 E
Number of main bearings 5
Compression ratio 15
F
Standard 2,800 (28, 28.56, 406)
Compression pressure
Minimum 2,200 (22, 22.44, 319)
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 450 (4.5, 4.59, 65.3) G
Unit: degree
Intake valve open (BTDC) 2
H
Intake valve close (ABDC) 30
Valve timing
Exhaust valve open (BBDC) 46
Exhaust valve close (ATDC) -2 I
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
J
Items Limit
Intake manifold 0.1 (0.004)
Surface distortion
Exhaust manifold 0.3 (0.012) K
DRIVE BELTS
Belt Deflection:
L
Belt deflection with 98 N (10 kg, 22 lb) force applied* mm (in)
Applied belt
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water M
Auto adjustment by auto-tensioner
pump belt
4.6 - 5.4 7.1 - 7.7
Power steering oil pump belt 11.3 (0.445)
(0.181 - 0.213) (0.280 - 0.303) N
*: When engine is cold.
Belt Frequency:
O
Belt frequency (Hertz)
Applied belt
New Adjusted Limit for re-adjusting
A/C compressor, alternator and water
Auto adjustment by auto-tensioner
P
pump belt
Power steering oil pump belt 290 245 162
*: When engine is cold.

CYLINDER HEAD

EM-271
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)
Items Standard Limit
Cylinder head distortion Less than 0.04 (0.0016) 0.1 (0.004)

JEM204G

VALVE
Valve Dimensions
Unit: mm (in)

SEM188

Intake 28.4 - 28.7 (1.1181 - 1.1299)

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

Valve Clearance
Unit: mm (in)

Items Cold Hot* (Reference data)

Intake 0.24 - 0.32 (0.009 - 0.013) 0.274 - 0.386 (0.011 - 0.015)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)

Available Shims

EM-272
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]

Stamped mark (A) Thickness mm (in) A

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

JPBIA3912ZZ

Valve Spring

EM-273
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]

Valve spring square mm (in) 1.9 (0.075)

Intake 43.7 (1.720)
Free height mm (in)
Exhaust 43.7 (1.720)
Pressure N (kg, lb) at height mm (in) 184 - 208 (18.77 - 21.22, 41.4 - 46.8) at 32.82 (1.2921)
Intake 24.95 (0.9823)
Height during valve open mm (in)
Exhaust 24.66 (0.9709)
Intake 250 - 274 (25.5 - 27.9, 56.2 - 61.6)
Load with valve open N (kg, lb)
Exhaust 308 - 336 (31.4 - 34.3, 69.2 - 75.5)

Valve Lifter
Unit: mm (in)

Items Standard
Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801)
Valve lifter bore diameter 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.025 - 0.061 (0.0010 - 0.0024)

Valve Guide
Unit: mm (in)

JEM156G

Items Standard Service

Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Items Standard Limit
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.10 (0.0039)
Projection length 10.4 - 10.6 (0.409 - 0.417)

Valve Seat

EM-274
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)
A

EM

E1BIA0294ZZ

JEM253G
M
Items Standard Oversize (Service) [0.5 (0.020)]

Cylinder head seat (1) recess diame- Intake 30.4 - 30.416 (1.1968 - 1.1975) 30.9 - 30.916 (1.2165 - 1.2165)
ter “D” Exhaust 28.200 - 28.216 (1.1102 - 1.1109) 28.7 - 28.716 (1.1299 - 1.1305) N
Intake (A) 30.48 - 30.5 (1.2 - 1.2008) 30.98 - 31.0 (1.2197 - 1.2205)
Valve seat outer diameter “d”
Exhaust (B) 28.28 - 28.296 (1.1134 - 1.1140) 28.78 - 28.796 (1.1331 - 1.1337)
O
Intake (A) 0.064 - 0.100 (0.0025 - 0.0039)
Valve seat interference fit
Exhaust (B) 0.064 - 0.096 (0.0025 - 0.0038)
Intake (A) 27.7 - 28.2 (1.0689 - 1.0886) 27.7 - 28.2 (1.0689 - 1.0886) P
Diameter “d1”
Exhaust (B) 25.1 - 25.6 (0.9882 - 1.0079) 25.1 - 25.6 (0.9882 - 1.0079)
Angle “α” 89.5°±45′
Intake (A) 6.84 - 6.94 (0.269 - 0.273) 6.39 - 6.49 (0.252 - 0.256)
Height “h1”
Exhaust (B) 6.84 - 6.94 (0.264 - 0.268) 6.84 - 6.94 (0.269 - 0.273)

EM-275
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Intake (A) 2.25 - 2.45 (0.089 - 0.096) 2.15 - 2.55 (0.085 - 0.1004)
Height “h2”
Exhaust (B) 2.9 - 3.1 (0.1142 - 0.1220) 2.8 - 3.2 (0.1102 - 0.1260)
Intake 8.85 - 9.15 (0.3484 - 0.3602)
Depth “H”
Exhaust 9.29 - 9.59 (0.3657 - 0.3776)
Intake 36.18 - 36.78 (1.4382 - 1.4559)
Projection (L)
Exhaust 36.16 - 36.96 (1.4236 - 1.4551)

CAMSHAFT
Unit: mm (in)

Items Standard Limit

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

SEM671

Intake 39.505 - 39.695 (1.5553 - 1.5628)

Cam height “A”
Exhaust 39.905 - 40.095 (1.5711 - 1.5785)
*: Total indicator reading

CYLINDER BLOCK
Unit: mm (in)

SEM899G

Standard Less than 0.03 (0.0012)

Top surface distortion
Limit 0.1 (0.004)

EM-276
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Grade No. 1 89.000 - 89.010 (3.5039 - 3.5043)
A
Standard Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Cylinder bore Inner diameter
Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.07 (0.0028) EM
Out-of-round (Difference between X and Y) 0.015 (0.0006)
Limit
Taper (Difference between A and C) 0.010 (0.0004)
Main bearing housing inner diameter (Without bearing) 66.656 - 66.680 (2.6242 - 2.6252) C
Difference in inner diameter
Limit Less than 0.05 (0.0020)
between cylinders
D
PISTON, PISTON RING AND PISTON PIN
Available Piston
Unit: mm (in) E

E1BIA0295ZZ

Grade No. 1 88.806 - 88.820 (3.496 - 3.4968) I

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

Items Standard Limit M

Top 0.04 - 0.06 (0.0016 - 0.0024) 0.17 (0.007)
Side clearance 2nd 0.08 - 0.12 (0.0031 - 0.0047) 0.13 (0.005)
N
Oil ring 0.030 - 0.070 (0.0012 - 0.0028) —
Top 0.18 - 0.28 (0.0071 - 0.0110)
End gap 2nd 0.32 - 0.47 (0.0126 - 0.0185) 1.0 (0.039) O
Oil ring 0.30 - 0.55 (0.0118 - 0.0217)

Piston Pin
P
Unit: mm (in)

Piston pin outer diameter 27.995 - 28.000 (1.1022 - 1.1024)

Piston to piston pin clearance 0.008 - 0.018 (0.0003 - 0.0007)
Standard 0.026 - 0.043 (0.0010 - 0.0017)
Connecting rod bushing clearance
Limit 0.057 (0.0022)

CONNECTING ROD
EM-277
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)

Center distance 154.47 - 154.53 (6.0815 - 6.0838)

Bend [per 100 (3.94)] Limit 0.12 (0.0047)
Torsion [per 100 (3.94)] Limit 0.12 (0.0047)
Connecting rod bushing inner diameter* 28.026 - 28.038 (1.1034 - 1.1039)
Connecting rod big end inner diameter* 55.000 - 55.013 (2.1654 - 2.1659)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.40 (0.0157)
*: After installing in connecting rod

CRANKSHAFT
Unit: mm (in)

Main journal dia. “Dm” 62.951 - 62.975 (2.4784 - 2.4793)

Pin journal dia. “Dp” 51.956 - 51.974 (2.0455 - 2.0462)
Center distance “r” 49.97 - 50.03 (1.9673 - 1.9697)

Out-of-round (Difference between X Standard 0.003 (0.0001)

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

SEM645 SBIA0535E

*: Total indicator reading

AVAILABLE MAIN BEARING

Main bearing

EM-278
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
Unit: mm (in)
A

EM

D
SEM255G

Grade number Thickness Width Identification color Remarks

E
0 1.812 - 1.809 (0.0713 - 0.0712) Black
1 1.815 - 1.812 (0.0715 - 0.0713) Brown
2 1.818 - 1.815 (0.0716 - 0.0715) Green
F
3 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are the
same for upper and
4 1.824 - 1.821 (0.0718 - 0.0717) Blue lower bearings.
5 1.827 - 1.824 (0.0719 - 0.0718) Pink G
6 1.830 - 1.827 (0.0720 - 0.0719) Purple
7 1.833 - 1.830 (0.0722 - 0.0720 Red
H
UPR 1.812 - 1.809 (0.0715 - 0.0712) Black
01
LWR 1.815 - 1.812 (0.0715 - 0.0713) Brown
UPR 1.815 - 1.812 (0.0715 - 0.0713) 19.9 - 20.1 Brown I
12
LWR 1.818 - 1.815 (0.0716 - 0.0715) (0.783 - 0.791) Green
UPR 1.818 - 1.815 (0.0716 - 0.0715) Green
23 J
LWR 1.821 - 1.818 (0.0717 - 0.0716) Yellow
UPR 1.821 - 1.818 (0.0717 - 0.0716) Yellow Grade and color are dif-
34 ferent between upper
LWR 1.824 - 1.821 (0.0718 - 0.0717) Blue and lower bearings. K
UPR 1.824 - 1.821 (0.0718 - 0.0717) Blue
45
LWR 1.827 - 1.824 (0.0719 - 0.0718) Pink
L
UPR 1.827 - 1.824 (0.0719 - 0.0718) Pink
56
LWR 1.830 - 1.827 (0.0720 - 0.0719) Purple
UPR 1.830 - 1.827 (0.0720 - 0.0719) Purple M
67
LWR 1.833 - 1.830 (0.0722 - 0.0720 Red

Undersize
Unit: mm (in) N
Size Thickness Main journal diameter “Dm”
Grind so that bearing clearance is the spec-
0.25 (0.0098) 1.949 - 1.953 (0.0767 - 0.0769) O
ified value.

AVAILABLE CONNECTING ROD BEARING

Connecting Rod Bearing P

Grade number Thickness mm (in) Width Identification color Remarks

EM-279
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE INFORMATION > [YD]
0 1.488 - 1.485 (0.0586 - 0.0585) Green
1 1.491 - 1.488 (0.0585 - 0.0587) Yellow
Grade and color are the same
2 1.494 - 1.491 (0.0588 - 0.0585) Blue
for upper and lower bearings.
3 1.497 - 1.494 (0.0589 - 0.0588) Pink
4 1.500 - 1.497 (0.0591 - 0.0589) Purple
UPR 1.488 - 1.485 (0.0586 - 0.0585) Green
01 22.9 - 23.1
LWR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
(0.902 - 0.909)
UPR 1.491 - 1.488 (0.0585 - 0.0587) Yellow
12
LWR 1.494 - 1.491 (0.0588 - 0.0585) Blue Grade and color are different
between upper and lower
UPR 1.494 - 1.491 (0.0588 - 0.0585) Blue bearings.
23
LWR 1.497 - 1.494 (0.0589 - 0.0588) Pink
UPR 1.497 - 1.494 (0.0589 - 0.0588) Pink
34
LWR 1.500 - 1.497 (0.0591 - 0.0589) Purple

Undersize
Unit: mm (in)

Size Thickness Crank pin journal diameter “Dp”

UPR 1.534 - 1.542 (0.0604 - 0.0607)
0.08 (0.0031)
LWR 1.536 - 1.540 (0.0605 - 0.0606)
UPR 1.554 - 1.562 (0.0612 - 0.0615)
0.12 (0.0047) Grind so that bearing clearance is the specified value.
LWR 1.556 - 1.560 (0.0613 - 0.0614)
UPR 1.619 - 1.627 (0.0637 - 0.0641)
0.25 (0.0098)
LWR 1.621 - 1.625 (0.0638 - 0.0640)

MISCELLANEOUS COMPONENTS
Flywheel
Unit: mm (in)

Flywheel deflection [TIR]* Standard 0.45 (0.0177) or less

*: Total indicator reading

Bearing Clearance
Unit: mm (in)

Main bearing oil clearance Standard 0.056 - 0.066 (0.0022 - 0.0026)

Connecting rod bearing oil
Standard 0.051 - 0.061 (0.002 - 0.0024)
clearance

E M -2 8 0