ENGINE MECHANICAL
B ENGINE
A
EM
SECTION
PRECAUTIONS .......................................................... 3
Precautions for Drain Engine Coolant ...................... 3
Precautions for Disconnecting Fuel Piping .............. 3
Precautions for Removal and Disassembly ............. 3
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 3
Precautions for Assembly and Installation ............... 3
Parts Requiring Angular Tightening ......................... 3
Precautions for Liquid Gasket .................................. 4
REMOVAL OF LIQUID GASKET SEALING .......... 4
LIQUID GASKET APPLICATION PROCEDURE ..... 4
PREPARATION ..................................... ...................... 5
Special Service Tools ............................................... 5
Commercial Service Tools ........................................ 7
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ................... ............................. 9
NVH Troubleshooting —Engine Noise ..................... 9
Use the Chart Below to Help You Find the Cause
of the Symptom. ....................................... ....... ....... 10
ENGINE ROOM COVER ...........................................11
Removal and Installation .........................................11
REMOVAL ............................................................11
INSTALLATION ....................................................11
DRIVE BELTS ........................................................... 12
Checking Drive Belts .............................................. 12
Tension Adjustment ................................................ 12
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 13
Drive Belt Auto Tensioner and Idler Pulley ............. 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 14
AIR CLEANER AND AIR DUCT ............................... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
CHANGING AIR CLEANER FILTER ................... 16
ENGINE MECHANICAL
CONTENTS
INTAKE MANIFOLD .................................................17
Removal and Installation ........................................ 17
REMOVAL ...........................................................18
INSPECTION AFTER REMOVAL ....................... 19
INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................21
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST ........... .......................... ................................. .... 22
Removal and Installation ........................................ 22
REMOVAL ...........................................................22
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23
OIL PAN AND OIL STRAINER ................................. 25
Removal and Installation ........................................ 25
REMOVAL ...........................................................25
INSPECTION AFTER REMOVAL ....................... 26
INSTALLATION ................................................... 26
INSPECTION AFTER INSTALLATION ................27
IGNITION COIL .............................................. ....... .... 28
Removal and Installation ........................................ 28
REMOVAL ...........................................................28
INSTALLATION ................................................... 28
SPARK PLUG (PLATINUM-TIPPED TYPE) .............29
Removal and Installation ........................................ 29
REMOVAL ...........................................................29
INSPECTION AFTER REMOVAL ....................... 29
INSTALLATION ................................................... 30
FUEL INJECTOR AND FUEL TUBE ........................ 31
Removal and Installation ........................................ 31
REMOVAL ...........................................................31
INSTALLATION ................................................... 32
INSPECTION AFTER INSTALLATION ................32
ROCKER COVER .....................................................33
Removal and Installation ........................................ 33
REMOVAL ...........................................................33
INSTALLATION ................................................... 34
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Revision; 2004 April 2003 Q45
EM-1
TIMING CHAIN .......................................................... 35
Removal and Installation ........................................35
REMOVAL ........................................................... 36
INSPECTION AFTER REMOVAL ........................39
INSTALLATION ...................................... ..............39
CAMSHAFT .............................. ...... ....... ....................46
Removal and Installation ........................................46
REMOVAL ........................................................... 46
INSTALLATION ...................................... ..............47
INSPECTION AFTER REMOVAL ........................49
Valve Clearance ......................................................52
INSPECTION ............................ ............. .............. 52
ADJUSTMENT .................................................... 54
OIL SEAL ..................................................................57
Removal and Installation of Valve Oil Seal .............57
REMOVAL ........................................................... 57
INSTALLATION ...................................... ..............57
Removal and Installation of Front Oil Seal .............58
REMOVAL ........................................................... 58
INSTALLATION ...................................... ..............58
Removal and Installation of Rear Oil Seal ..............60
REMOVAL ........................................................... 60
INSTALLATION ...................................... ..............60
CYLINDER HEAD ..................................................... 61
On-Vehicle Service .................................................61
CHECKING COMPRESSION PRESSURE .........61
Removal and Installation ........................................62
REMOVAL ........................................................... 62
INSPECTION AFTER REMOVAL ........................63
INSTALLATION ...................................... ..............63
Disassembly and Assembly ....................................64
DISASSEMBLY ................................................... 64
ASSEMBLY ......................................................... 65
Inspection After Disassembly .................................66
CYLINDER HEAD DISTORTION ........................66
VALVE DIMENSIONS ............................ ....... .......66
VALVE GUIDE CLEARANCE ....................... .......66
VALVE GUIDE REPLACEMENT .................. .......66
VALVE SEAT CONTACT ....................... ....... .......68
VALVE SEAT REPLACE ME NT ...........................68
VALVE SPRING SQUARENESS .........................69
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ........... ....................69
ENGINE ASSEMBLY ................................................70
Removal and Installation ........................................70
REMOVAL ........................................................... 70
INSTALLATION ...................................... ..............72
INSPECTION AFTER INSTALLATION ................72
CYLINDER BLOCK ................................................... 73
Disassembly and Assembly ....................................73
DISASSEMBLY ................................................ ....74
ASSEMBLY ...................................................... ....77
How to Select Piston and Bearing ..........................81
DESCRIPTION ....................................................81
HOW TO SELECT PISTON .................................82
HOW TO SELECT CONNECTING ROD BEAR-
ING .......................................................................83
HOW TO SELECT MAIN BEARING ....................84
Inspection After Disassembly ..................................87
CRANKSHAFT END PLAY ..................................87
CONNECTING ROD SIDE CLEARANCE ...........88
PISTON AND PISTON PIN CLEARANCE ...........88
PISTON RING SIDE CLEARANCE .....................89
PISTON RING END GAP ....................................89
CONNECTING ROD BEND AND TORSION .......90
CONNECTING ROD BEARING (BIG END) ........90
CONNECTING ROD BUSHING OIL CLEAR-
ANCE (SMALL END) ...........................................90
CYLINDER BLOCK DISTORTION ......................91
INNER DIAMETER OF MAIN BEARING HOUS-
ING .......................................................................92
PISTON TO CYLINDER BORE CLEARANCE ....92
OUTER DIAMETER OF CRANKSHAFT JOUR-
NAL ........................... ...........................................93
OUTER DIAMETER OF CRANKSHAFT PIN ......94
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT .................................................................94
CRANKSHAFT RUNOUT ....................................94
OIL CLEARANCE OF CONNECTING ROD
BEARING ........................ .....................................94
OIL CLEARANCE OF MAIN BEARING ...............95
CRUSH HEIGHT OF MAIN BEARING ................96
SERVICE DATA AND SPECIFICATIONS (SDS) ......97
Standard and Limit ..................................................97
GENERAL SPECIFICATIONS .............................97
DRIVE BELTS ......................................................97
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ...................................................................97
SPARK PLUG (PLATINUM-TIPPED TYPE) ........98
CYLINDER HEAD ........................ ....... ...... ....... ....98
VALVE .................................... ..............................98
CAMSHAFT AND CAMSHAFT BEARING ....... ..102
CYLINDER BLOCK ................ ...... ....... ...... ....... ..102
PISTON, PISTON RING AND PISTON PIN ......103
CONNECTING ROD ..........................................104
CRANKSHAFT ................ ....... ...... ....... ...... ....... ..105
MAIN BEARING .................................................106
CONNECTING ROD BEARING .......... ...... ....... ..107
Tightening Torque .................................................108
Revision; 2004 April 2003 Q45
EM-2
PRECAUTIONS
PRECAUTIONS PFP:00001
Precautions for Drain Engine Coolant EBS002QC
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping EBS002QD
● Before starting work, make sure 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.
A
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Precautions for Removal and Disassembly EBS002QE
● When instructed t o use special service tool s, use the specified tools. Al ways be careful to work safe ly,
avoid forceful or uninstructed operations.
● Exercise maximum care to avoid damage to mating or sliding surfaces.
● Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
● Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
● When looseni ng nu t s an d b ol t s, a s a b as ic ru le , st a r t wit h the on e fu rt he st o ut si de , the n th e on e d iag on al ly
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be
used where noted in the step.
Precautions for Inspection, Repair and Replacement EBS002QF
Before repairing or repla cing, thorou ghly inspect parts. In spect new repl acement parts in the s ame way, and
replace if necessary.
Precautions for Assembly an d Installation EBS002QG
● Use torque wrench to tighten bolts or nuts to specification.
● When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as spe ci fie d.
● Replace with new liqu id gasket, packing, oil seal or O-ring.
● Thoroughly wa sh, c lean , an d air- bl ow eac h p art. Care ful ly ch eck en gin e oil o r en gine coolan t p ass ages for
any restriction and blockage.
● Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, engine oil sliding surfaces well.
● Release air within route when refilling after draining engine coolant.
● After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust system s for leakage.
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Parts Requiring Angular Tighte ning EBS001LP
● Use an angle wrench for the final tighte ning of the following engine parts:
– Cylinder head bolts
– Main bearing cap bolts
– Connecting rod cap nuts
– Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular
tightening)
● Do not use a torque value for final tigh ten in g.
● The torque value for these parts are for a preliminary s tep.
● Ensure thread and seat surfaces are clean and coated with engine oil.
Revision; 2004 April 2003 Q45
EM-3
M
PRECAUTIONS
Precautions for Liquid Gasket EBS001LQ
REMOVAL OF LIQUID GASKET SEALING
● After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
● In areas where the cutter is difficult to use, use a plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is 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 liquid gasket application surface and the mating surface.
● Remove the liqu id gasket completely from the gro ove of the
liquid gasket application surface, mounting bolts, and bolt
holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0002E
3. Attach the liquid gasket tube to the tube pres s er.
Use Genuine Thread Sealant or equivalent. Refer to GI-46,
"RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
● If there is a groove for the liquid ga sket ap plicati on, ap ply the
liquid gasket to the groove.
● As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the
holes. Make sure to read the text of this manual.
● Within five minutes of liquid gasket application, install the mat-
ing component .
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minu te s o r mo re h ave passed from the installation, fill
the engine oil and engine coolant.
CAUTION:
If there are specific ins tructions in this manual, obs erve
them.
PBIC0003E
EMA0622D
SEM159F
Revision; 2004 April 2003 Q45
EM-4
PREPARATION
PREPARATION PFP:00002
Special Service Tools EBS001L5
The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool name
Description
A
EM
KV10111100
(J37228)
Seal cutter
KV10114400
(J-38365)
Heated oxygen sensor wrench
EG15050500
(J45402)
Compression gauge adapter
KV10116200
(J26336-A)
Valve spring compressor
1. KV10115900
(J26336-20)
Attachment
KV101151S0
(J38972)
Lifter stopper set
1. KV10115110
(J38972-1)
Camshaft pliers
2. KV10115120
(J38972-2)
Lifter stopper
KV10112100
(BT8653-A)
Angle wrench
S-NT046
S-NT636
ZZA1225D
NT022
S-NT041
Removing steel oil pan and rear timing chain
case
Loosening or tightening heated oxygen
sensors
a: 22 mm (0.87 in)
Inspection of compression pressure on No.7
and No.8 cylinders
Disassembling valve mechani sm
Changing valve lifter shims
Tightening bolts for bearing cap, cylinder
head, etc.
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S-NT014
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EM-5
Tool number
(Kent-Moore No.)
Tool name
PREPARATION
Description
KV10114700
(J38139)
Main bearing cap remover
KV10107902
(J38959)
Valve oil seal puller
KV10115600
(J38958)
Valve oil seal drift
EM03470000
(J8037)
Piston ring compressor
Removing crankshaft main bearing cap
ZZA0023D
Removing valve oil seal
S-NT011
Installing valve oil seal
Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) dia.
c: 10.3 (0.406) dia. f: 5 (0.20) dia.
Unit: mm (in)
S-NT603
Installing piston assembly into cylinder bore
ST16610001
(J23907)
Pilot bushing puller
WS39930000
(—)
Tube presser
S-NT044
Removing crankshaft pilot bushing
S-NT045
Pressing the tube of liquid gasket
S-NT052
Revision; 2004 April 2003 Q45
EM-6
PREPARATION
Tool number
(Kent-Moore No.)
Tool name
—
(J- 45476)
Ring gear stopper
PBIC1655E
—
(J-45488)
Quick connector release
PBIC0198E
Description
Removing and installing crankshaft pul le y
Removing fuel tube quick connectors in
engine room
(Available in SEC. 164 of P AR TS CATALOG:
Part No. 16441 6N210)
Commercial Service Tools EBS001L6
(Kent-Moore No.)
Tool name
Power tool Loosening bolts and nuts
Description
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PBIC0190E
Spark plug wrench Removing and installing spark plug
S-NT047
Loosening and tightening cylinder head bo lt,
and used with angle wrench [SST:
KV10112100 (BT8653-A)]
(J24239-01)
Cylinder head bolt wrench
NT583
Valve seat cutter set Finishing valve seat dimensions
S-NT048
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
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EM-7
PREPARATION
(Kent-Moore No.)
Tool name
Description
Piston ring expander Removing and installing piston ring
S-NT030
Valve guide drift Removing and installing valve guide
Intake & Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia.
S-NT015
Valve guide reamer 1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide
Intake & Exhaust:
1 : 6.0 mm (0.236 in) dia.
d
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2 : 10.2 mm (0.40 2 in) dia.
S-NT016
Front oil seal drift Installing front oil seal when front cover is
removed
ZZA0012D
Rear oil seal drift Installing rear oil seal
ZZA0025D
(J-43897-18)
(J-43897-12)
Oxygen sensor thread cleaner
AEM488
Anti-seize lubricant (Permatex 133AR
or equivalent meeting MIL
specification MIL-A-907)
AEM489
Reconditioning the exhaust system thre ads
before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
a: J-43897-18 (18 mm dia.) for zirconia
heated oxygen sensor
b: J-43897-12 (12 mm dia.) for titania
heated oxygen sensor
Lubricating heated oxygen sensor thre ad
cleaning tool when reconditioning exhaust
system threads
Revision; 2004 April 2003 Q45
EM-8
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003
NVH Troubleshooting —Engine Noise EBS002MG
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PBIC0192E
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EM-9
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
Use the Chart Below to Help You Find the Cause of the Symptom. EBS002MH
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.
Operating condition of engine
Location
of noise
Top of
engine
Rocker
cover
Cylinder
head
Crankshaft pulley
Cylinder
block
(Side of
engine)
Oil pan
Front of
engine
Timing
chain
cover
Front of
engine
A: Closely related B: Related C: Sometimes related —: Not related
Type of
noise
Ticking or
clicking
Rattle C A — A B C
Slap or
knock
Slap or
rap
Knock A B C B B B
Knock A B — A B C
T apping or
ticking
Squeaking or fizzing
CreakingABABAB
Squall
Creak
Before
warm-
up
—A—B B—
After
warm-
C A — A B — Tappet noise Valve clearance EM-52
A——BBA
AA—BBB
AB—B—C
AB—BAB
up
When
start-
ing
When
idling
When
racing
While
driving
Camshaft
bearing noise
Piston pin
noise
Piston slap
noise
Connecting
rod bearing
noise
Main bearing
noise
Timing chain
and chain
tensioner
noise
Drive belts
(Sticking or
slipping)
Drive belts
(Slipping)
Water pump
noise
Source of
noise
Check item
Camshaft journal clearance
Camshaft runout
Piston and piston pin
clearance
Connecting rod bushing oil clearance (Small
end)
Piston to cylinder bore
clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend
and torsion
Connecting rod bushing oil clearance (Small
end)
Connecting rod bearing (Big end)
Main bearing oil clearance
Crankshaft runout
Timing chain cracks
and wear
Timing chain tensioner
operation
Drive belts deflection
Idler pulley bearing
operation
Water pump operation CO-22
ence page
EM-50
EM-49
EM-88
EM-90
EM-92
EM-89
EM-89
EM-90
EM-90
EM-90
EM-95
EM-94
EM-39
EM-35
EM-12
Refer-
Revision; 2004 April 2003 Q45
EM-10
ENGINE ROOM COVER
ENGINE ROOM COVER PFP:14049
Removal and Installation EBS001ZC
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1. Engine cover 2. Relay box 3. Battery cover
4. Front air guide 5. Air duct (inlet) 6. Air cleaner cover
REMOVAL
● Remove clips on back with clip driver.
CAUTION:
Do not damage or scratch cover when installing or removing.
● Major parts and inspection points under each cover are as follows; (numbered as in illustration)
1. Upper side of engine assembly, power steering reservo ir tank, cooling fan reser voir tank
2. Relay
3. Battery, relay box
4. Cooling fan fluid cooler, power steering fluid cooling tube
5. Engine assembly front side, drive belts, cooling fan
6. Mass air flow sensor, air cl eaner case
INSTALLATION
Install in the reverse order of removal .
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Revision; 2004 April 2003 Q45
EM-11
DRIVE BELTS
DRIVE BELTS PFP:02117 Checking Drive Belts EBS001JT
WARNING:
Be sure to perform when the engine is stopped.
● Remove air duct (inlet) when inspecting drive belt for alternator, water pump and A/C compressor.
● Remove engine undercover (with power tool) when inspecting power steering oil pump belt.
● Make sure that indicator (single line notch) of each auto tensioner is within the allowable working range
(between three line notches).
NOTE:
● Check the aut o tensioner indication when the engine is cold.
● When the new drive belt is installed, the range should be A.
● The indicator notch is located on the moving side of the auto tensioner for alternator, water pump and
A/C compressor belt, while it is found on the fixed side for power steering oil pump belt.
● Visua lly check entire belt for wea r, damage or crac ks.
● If the indicator is out of allowable working range or belt is damaged, replace the belt.
Tension Adjustment EBS002MI
Belt tensioning is not necessary, as it is automatically adjusted by auto tensioner.
SBIA0361E
Revision; 2004 April 2003 Q45
EM-12
DRIVE BELTS
Removal and Installation EBS002MJ
REMOVAL
Alternator, Water Pump and A/C Compressor Belt
1. Remove air duct (inlet).
2. With box wrench, and while securely holding the hexagonal part
in pulley center of auto tensioner, move the wrench handle in the
direction of ar row (loosening direction of tensioner).
CAUTION:
Avoid placing hand in a lo ca tion w he re pinching may occ ur
if the holding tool accidentally comes off.
3. Under the above condition, inser t a metal bar of app roximately 6
mm (0.24 in) in diameter (hexagonal bar wrench shown as
example in the figure) through the holding boss to lock auto tensioner pulley arm.
● Leave auto tensio ner pulley arm locked un til belt is installed
again.
4. Remove alternator, water pump and A/C compressor b elt.
Power Steering Oil Pump Belt
1. Remove air duct (inlet) and engine undercover (with power tool).
2. Remove alternator, water pump and A/C compressor belt. Refer to EM-13, "
A/C Compressor Belt" .
3. While securely holding the hexagonal protrusion part of auto
tensioner pulley center with box wrench, move the wrench handle in the direction of arrow (loos en in g dir ec tio n of ten sioner).
CAUTION:
Avoid placing hand in a lo ca tion w he re pinching may occ ur
if the holding tool accidentally comes off.
4. Under the above condition, inser t a metal bar of app roximately 6
mm (0.24 in) in diameter (hexagonal bar wrench shown as
example in the figure) through the holding boss to lock auto tensioner pulley arm.
● Leave auto tensio ner pulley arm locked un til belt is installed
again.
5. Remove power steering oil pump belt.
Alternator, Water Pump and
PBIC0997E
SBIA0405E
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INSTALLATION
Power Steering Oil Pump Belt
Install in the reverse order of removal paying attention to the following.
CAUTION:
Make sure belt is securely installed around all pulleys.
● Unlock auto tensioner pulley arm to g ive tension to belt.
● Rotate crankshaft pulley several turns clockwise several times to equalize belt tension between pulleys.
● Check that belt tension is within the allowable working range, using indicator notch on the auto tensioner.
Refer to EM-12, "
Checking Drive Belts" .
Alternator, Water Pump and A/C Compressor Belt
Install in the reverse order of removal paying attention to the following.
CAUTION:
Confirm belts are completely set to pulleys.
● Release auto tens ion er, and apply auto tens ion s to belt.
● Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
● Confirm tensio ns of belt at indicator is wit hin the allowable working rang e. Refer to EM-12, "Checking
Drive Belts" .
Revision; 2004 April 2003 Q45
EM-13
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DRIVE BELTS
Drive Belt Auto Tensioner and Idler Pulley EBS002MK
SBIA0351E
REMOVAL
1. Remove air duct (inlet) and engine unde rcover (with power tool).
2. Remove drive belts. Refer to EM-13, "
● Keep auto tensioner pulley arm locked after belt is removed.
3. Remove auto tensioner and idler pulley with power tool.
● Keep auto tensioner pulley arm locked to install or remove auto tensioner.
Removal and Installation" .
INSTALLATION
Install in the reverse order of removal.
Revision; 2004 April 2003 Q45
EM-14
AIR CLEANER AND AIR DUCT
AIR CLEANER AND AIR DUCT PFP:16500
Removal and Installation EBS001JW
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1. Air cleaner filter 2. Holder 3. O-ring
4. Mass air flow sensor 5. V acuum hose 6. Bracket
7. Air duct 8. Air duct (inlet) 9. Air clea ner case
10. Resonator 11. Bracket 12. Bracket
SBIA0389E
REMOVAL
1. Remove engine c over and air cleaner cover. Refer to EM-11, "Removal and Installation" .
2. Remove harness connector from mass air flow sensor.
3. Remove air duct (inlet ), air cleaner c ase/ma ss air flow sensor a ssembly and air duct/ resonat or assem bly
disconnecting their joints.
● Add marks as necessary for easier instal lation.
4. Remove mass air flow sensor from air cleaner case.
CAUTION:
Handle mass air flow sensor with following ca res .
● Do not shock it.
● Do not disassemble it.
● Do not touch its sensor.
5. Remove reso nator in fender lifting left fender protector.
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INSTALLATION
Installation in the reverse order of removal paying attention to the following.
● Align marks. Attach each joint. Screw clamps firmly.
Revision; 2004 April 2003 Q45
EM-15
AIR CLEANER AND AIR DUCT
CHANGING AIR CLEANER FILTER
1. Remove air cleaner cover.
Refer to EM-11, "
2. Remove two clips and lift up air cleaner filter along with holder.
3. Remove air cleaner filter from holder.
Removal and Ins tallat ion" .
Revision; 2004 April 2003 Q45
EM-16
INTAKE MANIFOLD
INTAKE MANIFOLD PFP:14003
Removal and Installation EBS001L9
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PBIC2280E
1. PCV tube 2. PCV hose 3.
EVAP canister purge control solenoid
4.
valve
7. Vacuum gallery 8. Engine cover front bracket 9. EVAP hose
Revision; 2004 April 2003 Q45
5. EVAP hose 6. EVAP tube
EM-17
EVAP canist er purge co ntrol solenoid valve bracket
INTAKE MANIFOLD
10. VIAS control solenoid valve 11. Water gallery 12. Gasket
13. Intake manifold lower 14. Water hose 15. Electric throttle control actuator
16. Intake manifold adapter 17. Engine cover rear bracket 18. Accelerator wire bracket
19. Intake manifold upper 20. Vacuum tank 21. V acuum tank bracket
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.
1. Remove engine cover (with power tool), air cleaner cover and battery cover. Refer to EM-11, "
and Installation" .
2. Release fuel pressure. Refer to EC-48, "
3. Remove air cleaner case and air duct assembly. Refer to EM-15, "
4. Drain engine coolant when engine is cooled. Refer to CO-9, "
5. Disconnect fuel tube quick connector on engine side only.
FUEL PRESSURE RELEASE" .
Removal and Ins tallat ion" .
Changing Engine Co ol an t" .
Removal
● Using tool of quick conn ector release [SST:J-45488], perform
the following steps to disconnect quick connector.
a. Remove quick connector cap on engine side only.
b. With the sleeve side of quick connector release facing quick
connector, install quick connector release onto fuel tube.
c. Insert quick connector release into quick connector until sleeve
contacts and goes no further. Hold the quick connector release
on that position.
CAUTION:
Inserting the quick connector rele ase hard will not disconnect quick connector. Hold quick connec tor release where
it contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube.
CAUTION:
● Pull quick connector holding A position in illus trati on.
● Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
● Prepare container and cloth beforehand as fuel will leak out.
● Avoid fire and sparks.
● Be sure to cover openings of disconn ected pipes wi th plug or plastic bag to avoid fuel leaka ge
and entry of foreign materials.
SBIA0353E
KBIA0702E
SBIA0354E
Revision; 2004 April 2003 Q45
EM-18
INTAKE MANIFOLD
6. Move cooling fan fluid reservoir tank.
7. Remove or disconnect intake manifold upper, wiring harnesses, brackets, vacuum hose, vacuum gallery
and PCV hose and tube.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
8. Disconnect water hoses.
9. Remove electric throttle control ac tuator loosening fixing bolts diagonally.
CAUTION:
Handle carefully to avoid any shock.
10. Loosen bolts in reverse order of illustration to remove intake
manifold upper assembly with power tool.
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11. Loosen bolts in reverse order of illustration to remove intake
manifold lower assembly with power tool.
INSPECTION AFTER REMOVAL
Surface Distortion
Using straightedge and feeler gauge, inspect surface distortion of
intake manifold lower and intake manif old upper.
Limit : 0.1 mm (0.004 in)
PBIC0014E
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PBIC0016E
INSTALLATION
Install in the reverse order of removal paying attention to the following.
Revision; 2004 April 2003 Q45
EM-19
INTAKE MANIFOLD
Tightening Intake Manifold Lower Bolts
Tighten in numerical order as shown in the figure.
NOTE:
No.7 and 8 have longer bolt length than others.
Tightening Intake Manifold Upper Bolts
Tighten in numerical order as shown in the figure.
NOTE:
No.1 to 4 have longer bolt length than others.
PBIC0015E
Installation of Electric Throttle Control Actuator
● Install intake mani f old a da pt er g ask et an d e le ct ri c t hro ttl e co nt ro l a ctua t or ga sk et so that t hre e pro t rusi o ns
for installation identification do not face downward.
● Tighten fixing bolts of electric throttle control actuator equally and diagonally in several steps.
● After installation perform procedure in EM-21, " INSPECTION AFTER INST ALLATION" .
Connecting Water Hose
Install wa te r hose so th at i t s o ver l ap w i d th fo r conn ec ti o n i s b et wee n 2 7 m m (1 .0 6 i n ) an d 32 mm ( 1. 26 in) ( t a r-
get: 27 mm, 1.06 in).
Connecting Vacuum Hose
Refer to EC-24, "Vacuum Hose Drawing" .
Connecting Quick Conn ector of Fu el Tube
Install quick connector as follows on engine side only.
1. Make sure no foreign substances are deposited in and around tube and quick connector, and no damage
on them.
2. Thinly apply new engine oil around the fuel tube from tip end to the spool end.
3. Align ce nter to insert quick connector straightly into fuel tube.
● Insert fuel tu be into quick connecto r until edge side spool is
completely inside quick connector, and 2nd spool exposes
right below quick connector.
CAUTION:
● Hold A position in illustration whe n inserting fuel tube
into quick connector.
● Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
● Insert until you he ar a “click” sound and actually feel
the engagement.
PBIC0014E
PBIC0017E
Revision; 2004 April 2003 Q45
EM-20
INTAKE MANIFOLD
● To avoid misidentification of engagement with a similar
sound, be sure to perform the next step.
4. Pull quick connecto r by hand holdin g A posit ion. Mak e sure it is
completely engaged (connected) so that it does not come out
from fuel tube.
NOTE:
Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
5. Install quick conn ector cap on quick connect or joint (on engine
side only).
6. Install fuel hose and fuel tube to hose clamps.
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INSPECTION AFTER INSTALLATION
● After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps.
– a) Apply fuel pr essure t o fuel line s with turnin g ignition switch O N (with eng ine stoppe d). Then ch eck for
fuel leaks at connections.
– b) Start the engine and rev it up and check for fuel leaks at connections.
● Perform procedures for “Throttle Valve Closed Position Learnin g” after finishing repairs. Refer to EC-46,
"Throttle Valve Closed Position Learning" .
● If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after fin-
ishing repairs. Refer to EC-46, "
Idle Air Volume Learning" .
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EM-21
EXHAUST MANIFOLD AND THREE WAY CATALYST
EXHAUST MANIFOLD AND THREE WAY CATALYST PFP:14004 Removal and Installation EBS00NBE
SBIA0355E
1. Heated oxygen sensor 1 (bank 2) 2. Exhaust manifold cover (right bank) 3.
4. Gasket 5.
7. Heated oxygen sensor 1 (bank1)
Exhaust manifold and three way catalyst (left bank)
Exhaust manifold and three way catalyst (right bank)
6. Exhaust manifold cover (left bank)
REMOVAL
1. Remove heated oxygen sensors.
● Follow below steps to remo ve eac h he ate d ox ygen sensor.
a. Remove engine undercover and engine cover with power tool.
b. Remove harness connector of each heate d oxygen sensor , and harness from bracket an d middle clamp.
c. Using heated oxygen sensor wrench, remove both left and right
heated oxygen sensors.
CAUTION:
● Be careful not to damage heated oxygen sensor.
● Discard any heated oxygen sensor which has been
dropped from a height o f mo re tha n 0 .5 m (1 9.7 in ) onto a
hard surface such as a concrete floor; use a new one.
2. Remove exhaust manifold and three way catalyst (left bank) in
below steps.
a. Remove A/C compressor with power tool and put aside with pip-
ing connected. Refer to ATC-144, "
b. Remove exhaust front tube with power tool. Refer to EX-3, "
c. Remove steering lower joint to enable steering shaft to move freely.
d. Support and l ift u p bot tom of eng ine wi th t ransm issi on ja ck. R emove lef t engi ne mo unt i nsula tor alon g wit h
left engine mount brackets.
Compressor" .
Removal and Installation" .
PBIC1000E
Revision; 2004 April 2003 Q45
EM-22
EXHAUST MANIFOLD AND THREE WAY CATALYST
e. Remove exhaust manifold cover.
f. Loosen nuts in reverse order of illustration to remove exhaust
manifold and three way catalyst.
CAUTION:
Disregard the numerical order No.9 to 12 in removal.
3. Remove exhaust manifold and three way catalyst (right bank)
loosening nuts in reverse order in the figure.
a. Remove drive belt and alternator with power tool. Refer to SC-
19, "Removal and Installation" .
b. Remove exhaust front tube with power tool. Refer to EX-3,
"Removal and Installation" .
c. Remove nuts on bottom of right engine mounting ins ulator, and
lift up right si de of engine approximately 3 cm (1.18 in) with transmission jack.
d. Remove starter motor with power tool. Refer to SC-28, "
Removal and Installation" .
e. Support and lift up bottom of engine with transmission jack. Remove right engine mount insulator along
with right engine mount brackets.
f. Remove exhaust manifold cover.
g. Loosen nuts in reverse order of illustration to remove exhaust manifold and three way cataly st with power
tool.
CAUTION:
Disregard the numerical order No.9 to 12 in removal.
PBIC0022E
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INSPECTION AFTER REMOVAL
Surface Distortion
Use a reliable str aightedge and feeler gauge to check the flatness of
each exhaust manifold flange surface.
Limit : 0.3mm (0.012in)
INSTALLATION
Install in the reverse order of removal paying attention to the following.
Exhaust Manifold Gasket
Install exhaust ma nifold gasket with its directional protrusion set upward. Refer to illustration of com ponents
on former page.
Tightening Exhaust Manifold Nuts
● Install exhaust m anif old and three wa y cataly st in th e nume rical
order shown in the figure.
● Tighten nuts No.1 to No.4 in two steps. Orde r No.9 to 12 shows
second step.
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PBIC0022E
Revision; 2004 April 2003 Q45
EM-23
EXHAUST MANIFOLD AND THREE WAY CATALYST
Installation of Heated Oxygen Sensor
CAUTION:
● When using heated oxygen sensor wrench (KV10114400), tighten to the middle of specified torque
because length of tool may induce slight indication increase. (Do not tighten to the maximum
specified torque)
● Before installing a new heated oxygen sensor, clean exhaust system threads using oxygen sensor
thread cleaner tool, J-43897-18 or J-438 97 -12 , and app ly ant i-se iz e lubric ant.
● Do not ov er torque the heate d oxy gen s ensor. Doing so may c ause damage to th e heated oxyg en
sensor, resulting in the MIL coming on.
Revision; 2004 April 2003 Q45
EM-24
OIL PAN AND OIL STRAINER
OIL PAN AND OIL STRAINER PFP:11110
Removal and Installation EBS001LC
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SBIA0362E
1. Oil pan 2. O-ring 3. Crankshaft position sensor (POS)
4. O-ring 5. Oil pressure switch 6. Gasket
7. Oil strainer 8. Drain plug 9. Washer
10. Oil filter 11. Rear plate cover
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
1. Remove front tire.
2. Remove hood assembly. Refer to BL-15, "
3. Remove engine undercover and engine cover with power tool.
4. Drain engine oil. Refer to LU-7, "
Changing Engine Oil" .
5. Remove drive belts. Refer to EM-13, "
6. Remove auto tensio ner of power steering oil pump be lt. Refer to EM-14, "
Idler Pull ey" .
7. Move power s teering oil pump and remove power steering oil pump bracket.
8. Remove oil filter. Refer to LU-8, "
Removal and Installation" .
9. Remove A/C compressor fitting bolts, and install A/C compressor temporarily on vehicle side with ropes or
equivalent.
10. Disconnect harness and wires of lower side of oil pan from oil pan.
11. Remove crankshaft position sensor (P OS) from transmission.
CAUTION:
● Do not drop or shock it.
● Do not disassemble it.
Removal and Installation of Hood Assembly" .
Removal and Ins tallat ion" .
Drive Belt Auto Tensioner and
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EM-25
OIL PAN AND OIL STRAINER
● Do not let steel powders contact magnetic parts of sensor tips.
● Do not leave where magnetically effected.
12. Install engine slinger and hang engine assembly to secure position. Refer to EM-70, "
lation" .
13. Remove front suspension member. Refer to FSU-15, "
14. Remove oil pan in the order shown below.
a. Remove rear plate cover.
b. Remove transmission joint bolts ( M12: 4 bolts) which pierce oil pan.
c. Lo osen oil pan bolts w ith power tool in reverse order o f illustra-
tion to remove.
NOTE:
Exclude No.11 and No.17 in removal.
d. Insert seal cutter betw een oil pan and cylinder blo ck. Slide seal
cutter by tapping on side of the seal cutter with a hammer.
Remove oil pan.
15. Remove oil strainer.
FRONT SUSPENSION MEMBER" .
Removal and Instal-
PBIC0194E
INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
1. Install oil strainer.
2. Install oil pan in the order below.
a. Apply liquid gasket thoroughly as in illustration.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-46, "
SEALANTS" .
b. Install new O-ring to oil pump and timing chain case side.
RECOMMENDED CHEMICAL PRODUCTS AND
SEM365E
PBIC0195E
Revision; 2004 April 2003 Q45
EM-26
OIL PAN AND OIL STRAINER
c. Tighten bolts in numerical order as shown.
● No.11 and 17 indicate double tightening of bolts 1 and 2.
NOTE:
Refer to the below for locating bolts.
d. M6 × 30 mm (1.18 in): No.18, 19
M8 × 100 mm (3.97 in): No.5, 9
M8 × 45 mm (1.77 in): Except the above
e. Tighten transmission j oint bolts. Refer to AT- 29 7 , "
SION ASSEMBLY" .
f. Install rear plate cover.
3. Install oil pan drain plug. Refer to illustration of components of
former page for installation direction of washer.
4. Install in the reverse order of removal after this step.
● Pour engine oil at least 30 minutes after oil pan is installed.
INSPECTION AFTER INSTALLATION
● Check engine oil level. Refer to LU-6, "ENGINE OIL LEVEL" .
● Check for leakage of engine oil when engine is warmed.
TRANSMIS-
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EM-27
IGNITION COIL
IGNITION COIL PFP:22448 Removal and Installation EBS001LD
SBIA0384E
1. Ignition coil 2. Spark plug
REMOVAL
1. Remove engine cover (with power tool), air cleaner cover and battery cover. Refer to EM-11, " Removal
and Installation" .
2. Move heat er hose and its peripheral parts aside. (No.7 cylinder)
3. Disconnect harness connector from ignition coil.
4. Remove ignition coil.
CAUTION:
Do not shock it.
INSTALLATION
Install in the reverse order of removal.
Revision; 2004 April 2003 Q45
EM-28
SPARK PLUG (PLATINUM-TIPPED TYPE)
SPARK PLUG (PLATINUM-TIPPED TYPE) PFP:22401
Removal and Installation EBS001LE
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1. Ignition coil 2. Spark plug
REMOVAL
1. Remove engine cover with power tool. Refer to EM-11, "ENGINE ROOM COVER" .
2. Remove ignition coil. Refer to EM-28, "
IGNITION COIL" .
3. Remove spark p lug with spark plug wr en ch (c om m erc ia l se rvi ce
tool).
INSPECTION AFTER REMOVAL
● Use standard type spark plug for normal condition.
The hot type spark plug is suitable wh en fouling occurs with the standard type spark plug under cond itions
such as:
● Frequent engine starts
● Low ambient temperatu res
The cold type spark pl ug is sui table whe n spark knock occurs wi th the standard type s park plug under co nditions such as:
● Extended highway driving
● Frequent high engine revolution
Spark plug (Platinum-tipped type):
Make NGK
Standard type PLFR5A-11
Hot type PLFR4A-11
Cold type PLFR6A-11
SBIA0384E
SEM294A
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Gap (Nominal) : 1.1 mm (0.043 in)
Revision; 2004 April 2003 Q45
EM-29
SPARK PLUG (PLATINUM-TIPPED TYPE)
CAUTION:
● Do not use a wire brush for cleaning.
● If plug tip is covered with carbon, spark plug cleaner may
be used.
Cleaner air p ressure:
Less than 588 kPa (6 kg/cm
Cleaning time:
Less than 20 seconds
● Checking and adjusting plug gap is not required between
change intervals.
2
, 85 psi)
SMA773C
INSTALLATION
Install in the reverse order of removal.
Spark plug:
: 19.6 - 29.4 N·m (2.0 - 2.9 kg-m, 15 - 21 ft-lb)
SMA806CA
Revision; 2004 April 2003 Q45
EM-30
FUEL INJECTOR AND FUEL TUBE
FUEL INJECTOR AND FUEL TUBE PFP:16600
Removal and Installation EBS001LF
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1. Fuel injector sub har ness (RH) 2. Fuel tube assembly (RH) 3. O-ring
4. Fuel dam per assem bl y (RH ) 5. Fuel inject or su b harn ess (LH) 6. Fuel tube asse mbly (LH)
7. Fuel damper assembly, with hose 8. Fuel feed damper assembly 9. Insulator
10. Fuel injector 11. Clip
CAUTION:
● Apply new engine oil when installing the parts that specified to do so in the figure.
● Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
1. Release fuel pressure . Refe r to EC-48, "FUEL PRESSURE RELEASE" .
2. Remove intake manifold upper with power tool. Refer to EM-17, "
3. Disconnect fuel injector sub harness connectors.
4. Disconnect fuel damper assembly with hose fro m fuel tube RH and LH.
5. Remove fuel injectors with fuel tube assembly.
Removal and Installation" .
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EM-31
FUEL INJECTOR AND FUEL TUBE
6. Expand and remove clips securin g fuel injectors.
7. Extract fuel injectors straight from fuel tubes.
● Be careful not to damage injector nozzles during
removal.
● Do not bump or drop fuel injectors.
INSTALLATION
1. Carefully install O-rings, including the one used the fuel da mper.
● Lubricate O-rings by smearing ne w eng ine oil.
● Be careful not to damage O-rings and surfaces for O-ring sealing with service tools, finger nails
or clips. Do not expand or twist O-rings.
● Discard old clips; replace with new ones.
2. Position clips in grooves on fuel injectors.
● Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
3. Align p rotrusions of fuel tubes with those of fuel injec tors.
4. After properly inserting fuel injectors, check to make sure that fuel tube protrusions are engaged with
those of fuel injectors, and that fla n ges of fuel tubes are enga ged with clips.
5. Tighten fuel tube assembly moun ting bolts “a” to “c” in illu stration and in two steps.
1st step
: 9.3 - 10.8 N·m (0.95 - 1.1 kg-m, 6.2 - 7.9 ft-lb)
2nd step
: 20.6 - 26.5 N·m (2.1 - 2.7 kg-m, 16 - 19 ft-lb)
6. Install all removed parts in the reverse order of removal.
SBIA0364E
PBIC1002E
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
● After installing fu el tubes, make sure there is no fuel leakage at connect ions in the following steps.
– a) Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for
fuel leaks at connections.
– b) Start the engine and rev it up and check for fuel leaks at connections.
NOTE:
Use mirrors for c hecking on invisible points.
CAUTION:
Do not touch the engine immediately after stopped, as engine becomes extremely hot.
Revision; 2004 April 2003 Q45
EM-32
ROCKER COVER
ROCKER COVER PFP:13264
Removal and Installation EBS001LG
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1. Rocker cover (left bank) 2. PCV valve 3. O-ring
4. Rocker cover gasket (left bank) 5. Rocker cover (right bank) 6. PCV valve
7. O-ring 8. Oil filler cap 9. Oil catcher
10. Rocker cover gasket (right bank)
REMOVAL
1. Refer to the followings for removal works related to left-bank.
a. Remove engine c over (with power tool ) and air cl eane r cove r. Refer to EM-11, "
b. Remove air duct and air cleaner case assembly . Refer to EM-15, "
c. Remove bracket (installation parts for No.6 camshaft bracket).
d. Move harness on upper rocker cover and i ts peripheral aside.
e. Remove ignition coil. Refer to EM-28, "
Removal and Installa tio n" .
f. Remove PCV valve hose fro m PCV valve.
2. Refer to the followings for removal works related to right-bank.
a. Remove engine cover (with power tool) and battery cover. Refer to EM-11, "
b. Move harness on upper rocker cover and i ts peripheral aside.
c. Remove ignition coil EM-28, "
Removal and Installation" .
d. Remove PCV valve hose from PCV valve.
Removal and Installation" .
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Removal and Installation" .
Revision; 2004 April 2003 Q45
EM-33
ROCKER COVER
3. Loosen bolts in reverse order shown in the figure (with power
tool).
CAUTION:
Do not hold oil filler neck (right bank) not to damage it.
INSTALLATION
1. Apply liquid gas ket to joint part of cylinder h ead and camshaft
bracket following the below steps.
NOTE:
Illustration shows an example of left-bank side (zoomed in
shows No.1 camshaft bracket). Apply only to No.1 camshaft
bracket for right-bank side.
a. Refer to illustration “a” to apply liquid gasket to joint part of No.1
and No.6 camshaft bracket and cylinder hea d.
b. Refer to illustration “b” to apply liquid gasket in 90° to illustration
“a”.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-46, "
SEALANTS" .
2. Install rocker cover.
● Check if rock er cover gasket is no t dropped from i nstallation
groove of rocker cover.
RECOMMENDED CHEMICAL PRODUCTS AND
PBIC0027E
3. Tighten bolts in two steps separately in order numbers in illustration.
1st step
: 1.0 - 3.0 N·m (0.1 - 0.31 kg-m, 9 - 26 in-lb)
2nd step
: 7.4 - 9.3 N·m (0.75 - 0.95 kg-m, 66 - 82 in-lb)
4. Install in the reverse order of removal after this step.
PBIC0028E
PBIC0027E
Revision; 2004 April 2003 Q45
EM-34
TIMING CHAIN
TIMING CHAIN PFP:13028
Removal and Installation EBS00JX6
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Revision; 2004 April 2003 Q45
EM-35
TIMING CHAIN
1. Camshaft sprocket (left bank EXH) 2. Camshaft sprocket (left bank INT) 3. Camshaft sprocket (right bank INT)
4. Camshaft sprocket (right bank EXH) 5. Front cover 6.
7. O-ring 8. Seal ring 9.
10. O-ring 11.
13. O-ring 14.
Intake valve timing control solenoid
16.
valve (l eft bank)
19. Oil level gauge guide 20. O-ring 21. Crankshaft pulley bolt
22. Crankshaft pulley 23. Front oil seal 24. Chai n te nsi one r cov er
25. Camshaft position sensor (PHASE) 26. O-ring 27. Oil pump drive spacer
28. Oil pump assembly 29. Crankshaft sprocket 30. O-ring
31. O-ring 32.
34. Timin g chai n (rig ht bank) 35. Timing chain (left bank) 36. Chain tensi oner (left bank)
37. Chain tensioner (right bank) 38.
40. O-ring
Intake valve timing control cover
(right bank)
Intake valve timing control cover (left
bank)
17. O-ring 18. Oil level gauge
Timing chain tension guide
(right bank)
Timing chain slack guide
(left bank)
Intake valve timing control solenoid
valve (right bank)
Intake valve timing control position
sensor (right bank)
Intake valve timing control position
12.
sensor (left bank)
15. Seal ring
Timing chain slack guide
33.
(right bank)
Timing chain tension guide
39.
(right bank)
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove engine assembly from vehicle. Refer to EM-70, "R e mo va l an d I ns tallation" .
2. Remove the following components and related parts:
● Drive belt auto tensioner and idler pulley. Refer to EM-14, "Drive Belt Auto T ensioner and Idler Pulley" .
● Thermost at housing and hose. Refer to CO-24, "Removal and Installation" .
● Oil pan and oil strainer. Refer to EM-25, "Removal and Ins talla tio n" .
● Ignition coil (When camshaft sprocket is removed). Refer to EM-28, "Removal and Insta llation" .
● Rocker cover (When camshaft sprocket is removed). Refer to EM-33, "Removal and Installation" .
3. If necessary, remove intake valve timing control position sensor
(right and left) and camshaft position sensor (PHASE) from
intake val ve timing control cover and front cover.
CAUTION:
● Handle components and parts carefully to avoid dropping
and shocks.
● Do not disassemble.
4. If necessary, remove intake valve timing control solenoid valve
from intake valve timing control cover.
CAUTION:
● Handle components and parts carefully to avoid dropping
and shocks.
● Do not disassemble.
PBIC0050E
Revision; 2004 April 2003 Q45
EM-36
TIMING CHAIN
5. Remove intake valve timing control cover as follows:
a. Loosen and remove fixing bolts in the reverse order of that
shown in figure.
b. Use seal cutter or the equivalent to cut liquid gasket for removal.
CAUTION:
● Exercise care not to damage mating surfaces.
● Pull out cover keeping levelness without an angle, as
inner part of cover is engaged with the center of intake
cam sprocket.
6. Obtain compression TDC of No. 1 cylinder as follows:
a. Turn crankshaft pulley clockwise to align the TDC identification
notch (without paint mark) with timing indicator on front cover.
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b. At this time, check that the mating mark on camshaft sprocket is
in the position as shown in the figure.
● If the mating mark does not co me in the p osition sho wn, turn
crankshaft pulley once more to bring the mark in the position.
7. Remove crankshaft pulley as follows:
a. Lock crankshaft with a hammer handle or similar tool to loosen
fixing bolts.
b. Pull crankshaft pulley with both hands to remove it.
CAUTION:
● Do not remove fixin g bolts. Keep loosen ed fix ing bo lts in
place to protect removed crankshaft pulley from dropping.
● Do not remove balance weight (inner hexagon bolt) at the
front of crankshaft pulley.
PBIC0052E
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TIMING CHAIN
8. Remove front cover as follows:
a. Loosen and remove fixing bolts in the reverse order of that
shown in figure.
b. Use seal cu tter or t he equi valent to cut li quid gaske t for re moval.
CAUTION:
Exercise care not to damage mating surfaces.
9. If replacement of front oil seal is necessa ry, lift the se al with a
screwdriver for removal.
CAUTION:
Exercise care not to damage front cover.
10. Remove oil pump drive spacer.
● Install bolts into two bolt holes [M6 x pitch 1.0 mm (0.04 in )]
on front surface. Using a small puller, pull spacer off from
crankshaft.
NOTE:
The center-t o-c en te r di me nsi on be tw e en th e t wo bo l t h oles is 33
mm (1.30 in).
11. Remove oil pump. Refer to LU-9, "
12. Remove chain tensioner on left bank.
NOTE:
To remove timing ch ai n and a sso ci at ed p a r t s, st a r t wi th th os e on
left bank. The procedure for removing parts on right bank is omitted because it is the same as that for left
bank.
a. Press tab in the direction of arrow (or turn lever in the direction
of arrow) to unlock the locking with the groove that s tops tensioner plunger from returning.
● Lightly press tensioner plunger to release the tension of
spring for this operation.
b. Push in tensioner plunger to align the hole on lever and that on
pump main body.
● Pushing in tens ione r too far do es n ot a llow the hole s to align .
Therefore, pus h in pl unger to the de gree at which th e start of
stopper groove and tab engages.
c. Insert a stopper pin [hard wire with approx. 0.5 mm (0.020 in)
diameter or a similar tool] to fix plunger. With plunger fixed, remove chain tensioner.
13. Remove chain tensioner guide and slack guide.
14. Remove timing chain and crankshaft sprocket.
15. With hexagonal part of camshaft locked with wrench, loosen
bolts securing camshaft sprocket to remove camshaft sprocket.
CAUTION:
To avoid interference between valves and pistons, do not
turn crankshaft or camshaft with timing chain is disconnected.
16. Using th e sa me p roc edu re as for le ft ba nk, r em ove timin g ch ain
and associated parts on right side .
OIL PUMP" .
KBIA0354J
PBIC0054E
PBIC0055E
PBIC0030E
Revision; 2004 April 2003 Q45
EM-38
TIMING CHAIN
INSPECTION AFTER REMOVAL
Check for cracks and any excessive wear at link plates. Replace
chain if necessary.
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NOTE:
● The above figu re shows the rela tionship bet ween the mat ing mark on each timing chain a nd that on the
corresponding sprocket, with the components installed.
● Parts with an identific ation mark (R or L) sh ould be installed on the corresp onding bank ac cording to the
mark.
Parts with an identification mark:
● Intake camsh aft sprocket
● Dowel pin groove of exha us t cam s ha ft sp roc ke t (ca ms ha ft sp roc k et is sa m e part both ba nk s)
● Chain tension guide
● Chain slack gu ide
● Because of parallel manufacture, there are two types of mark (link colors) for timing chain.
● To install timing ch ain and associated parts, start with those on right bank. The procedure for installin g
parts on left bank is omitted because it is the same as that for installation on right bank.
Revision; 2004 April 2003 Q45
EM-39
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TIMING CHAIN
1. Check that the crankshaft key and dowel pin of each camshaft
are facing in the direction indicated.
2. Install camshaft sproc k ets.
● Install onto correct side by checking with identification mark
on surface
● Install exhaust-side camshaft sprocket by selectively using
the groove of dowel pin according to the bank. (Common part
used for both banks.)
● Lock the hexa gonal part of camshaft in th e same way as for
removal, and tighten fixing bolts.
SBIA0356E
3. Install crankshaft sproc kets for both banks.
● Install each crankshaft sprocket so that its flange side (the
larger diameter side without teeth) faces in the direction
shown in figure.
NOTE:
The same parts are used but facing directions are different.
PBIC0037E
PBIC0057E
Revision; 2004 April 2003 Q45
EM-40
4. Install timing chains and associated parts.
TIMING CHAIN
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● Align the mating mark on each sprocket and the timing chain for installation.
NOTE:
Before installing chain tensioner, it is possible to change t he position of mating mark on timing chain for
that on each sprocket for alignment.
CAUTION:
For the above reason , after the mating marks are ali gned, keep them aligned by holding them
with a hand.
● Install slack guides and tension guides onto correct side by checking with identification mark on sur-
face.
● Install chain tensioner with plunger fixed as described in its removal.
CAUTION:
● Before and after the installation of chain tensioner, make sure that the mating mark on timi ng
chain is not out of alignment.
● After installing chain tensioner, remove the sto pper pin to release t ensioner. Check that ten-
sioner is released.
● To avoid chain-link skipping of timing chain, never m ove crankshaft or cams hafts until front
cover is ins talled.
5. In the same way as for right bank, install timing chain and associated parts on left side.
6. Install oil pump.
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EM-41
TIMING CHAIN
7. Install oil pump drive spacer as foll ow s :
a. Insert oil pump drive spacer according to the directions of crank-
shaft key and the two flat surfaces of oil pump inner rotor.
● If the positional relationship does not allow the insertion,
rotate oil pump inner rotor with a finger to allow the spacer.
b. After confirming that the posit ion of each part is in corre ct condi-
tion to allow for the space r, force fit the spacer by lightl y tappin g
with a plastic hammer until it contacts and does not go furt her.
8. Install front oil seal onto front cover.
● Using oil seal drift or drift with 54 mm (2.13 in) diameter, force
fit the seal until it levels with the front end surface of front
cover.
PBIC0058E
● Install new oil seal in the direction shown in the figure.
CAUTION:
Be careful not to scratch or make burrs on circumference
of oil seal.
9. Inst all chain tensioner cover onto front cover.
● Apply liquid gasket as shown in the figure.
Use Genuine RTV Silicone Sea lan t or equ iva le nt. Re fer to
GI-46, "
SEALANTS" .
RECOMMENDED CHEMICAL PRODUCTS AND
PBIC0059E
SEM715A
SBIA0372E
Revision; 2004 April 2003 Q45
EM-42
TIMING CHAIN
10. Install front cover as follows:
a. Install new O-rin gs o nto RH and L H cyli nd er hea ds and c ylin der
block.
b. Apply liquid gasket as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-46, "
SEALANTS" .
c. Check again that the timing mating mark on timing chain and
that on each sprocket are aligned. Then, install front cover.
CAUTION:
Be careful to avoid interference with the front end of oil
pump drive spacer. Such interference may damage front oil
seal.
RECOMMENDED CHEMICAL PRODUCTS AND
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d. Tig h ten fixing bolts in the order shown in figure.
e. After tightening, re-tighten to the specified torque.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking onto
surface mati ng with oil pan.
11. Install intake valve timing control cover as follows:
a. At the back of intake valve timing control cover, install new seal rings (three for each) to the area to be
inserted into intake camshaft sprocket.
CAUTION:
Do not spread seal ring excessively to avoid breaks and deformation.
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Revision; 2004 April 2003 Q45
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TIMING CHAIN
b. On the side of front cover, install new O-ring (one for each
bank).
c. Apply liquid gasket as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-46, "
SEALANTS" .
RECOMMENDED CHEMICAL PRODUCTS AND
SBIA0374E
d. T ighten fixing bolts in the order shown in figure.
12. Install intake valve timin g cont rol pos it ion se nsor, intake valve timi ng con trol so le noid valve and ca msh aft
position sensor (PHASE) to intake va lv e tim in g contro l cov e r and fron t co ve r.
● Be sure to tighten bolts with flanges completely seated.
13. Install crankshaft pulley.
● Install according to the dowel pin of oil pump drive spacer.
● Lightly tapping its center with pla s tic hammer, insert pulley.
CAUTION:
Do not tap pulley on the side surface where belt is installed (outer circumference).
14. Tighten fixing bolts of crankshaft pulley.
● Lock crankshaft with a hamm er ha nd le or similar tool to tighten fixing bo lts.
● Perform the following steps for angular tightening:
a. Apply engine oil onto threaded pa rts of bolts and seating areas.
b. Tighten bolt 88.2 to 98.0 N·m (9.0 to 9.9 kg-m, 65 to 72 ft-lb).
SBIA0375E
PBIC0051E
Revision; 2004 April 2003 Q45
EM-44
TIMING CHAIN
c. Select one most visible notch of the four on bolt flange. Corre-
sponding to the selected notch, put a mating mark (such as
paint) on crankshaft pu lle y.
d. Tighten further by 90° to 96° [target: 90°].
● Check the tighten in g angl e by r efe ren ci ng to the no t che s. Th e
angle between two no tch es is 90 °.
PBIC0065E
15. Rotate c rankshaft pulley in normal directio n (clockwise when vi ewed from FRONT ) to check for interference among par ts.
16. For the following operations, perform steps in the reverse order of removal.
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CAMSHAFT
CAMSHAFT PFP:13001 Removal and Installation EBS001JZ
1. Cylinder head (right bank) 2. Camsh aft bracket (No.2, 3, 4, 5) 3. Adjusting shi m
4. Valve lifter 5. Camshaft bracket (No.1) 6. Washer
7. Ca ms haf t (exhaust) 8. Camshaft sprocket (exhaust) 9. Camshaft sprocket (intake)
10. Cams haf t (intake) 11. Cylinder head ( left bank) 12. Adjusting shim
13. Valve lifter 14. Camshaft (intake) 15. Camshaft sprocket (intake)
16. Camshaft sprocket (exhaust) 17. Camshaft (exhaust) 18. Camshaft bracket (No.1)
19. Washer 20. Camshaft bracket (No.2, 3, 4, 5) 21. Camshaft bracket (intake, No.6)
CAUTION:
Apply new engine oil to parts marked in illustration before installation.
REMOVAL
1. Remove timing chain. Refe r to EM-35, "Removal and Installation" .
2. With hexagonal part of camshaft locked with wrench, loosen
bolts securing camshaft sprocket to remove camshaft sprocket.
CAUTION:
To avoid interference between valves and pistons, do not
turn crankshaft or camshaft with timing chain disconnected.
SBIA0365E
PBIC0030E
Revision; 2004 April 2003 Q45
EM-46
CAMSHAFT
3. Loosen fixing bolts in the reverse order of that shown in figure to
remove camsha ft bra ck ets.
● Lightly tapping with plastic hammer, remove No. 1 camshaft
bracket and No. 6 camshaft bracket.
NOTE:
The bottom surface of each bracket will be stuck to cylinder
head because of liquid gasket.
4. Remove camshaft.
5. Remove adjusting shims and valve lifters if necessary.
● Correctly identif y location where each part is ins talled. Keep
parts in an organized way to avoid mixing them up.
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INSTALLATION
1. Install adjusting shims and valve lifters if necessary.
● Install removed parts in the same locations as before.
2. Install camshafts. Refer to the table below for identification of
right and left bank, and intake and exhaust.
Bank IN/EX
LH
RH
● Install so that do wel pin at the fro nt of c amshaf t face i s in the
IN Blue — No. LH
EXH — Orange No. LH
INT Blue — Yes. RH
EXH — Orange Yes. RH
direction shown in the figure.
Identifica-
tion paint
(front)
Identifica-
tion paint
(rear)
Identifica-
tion rib
Identifica-
tion sym-
bol
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EM-47
CAMSHAFT
3. Install camshaft brackets.
● Install by referring to id en tification mark on upper surface an d
front mark.
● Install so that identification mark can be correctly read when
viewed from the side of left exhaust ban k .
● Install No. 1 camshaft bracket as fo llow:
– Apply liquid gasket to No.1 camshaft bracket as in illustration.
Use Genuine RTV Silicone Sea lan t or equ iva le nt. Re fer to
GI-46, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
CAUTION:
● After installation, be sure to wip e off a ny excessive liq-
uid gasket leaking from part “A” and “B”(both on rig ht
and left sides).
● Remove completely any excess of liquid gasket inside
bracket.
● Apply liquid gasket to No.6 camshaft bracket on left bank
intake as in illustration.
CAUTION:
● After installation, be sure to wip e off a ny excessive liq-
uid gasket leaking from part “A”, and “ B”(both on
right and left sides).
● Remove completely any excess of liquid gasket inside
bracket.
PBIC0034E
PBIC0035E
PBIC0036E
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EM-48
CAMSHAFT
4. Tighten fixing bolts of camshaft brackets as follows:
a. Tighten in the order from 9 to 12 with tightening torque 1.96 N·m
(0.2 kg-m, 17 in-lb).
b. Tighten in the order from 1 to 8 with tigh tening torqu e 1.96 N·m
(0.2 kg-m, 17 in-lb).
c. Tighten in the order from 13 to 14 with tightening torque 1.96
N·m (0.2 kg-m, 17 in-lb) (Left bank only).
d. Tighten all bolts in the specified order with tightening torque 5.88
N·m (0.6 kg-m, 52 in-lb)
e. Tighten in the order fr om 1 to 12 with tighte ning torque 9.02 to
11.8N·m (0.92 to 1.2 kg-m, 80 to 104 in-lb).
f. Tighten in the o rder from 13 to 14 with tighten ing torqu e 29.4 to
33.3 N·m (3.0 to 3.3 kg-m, 22 to 24 ft-lb) (left bank only).
CAUTION:
After tightening fixing bolts of camshaft brackets, be sure
to wipe off excessive liquid gasket from the parts listed
below.
● Mating surface of rocker cover
● Mating surface of front cover
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5. Install camshaft sprockets.
● Install by checking with identification mark on surface.
● Install exhaust-side camshaft sprocket by selectively using
the groove of dowel pin according to the bank. (Common part
used for both banks.)
● Lock the hexagonal part of camshaft in the same way as for
removal, and tighte n fix in g bol ts.
6. For the following operations, perform steps in the reverse order
of removal.
7. Check and adjust valve clearan ce s.
Refer to EM-52, "
V alve Clearance" .
INSPECTION AFTER REMOVAL
Camshaft Runout
1. Put V block on precise flat bed, and support No.2 and No.5 journal of camshaft.
2. Set dial gauge vertically to No.3 journal.
3. Turn camshaft to one dire ction with hands, and meas ure camshaft runout on dial gauge.
● 1/2 of runout is bend.
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PBIC0037E
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Standard : Less than 0.02 mm (0.0008 in)
4. If it exceeds the specification, replace camshaft.
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CAMSHAFT
Camshaft Cam Height
1. Measure camsha ft ca m he igh t.
Standard cam height:
Intake: 44.865 - 45.055 mm (1.7663 - 1.7738 in)
Exhaust: 43.925 - 44.115 mm (1.7293 - 1.7368 in)
2. If wear is beyond the specifications, replace camshaft.
Camshaft Journal Clearance
Outer Diameter of Camshaft Journal
Measure outer diameter of camshaft journal.
Standard outer diameter:
No.1: 25.938 - 25.955 mm (1.0212 - 1.0218 in)
No.2, 3, 4, 5: 25.953 - 25.970 mm (1.0218 - 1.0224 in)
PBIC0039E
Inner Diameter of Camshaft Bracket
● Tighten camshaft bracket bolt with specified torque.
● Using inside micrometer, measure inner diameter of camshaft
bracket.
Standard:
26.000 - 26.021 mm (1.0236 - 1.0244 in)
Calculation of Camshaft Journal Clearance
(Journal clearan ce) = (inner diameter o f camshaft bracket) – (out er
diameter of camshaft journal)
Standard:
No.1 : 0.045 - 0.083 mm (0.0018 - 0.0033 in)
No.2, 3, 4, 5 : 0.030 - 0.068 mm (0.0012 - 0.0027 in)
● When out of the specified range above, replace either or both camshaft and cyli nder head.
NOTICE:
Inner diameter of camshaft bracket is manufactured together with cylinder head. Replace the whole cylinder head assem bly.
Camshaft End Play
● Install dial gauge in thrust direction on front end of camshaft.
Measure end play when camshaft is moved forward/backward
(in direction to axis).
PBIC0040E
PBIC0041E
Standard:
0.115 - 0.188 mm (0.0045 - 0.0074 in)
● When out of the specified range, replace with new camshaft and
measure again.
● When out of the specified range again, replace with new cylinder
head.
Revision; 2004 April 2003 Q45
EM-50
PBIC0042E
CAMSHAFT
Camshaft Sprocket Runout
1. Install camshaft in cy li nder head.
2. Install camshaft sprocket to camshaft.
3. Measure camshaft sprocket runout.
Runout : Less than 0.15 mm (0.0059 in)
4. If it exceed s the specifications, replace camshaft sprocket.
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Valve Lifter and Adjusting Shim
Check if surface of valve lifter and adjusting shim has any wear or
cracks.
Valve Lifter Clearanc e
Outer Diameter of Valve Lifter
Measure outer diameter of valve lifter.
Standard: 33.965 - 33.975 mm (1.3372 - 1.3376 in)
PBIC0930E
PBIC0231E
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Valve Lifter Hole Diameter
Using inside micrometer, measure diameter of valve lifter hole of cylinder head.
Standard:
34.000 - 34.016 mm (1.3386 - 1.3392 in)
Calculation of Valve Lifter Clearance
(Valve lifter clearance) = (hole diameter of valv e li fte r) – (o ute r diameter of valve lifter)
Standard:
0.025 - 0.051 mm (0.0010 - 0.0020 in)
● When out of specified range, referring to each specification of outer and inner diameter, replace either or
PBIC0043E
both valve lif ter and cylinder head.
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Va lve Clearance EBS002MQ
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unus ua l e ng ine c on di t io ns du e to c ha ng es in va lv e c le ara nce ov er ti me (s tarting, idling, an d/or n oi se ).
1. W arm up engine. Then, stop it.
2. Remove engine cover and engine room covers (RH and LH) with power tool and air duct (inlet). Refer to
EM-11, "
3. Remove RH and LH rocker covers with power tool. Refer to EM-33, "
4. Turn crankshaft pulley in normal direction (clockwise when
viewed from FRONT ) to align TDC identific ation notch (without
paint mark) with timing indicat or.
5. At this time, check that the both intake and exhaust cam noses
of No. 1 cylinder (top front on left bank) face outside.
● If they do not face outside, turn crankshaft pulley once more.
Removal and Installation" .
Removal and Installation" .
PBIC0044E
6. By referring to the figu re, measure valve cle ara nc e s a t lo ca ti on s
marked X as shown in the table be low (locations indic ated with
black arrow in figure) with a thickness gauge.
NOTE:
Firing order 1-8-7-3-6-5-4-2
● No.1 cylinder compression TDC
Measuring position (RH bank) No.2 CYL No.4 CYL No .6 CYL No. 8 CYL
No. 1 cylinder at TDC
Measuring position (LH bank) No.1 CYL No. 3 CYL No. 5 CYL No. 7 CYL
No. 1 cylinder at TDC
EXH ×
INT ××
INT ××
EXH ××
KBIA0400J
PBIC0823E
Revision; 2004 April 2003 Q45
EM-52
CAMSHAFT
● Use a fine thickness gauge.
V a lve clearance standard:
Hot Intake : 0.32 - 0.40 mm (0.013 - 0.016 in)
Exhaust : 0.33 - 0.41 mm (0.013 - 0.016 in)
Cold* Intake : 0.26 - 0.34 mm (0.010 - 0.013 in)
Exhaust : 0 .29 - 0.37 mm (0.011 - 0.015 in)
*Approximately 20°C (68°F)
CAUTION:
If inspection was carried out with cold engine, check that
values with fully warmed up eng ine are still within sp ecifications.
7. Turn crankshaft pulley clockwise by 270° from the p osition of No. 1 cylinder com pression TDC to obtain
No. 3 cylinder comp ression TDC.
8. By referring to the figure, measure valve clearances at locations
marked X as shown in the table below (locations indicated with
white arrow in figure)
● No.3 cylinder compression TDC
PBIC0046E
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Measuring position (RH bank) No.2 CYL No.4 CYL No.6 CYL No. 8 CYL
No. 3 cylinder at TDC
Measuring position (LH bank) No.1 CYL No. 3 CYL No. 5 CYL No. 7 CYL
No. 3 cylinder at TDC
EXH ×
INT ×
INT ××
EXH ××
9. Turn crankshaft pulley clockwise by 90° from the po sitio n of N o.
3 cylinder comp ression TDC (clockwis e by 360° from the posi tion of No. 1 cylinder compression TDC) to measure intake and
exhaust valve clearances of No . 6 cylinder and exhaust valve
clearance of N o.2 cylinder.
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10. If out of specifications, adjust as follows:
Revision; 2004 April 2003 Q45
EM-53
CAMSHAFT
ADJUSTMENT
Adjust valve clearance while engine is cold.
1. Turn crankshaft, to posi tion cam lobe o n camshaft o f valve that
must be adjusted upward.
2. Thoroughly wipe off engine oil around adjusting shim using a
rag.
3. Using a extra-fine screwdriver, turn the round hole of the adjusting shim in the direction of the arrow.
4. Place Tool (A) around camshaft as shown in figure.
● Before placing Tool (A), rotate cam lobe toward center of cyl-
inder head (See (1) in figure.) to simplify shim removal later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
5. Rotate Tool (A) (See (2) in figure.) so that valve lifter is pushed
down.
PBIC0047E
6. Place Tool (B) between camshaft and the edge of the valve lifter
to retain valve lifter.
CAUTION:
● Tool (B) must be placed as close to camshaft bracket as
possible.
● Be careful not to damage cam surface with Tool (B).
7. Remove Tool (A).
8. Blow air into the hole to separate adjusting shim from valve lifter.
CAUTION:
When blowing, use goggles to protect your eye.
SBIA0408E
SEM870E
SEM871E
Revision; 2004 April 2003 Q45
EM-54
CAMSHAFT
9. Remove adju sting shim using a small screwdrive r and a magnetic finger.
10. Determine replacement adjusting shim size following formula.
● Using a micrometer determine thickness of removed shim
with measured at center.
● Calculate thickness of new adjusting shim so valve clearance
comes within sp ecified values (Cold value).
R = Thickness of removed shim
N = Thickness of new shim
M = Measured valve clearance
Intake : N = R + [M − 0.30 mm (0.0118 in)]*
Exhaust : N = R + [M − 0.33 mm (0.0130 in)]*
*: Approximately 20° C (68° F)
Shims are available in 64 sizes from 2.32 mm (0.0913 in) to 2.95 mm (0.1161 in) in steps of 0.01
mm (0.0004 in).
● Select new shim with thickness as close as possible to calcu-
lated value.
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● Install with the surface on which the thickness is
stamped facing down.
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EM-55
CAMSHAFT
12. Place Tool (A) as mentioned in steps 4 and 5.
13. Remove Tool (B).
14. Remove Tool (A).
15. Recheck valve clearance. (Cold value)
16. Finally check valve clearance with warmed up engine. (Hot
value)
Valve clearance:
Cold* (reference data) Hot
Intake 0.26 - 0.34 (0.010 - 0.013) 0.32 - 0.40 (0.013 - 0.016)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.33 - 0.41 (0.013 - 0.016)
*: Approximately 20°C (68°F)
SEM874E
Unit: mm (in)
Revision; 2004 April 2003 Q45
EM-56
OIL SEAL
OIL SEAL PFP:00100
Removal and Installation of Valve Oil Seal EBS00JX7
REMOVAL
1. Remove camshaft relating to valve oil seal to be removed. Refer to EM-4 6, "CAMSHAFT" .
2. Remove adjusting shims and valve lifters. Refer to EM-46, "
● Correctly identify location where each part is installed. Keep parts in an organized way to avoid mixing
them up.
3. Turn crankshaft until the cylinder requiring new oil seals is at TDC. This will prevent the valve from dropping into the cylinder.
4. Remove valve collet.
● Compress valve spring with valve spring compressor.
Remove valve col let with magnet driver.
5. Remove valve spring retainer and valve spring.
CAUTION:
Do not remove valve spring seat from valve spring.
CAMSHAFT" .
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6. Remove valv e oi l se al us ing valve oil seal pull er (special service
tool).
INSTALLATION
1. Apply engine oil on new valve oil seal joint and seal lip.
2. Install valve oil seal.
● Install with valve oil seal drift to match dimension in illustra-
tion.
3. Perform steps in the reverse order of rem oval for the following
operations.
PBIC0071E
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EM-57
OIL SEAL
Removal and Installation of Front Oil Seal EBS00JX8
REMOVAL
1. Remove the following parts:
● Undercover
● Drive belt; Refer to EM-12, "DRIVE BELTS" .
● Cooling fan; Refer to CO-18, "COOLING FAN" .
2. Set ring gear stopper (SST).
PBIC1656E
3. Remove crankshaft pulley.
4. Remove front oil seal using a suitable tool.
CAUTION:
Be careful not to damage front timing chain case and crankshaft.
INSTALLATION
1. Install front oil seal onto front cover.
● Apply engine oil on new front oil seal.
● Using oil seal drift or drift with 54 mm (2.13 in) diameter, force
fit the seal until it levels with the front end surface of front
cover.
SBIA0358E
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Revision; 2004 April 2003 Q45
EM-58
OIL SEAL
● Install new oil seal in the direction shown in the figure.
CAUTION:
Be careful not to scratch or make burrs on circumference of
oil seal.
2. For the following operations, perform steps in the reverse order
of removal.
3. Perform steps in the reverse order of rem oval for the following
operations.
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EM-59
OIL SEAL
Removal and Installation of Rear Oil Seal EBS00JX9
REMOVAL
1. Remove transmission assembly. Refer to AT-297, "TRANSMISSION ASSEMBLY" .
a. Remove drive plate.
● Holding crankshaft pulley mounting bolts, lock crankshaft to remove bolts fixing drive plate.
● Loosen fixing bolts diagonally.
CAUTION:
● Be careful not to damage drive plate. Especia lly, avoid deforming and damaging of signal plate
teeth (circumference position).
● Place the drive plate with signal plate surface facing other than downward.
● Keep magnetic materials away from signal plate.
b. Remove engine rear plate.
2. Remove rear oil seal using a suitable tool.
CAUTION:
Be careful not to damage crankshaft and oil seal retainer
surface.
INSTALLATION
1. Install rear oil seal to oil seal retainer.
● Tap until flatte ned with front edge of oil sea l retainer. Do not
damage or scratch outer circumference of oil seal.
● Install new oil seal in the direction shown in the figure.
CAUTION:
Be careful not to scratch or make burrs on circumference
of oil seal.
2. Perform steps in the reverse order of removal fo r the following
operations.
SBIA0360E
SBIA0360E
SEM715A
Revision; 2004 April 2003 Q45
EM-60
CYLINDER HEAD
CYLINDER HEAD PFP:11041
On-Vehicle Service EBS001K1
CHECKING COMPRESSION PRESSURE
1. Remove engine cover with power tool, air cleaner cover and battery cover. Refer to EM-11, "Removal and
Installation" .
2. Warm up engine thoroughly. Then, stop it.
3. Release fuel press ure .
a. Remove fuel pump fuse, and start engine. Refer to EC-48, "
fuse location.
b. After engine stalls, crank it two or three times to release all fuel pressure.
● Let fuel pump f use removed until the end of step 7.
4. Remove ignition coil and spark plug from each cylinder. Refer to EM-28, "
EM-29, "
Removal and Installation" .
5. Connect engine tachometer (not required in use of CONSULT-II).
6. Install compression gauge with adapter onto spark plug hole.
● Use compression gauge adapter which is required on No.7
and No.8 cylinders.
FUEL PRESSURE RELEASE" fo r fue l p ump
Removal and Ins tallation" an d
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● Use compression gauge whose picking up end inserted to
spark plug hole is smaller than 20 mm (0.79 in) in diameter.
Otherwise, it may be caught by cylinder head during removal.
7. With accelerator pedal fully depressed, turn ignition switch to
“START” for cr anking. When the gauge pointe r stabilizes, read
the compressio n pre ss ure a nd en gi ne rpm . Perform these ste ps
to check each cylinder.
Compressio n pressure
Standard Minimum Deference limit between cylinders
1,320 (13.5, 191) / 300 1,130 (11.5, 164) / 300 98 (1.03, 14) / 300
CAUTION:
Always use a fully charged battery to obtain specified engine speed.
● If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine
speed again with normal battery gravity.
● If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again .
● If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
– If the added engine oil impro ves th e comp ressi on, the pist on ri ngs ma y be worn o ut or d amage d. Check
the piston rings and replace if necessary.
– If the compre ssion pre ssure remain s at low level des pite the a ddition of engine oi l, the valv es may be
malfunctio ning. Check the valves for damage. Replace the valve or valve seat accordingly.
PBIC0066E
SEM387C
Unit: kPa (kg/cm2 , psi) /rpm
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CYLINDER HEAD
● If two adjacent cylinders have respec tively low compress ion pressure and their com pression remains
low even after the addition of engine oil, the gaskets are leaking. In such a case, replace the cylinder
head gaskets.
8. Install removed parts in the reverse order of remov al .
9. Start engine, and confirm that engine runs smoothly.
10. Perform troubl e diagnosis. If DTC appears, erase it. Refer to EC-74, "
TROUBLE DIAGNOSIS" .
Removal and Installation EBS00NBD
1. Engine coolant temperature sensor 2. Washer 3. Cylinder hea d gasket (left bank)
4. Harness bracket 5. Cylinder head (right bank) 6. Cylinder hea d bol t
7. Cylinder head gasket (right bank) 8. Cylinder head bolt 9. Cylinder hea d (lef t ban k)
REMOVAL
1. Remove engine assembly from vehicle. Refer to EM-70, "R e mo va l an d I ns tallation" .
2. Remove the following components and related parts:
● Auto tensioner of drive belts and idler pulley. Refer to EM-14, "Drive Belt Auto Tensioner and Idler Pul-
ley" .
● Thermost at housing and hose. Refer to CO-24, "Removal and Installation" .
● Oil pan and oil strainer. Refer to EM-25, "Removal and Ins talla tio n" .
● Intake manifold upper and intake manifold lower. Refer to EM-17, "Removal and Installation" .
● Fuel tube and fuel injector assembly. Refer to EM-31, "Removal and Installation" .
● Ignition coil. Refer to EM-28, "Removal and Installation" .
● Rocker cover. Refer to EM-33, "Removal and Installation" .
● Exhaust manifold and three way catalyst. Refer to EM -2 2, "Removal and Installation" .
3. Remove cran ks ha ft p ul l ey, front cov er, oil pump, an d t imi ng ch ain . Re fer t o EM-35, "
tion" .
4. Remove camshaft sprockets and camshafts. Refer to EM-46, "
Removal and Installation" .
Removal and In st a ll a-
PBIC1667E
Revision; 2004 April 2003 Q45
EM-62
CYLINDER HEAD
5. Remove cylin der head loosening bolts in reverse order shown in
the figure and using cylinder head bolt wrench (Commercial service tool).
INSPECTION AFTER REMOVAL
Outer Diameter of Cylinder Head Bolts
● Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with new one.
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Limit (d1 - d2) : More than 0.18 mm (0.0071 in)
● If reduction of outer diameter appears in a posi tion other than
d2, use it as d2 point.
INSTALLATION
1. Install cylinder head gasket.
2. Follow the steps below to tighten fixing bolts in the order shown
in figure to install cylinder head.
CAUTION:
● If cylinder head bolts are re-used, check their outer diam-
eters before installation. Refer to above EM-63, "
Diameter of Cylinder Head Bolts" .
● In step “c”, loosen bolts in the reverse order of that indi-
cated in figure.
a. Apply engine oil to threads and seating surface of bolts.
b. Tighten all bolts to 98.1 N·m (10 kg-m, 72 ft-lb).
c. Completely loosen all bolts.
d. Tighten all bolts to 39.2 to 49.0 N·m (4.0 to 5.0 kg-m, 29 to 36 ft-lb).
e. Turn all bolts 60 to 65 (target: 60) degrees clockwise.
f. Turn all bolts 60 to 65 (target: 60) degrees clockwise again.
CAUTION:
Check and confirm the tightening angle by using angle
wrench (SST) and cylinder head bolt wrench (commercial
service tool). Avoid judgment by visual inspe ction without
the SST.
Outer
KBIA0189E
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3. Install followings in reverse order of removal.
Revision; 2004 April 2003 Q45
EM-63
CYLINDER HEAD
Disassembly and Assembly EBS002MT
1. Spark plug 2. Adjusting shim 3. Valve lifter
4. Valve collet 5. Valve spring retainer 6. Valve spring (with valve spring seat)
7. Valve oil seal 8. Valve gu ide 9. Valve seat (INT)
10. Valve (INT) 11. Valve (EXH) 12. Valve seat (EXH)
13. Cylinder head (left bank) 14. Cyl i nder head (right bank)
DISASSEMBLY
1. Remove spark plug with spark plug wrench.
2. Remove spark plug tube, as necessary.
● Using a pair of pliers, pull spark plug tube out of cylin de r hea d.
CAUTION:
● Take care not to damage cylinder head.
● Once spark plug tube is removed, i t will be deformed and can not be reused. Do not rem ove it
unless absolutely necessary.
3. Remove adjusting shim and valve lifter.
● Confirm installation point. Keep parts in an organized w ay ti avoid.
4. Remove valve collet.
● Compress valve spring with valve spring compressor.
Remove valve collet with magnet driver.
5. Remove val ve spring retainer and val v e spring.
CAUTION:
Do not remove valve spring seat from valve spring.
6. Push valve stem to combustion chamber side, and remove
valve.
● Inspect valve guid e clearance before removal. Refer to EM-
66, "VALVE GUIDE CLEARANCE" .
SBIA0390E
PBIC0071E
Revision; 2004 April 2003 Q45
EM-64
CYLINDER HEAD
● Confirm installation point. Keep parts in an organized way ti avoid.
7. Remove valve oil seal with valve oil seal puller.
8. When valve seat must be replaced, refer to EM-68, "
SEAT REPLACEMENT" .
9. When valve guide must be replaced, refer to EM-66, "
GUIDE REPLACEMENT" .
VALVE
VALVE
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ASSEMBLY
1. Install valve guide. Refer to EM-66, "VALVE GUIDE REPLACEMENT" .
2. Install valve seat. Refer to EM-68, "
3. Install valve oil seal.
● Install with valve oil seal drift to match dimension in illustra-
tion.
4. Install valve.
● Install l a rger diameter to intake side.
5. Install valve spring.
● Install smaller pitch (valve spring seat side) to cylinder head
side.
6. Install valve spring retainer.
7. Install valve collet.
● Compress valve spring with valve spring compressor. Install
valve collet with magnet hand.
● Tap stem ed ge ligh tly w ith plast ic ham mer aft er insta llation to
check its in stalled condition.
8. Install valve lifter.
9. Install spark plug tube.
● Press-fit spark plug tube following procedure below.
a. Remove old liquid gasket adhering to cylinder-head mounting
hole.
b. Apply liqu id gasket to area within approximately 12 mm (0.47 in)
from edge of spark plug tube press-fit side.
● Use Genuine liqu id gasket or equivalent.
c. Using a drift, press-fit spark plug tube so that its height “H” in the
figure is as specified.
Standard press-fit height “H”:
38.4 - 39.4 mm (1.512 - 1.551 in)
VALVE SEAT REPLACEMENT" .
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CAUTION:
● When press-fitting spark plug tube, take care not to deform it.
● After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face.
10. Install spar k plug with spark plug wrench.
Revision; 2004 April 2003 Q45
EM-65
CYLINDER HEAD
Inspection After Disassembly EBS003MN
CYLINDER HEAD DISTORTION
1. Wipe off oil and remove water scale (like deposit), gasket,
sealer, carbon, etc. with scraper.
CAUTION:
Use utmost care not to allow liquid gasket debris to enter
passag es for oil or water.
2. At each of several locatio ns on botto m surfa ce of cylin de r head ,
measure distortion in six directions.
Limit : 0.1mm (0.004 in)
PBIC0075E
VALVE DIMENSIONS
● Check dimensions of each valve. For dimensions, refer to EM-
98, "Valve Dimensions" .
VALVE GUIDE CLEARANCE
Perform this inspection before removing valve guide.
1. Make sure that the valve stem diameter is within the specification.
2. Push the valve out by approx. 15 mm (0.59 in) toward the combustion chamber side to measure the
valve's run- out volume (in the direction of dial gauge) with dial gauge.
3. The half of the run-out volume accounts for the valve guide clearance.
Standard
Intake : 0.020 - 0.046 mm (0.0008 - 0.0018 in)
Exhaust : 0.030 - 0.056 mm (0.0012 - 0.0022 in)
VALVE GUIDE REPLACEMENT
When valve guide is removed, replace with oversized (0.2 mm, 0.008 in) valve guide.
1. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil.
SEM188A
PBIC0077E
SEM008A
Revision; 2004 April 2003 Q45
EM-66
CYLINDER HEAD
2. Drive out va lv e gu id e with a press [under a 20 kN (2 ton , 2.2 U S
ton, 2.0 lmp ton) pressure] or hammer and suitable tool.
CAUTION:
Cylinder head con tains heat, when w orking wear prot ective
equipment to avoid getting bur ned.
3. Ream cylinder head valve guide hole.
V a lve guide hole diameter (for service parts)
Intake and exhaust:
10.175 - 10.196 mm (0.4006 - 0.4014 in)
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
5. Press valve guide from camshaft side to dimensions as in illustration.
CAUTION:
Cylinder head con tains heat, when w orking wear prot ective
equipment to avoid getting bur ned.
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6. Using valve gui de reamer, apply reamer finish to valve guide.
Standard
Intake and exhaust:
6.000 - 6.018 mm (0.2362 - 0.2369 in)
PBIC0078E
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CYLINDER HEAD
VALVE SEAT CONTACT
● Afte r confirming that the dime nsions of valv e guides an d valves
are within specifications, perform this procedure.
● Apply prussian blue (or white lead) onto contacting surface of
valve seat t o check the condition of the valve contac t on the surface.
● Che ck if the co ntact area ban d is contin uous all aro und the cir-
cumference.
● If not, grind to adjus t va lv e f i tti ng an d che ck ag ai n. I f the co ntact-
ing surface still has N.G conditions even after the re-check,
replace valv e seat.
VALVE SEAT REPLACEMENT
When valve seat is removed, replace with oversized (0.5 mm, 0.020 in) valve seat.
1. Bore out old seat unt il it colla pses. Bor ing sh ould not con tinu e beyo nd the botto m face of th e seat recess
in cylinder head. Set the machine depth stop to ensure this.
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake 37.500 - 37.516 mm (1.476 4 - 1.4770 in)
Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in)
SBIA0322E
● Be sure to ream in cir cle s conc entr ic to the va lve g uide center.
● This will enable valv e se at to fit corre ctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
4. Provide valve seats c ooled well w ith dry ic e. F orce fit va lve s eat
into cylinder head.
CAUTION:
● Avoid directly touching cold valve seats.
● Cylinder head contains heat, when working wear protec-
tive equipment to avoid getting burned.
5. Using va lv e s eat cu tte r s et a nd val ve se at gr in der, finish th e se at
to the specified dimensions.
CAUTION:
When using valve sea t cutter, firmly grip the cutter handle
with both hands. Then, pres s on the contacting surface all
around the circumference to cut in a single dri ve. Improp er
pressure on with the cutter or cutting many different times
may result in stage valve seat.
SEM795A
SEM008A
SEM934C
Revision; 2004 April 2003 Q45
EM-68
CYLINDER HEAD
● Grind to obtain the dimensions indicated in figure.
6. Using compou nd, grind to adjust valv e fitt ing .
7. Check again for no rma l co ntact.
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VALVE SPRING SQUARENESS
Set try square along th e side of valve spring and rotate the spring.
Measure the maximum clearance between the top face of spring and
try square.
Limit : 2.0 mm (0.0 79 in)
● If it exceeds the limit, replace valve spring.
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
Check valve spring pressure at specified spring height.
CAUTION:
Do not remove valve spring seat from valve spring (parts for
assy).
Standard:
Free height 46.35 - 46.85 mm (1.8247 - 1.8444 in)
Installation height 33.8 mm (1.331 in)
Installation load 165- 189 N (16.8 - 19.3 kg, 37- 42 lb)
Height during valve open 24.4 mm (0.961 in)
Load with valve open 290- 330 N (29.6- 33.7 kg, 65 - 74 lb)
PBIC0080E
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● If the dimensions exceed the standard, replace the valve spring.
Revision; 2004 April 2003 Q45
EM-69
ENGINE ASSEMBLY
ENGINE ASSEMBLY PFP:10001 Removal and Installation EBS001K5
PBIC0081E
1. Rear engine mounting insulator 2. Rear member 3. LH engine mounting bracket
4. Heat insulator 5. LH engine mounting insulator 6. RH engine mounting bracket
7. Heat insulator 8. RH engine mounting insulator
WARNING:
● Situate vehicle on a flat and solid surface.
● Place chocks at front and back of rear wheels.
● 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.
● Do not start working until exhaust system and engine coolant are cool enough.
● If items or work required are not covered by the engine section, refer to the applicable sections.
● Always use the support point specified for lifting.
● Use either 2-point lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, s upport at the rear ax le jacking point with tra nsmission ja ck or similar tool
before starting work, in preparation for the backward shift of center of gravity.
● For sup porting points for lifting and jacking point a t rear axle, refer to GI-40, " Garage Jack and
Safety Stand" .
REMOVAL
Outline
After removal of transmission, lift up engine assembly to remove it from vehicle.
Preparation
1. Release fuel pressure. Refer to EC-48, "
2. Remove engine cover and engine undercover with power tool.
FUEL PRESSURE RELEASE" .
Revision; 2004 April 2003 Q45
EM-70
ENGINE ASSEMBLY
3. Drain engine coolant from radiator drain plug. Refer to CO-9, "Changing Engine Coolant" .
4. Remove the following parts:
● Engine hood
● Front tower bar
● Battery
● Air duct (inlet)
● Air duct and air cleaner case assembly
● Drive belts (Refer to EM-13, "REMOVAL" .)
● Power valve vacuum tank
● Cooling fan and tubes
● Radiator assembly and hoses (Refer to CO-12, "RADIATOR" .)
● Water suction pipe
Engine room LH
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
7. Disconnect wire bonding exhaust manifold cover to vehicle.
8. Disconnect va cuum hose between vehicle and engine and set it aside.
9. Remove reservoir tank for cooling fan.
10. Rem ove A/C compres sor from brackets, a nd install A/ C com pressor tem porarily with ropes or equiva lent
to avoid applying any pressures on piping or disturbing installation or removal of any vehicle parts. Refer
to ATC-144, "
Engine room RH
11. Disconnect fuel hose at the engine side connection.
● For disconnection/connection of quick connector, refer to EM-31, "Removal and Ins talla tio n " .
12. Disconnect engine room harness from the engi ne side and set it aside for easier work.
13. Disconnect wire bonding exhaust manifold cover to vehicle.
14. Disconnect vacuum hose between vehicle and engine and set it aside.
15. Disco nn ec t rese rv oir tank for po wer steeri ng from en gine and move it aside for easier work .
16. Move away relay case.
Vehicle underbody
17. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for easier work. Refer to PS-23, "
18. Remove pipe of coo ler for automatic transmission.
19. Remove exhaust front tube.
20. Disco nnect steering lower joint, and rele ase steering s haft. Refer to PS-15, "
AND LINKAGE" .
21. Disconnect propeller shaft. Refer to PR-3, "
● After disconnection, plug the openi ng on transmission side.
Removal
22. Remove transmission assembly. Refer to AT- 297, "
23. Install en gine slingers into front of left bank cy linder head and
rear of right bank cylinder head.
Compressor" .
POWER STEERING OIL PUMP" .
POWER STEERING GEAR
REAR PROPELLER SHAFT" .
TRANSMISSION ASSEMBLY" .
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Slinger bolts:
: 30.4 - 36.3 N·m (3.1 - 3.7 kg-m, 23 - 26 ft-lb)
24. Lift with hois t and secure the engine in position.
25. Remove engine mounting nuts on bottom surface.
26. Carefully lift up engine assembly, avoiding interference with
vehicle body, move it away and upward.
PBIC0082E
Revision; 2004 April 2003 Q45
EM-71
ENGINE ASSEMBLY
27. With engine assembly lifted up, remove rear end of exhaust manifold to avoid contact with vehicle.
28. Remove engine assembly from vehicle.
CAUTION:
● Before and during this lifting, always check if any har-
nesses are left connected.
● Avoid damage to oil/grease smearing or spills onto
engine mount insulator.
INSTALLATION
Install in the reverse order of removal.
● Where positioning pin is used, be sure to securely insert it into
the hole of mating part.
● When installing front engine mount bracket to cylinder block, first
tighten two bolts on upper side. Then, ti ghten two bolts on lo wer
side. (The same applies to both right and left.)
KBIA0372J
INSPECTION AFTER INSTALLATION
● Before starting engine, check the levels of engine coolant, lubrications, working oils.
● Run engine to check for unusual noise and vibration.
● Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil,
fuel, and exhaust gas.
● Bleed air from passa g es in pipes and tubes of applicable lines.
PBIC0083E
Revision; 2004 April 2003 Q45
EM-72
CYLINDER BLOCK
CYLINDER BLOCK PFP:11010
Disassembly and Assembly EBS001K6
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1. Knock sensor sub harness 2. Knock sensor 3. Cylin der block
4. Cover 5. Main bearing 6. Top ring
7. Second ring 8. Oil ring 9. Crankshaft key
10. Piston 11. C onnecting rod 12. Snap ring
13. Piston pin 14. Connecting r od bear i ng 15. Conne ct ing rod bea ring cap
16. Block heater protector 17. Connector cap 18. Cylinder block heater (For Canada)
19. Gasket 20. Main bearing ca p 21. Thrust bearing
22. Main bearing 23. Rear plat e 24. Crankshaft
25. Pilot convertor 26. Drive plate 27. Thrust bearing
28. Side bolt 29. Rain force plate 30. Cran kshaft position sensor (POS)
31. O-ring 32. Rear oil seal 33. Rear oil seal retainer
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EM-73
CYLINDER BLOCK
DISASSEMBLY
NOTE:
Explained here is how to disas semble with engine stand sup porting tra nsmission surface. Whe n using different type of engine stand, note with difference in steps and etc.
1. Remove engine assembly. Refer to EM-70, "
2. Remove the parts that may restrict installation of engine to general-purpose engine stand.
NOTE:
The procedure is described assuming that you use a general-purpose engine stand holding the surface, to
which transmission is installed.
a. Remove drive plate.
● Holding crankshaft pulley mounting bolts, lock crankshaft to remove bolts fixing drive plate.
● Loosen fixing bolts diagonally.
CAUTION:
● Be careful not to damage drive plate. Especia lly, avoid deforming and damaging of signal plate
teeth (circumference position).
● Place the drive plate with signal plate surface facing other than downward.
● Keep magnetic materials away from signal plate.
b. Remove engine rear plate.
3. Lift the engine with hoist to install it onto the general-purpose engine stand.
CAUTION:
Use an engine stand that has a load capacity [240 kg (529 pou nd) or more] large enoug h for supporting the engine weight.
● If the load c apacity of the stand is n ot adequ ate, remove the follo wing parts before hand to re duce the
potential risk of overturning the stand.
– Remove intake manifold upper and intake manifold lower. Refer to EM-17, "INTAKE MANIFOLD" .
– Remove exhaust manifold and three way catalyst. Refer to EM-22, "EXHAUST MANIFOLD AND
THREE WAY CATALYST" .
– Remove fuel injector and fuel tube. Refer to EM-31, "FUEL INJECTOR AND FUEL TUBE" .
– Remove starter motor. Refer to SC-28, "Removal and Installation" .
– Remove ignition coil. Refer to EM-28, "IGNITION COIL" .
– Remove rocker cover. Refer to EM-33, "ROCKER COVER" .
– Other removable brackets.
NOTE:
The figure shows an example of general-purpose engine
stand that can hold m ating surf ace of tr ansmissi on with drive
plate and rear plate remove d.
CAUTION:
Before removing the hanging chains, make sure the
engine stand is stable and there is no risk of overturning.
4. Drain engine oil and engine coola nt from inside of engine.
5. Remove the following components and associated parts (The
parts listed in step 3 are not included here.)
● Oil pan and oil strainer: Refer to EM-25, "OIL PAN AND OIL
STRAINER" .
● Crankshaft pulley, fron t cover and timing chain: Refer to EM-35, "TIMING CHAIN" .
● Camshaft: Refer to EM-46, "CAMSHAFT" .
● Cylinder head: Refer to EM-61, "CYLINDER HEAD" .
6. Remove knock sensor.
CAUTION:
Carefully handle the sensor, avoiding shocks.
ENGINE ASSEMBLY" .
PBIC0085E
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7. Remove the piston and connecting rod assembly.
a. Position th e cranksh aft pin corre sponding to the conn ecting rod
to be removed onto the bottom dead center.
b. Remove the conn ecting rod cap.
c. Using a hammer handle or similar tool, push the piston and con-
necting rod assembly out to the cylinder head side.
● Before removing the piston and connecting rod assembly,
check the connecting rod side clearance. Refer to EM-88,
"CONNECTING ROD SIDE CLEARANCE" .
8. Remove the conn ecting rod bearings.
CAUTION:
● When removing them, note the installation position. Keep them in the correct order.
9. Remove the piston rings form the piston.
● Use a piston ring expander.
CAUTION:
● When removing the pi ston rings, be careful not to dam -
age the piston.
● Be careful not to damage piston rings by expanding them
excessively.
● Before removing the piston rings, check the piston ring side
clearance. Refer to EM-89, "
ANCE" .
10. Remove the pisto n from the connecting rod as follows.
a. Using a snap ring pliers, remove the snap ring.
PISTON RING SIDE CLEAR-
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c. Push out piston pin with stick of outer diameter approximately 20
mm (0.8 in).
11. Remove the rear oil seal retainer from the cylinder block.
● Insert a minus-head screwdriver or similar tool between the
rear end of the crankshaft counter weight and rear oil seal
retainer, and separate the liquid gasket to remove.
CAUTION:
Be careful not to damage the mating surface.
12. Using a minus-head screwdriver or similar tool, and lever off the
rear oil seal from the rear oil seal retainer.
13. Remove the main bearing cap as follows:
● Before loosening the main bearing cap bolts, measure the
crankshaft end play. Refer to EM-87, "
PLAY" .
● Loosen bolt s in several different st eps.
a. Remove the cover attached to the rear right side of the cylind er
block (next to the starter motor housing).
NOTE:
Bolts (No. 28 show n in the figure) a re installed on th e inside of
the cover.
b. Loosen the side bolts (M10) starting from 30 to 21 to remove.
c. Loosen the main bearing cap sub bolts (M9) starting from 20 to 11 to remove.
d. Loosen the main bearing cap bolts (M12) starting from 10 to 1 to remove.
e. Using a main bearing cap remover, remove the main bearing
cap.
CRANKSHAFT END
EMM0072D
PBIC0090E
14. Remove the crankshaft.
15. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.
● When removing them, note the installation position. Keep them in the correct order.
16. If the pilot converter must be re moved, remove it from the rear
end of the crankshaft using a pilot bearing puller.
● Removal and installation without the engine stand is possible.
PBIC0091E
PBIC0092E
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CYLINDER BLOCK
ASSEMBLY
1. Fully air-blow the engine coolant and engine oil passages in the cylinder block, the cylinder bore, and the
crankcase to remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to the cylinder block. (Only screwed-type plugs
are shown in the figure.)
● Apply liquid gasket.
Use Genuine Thread Sealant or equivalent. Refer to GI-
46, "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS" .
● Replace the copper washers with new ones.
● Tigh ten them as specified below.
Part Washer Tightening torque
A Yes. 49.0 - 58.8 N ·m (5.0 - 6. 0 kg- m , 37 - 43 ft-lb)
B No. 14.7 - 24.5 N·m (1.5 - 2.5 kg-m, 11 - 18 ft-lb)
C Yes. 57.8 - 67.6 N·m (5.9 - 6.9 kg-m, 43 - 49 ft-lb)
D Yes. 57.8 - 67.6 N·m (5.9 - 6.9 kg-m, 43 - 49 ft-lb)
3. Install the main bearings and the thrust bearings.
a. Remove dust, dirt, and engine oil on the bearing mating sur-
faces of the cylinder block and the main bearing caps.
b. Install the thru st bearings to t he both sides o f the No. 3 journal
housing on the cylinder block and main bearing caps
● Install th e th r us t bear i ng s wi t h t he e ng in e oi l g roo ve f ac in g th e
crankshaft arm (outside).
● Install the thrus t bearings with a protrusion in the center on
the main bearing caps.
PBIC0230E
PBIC0093E
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c. Install the main bearings paying attentio n to the direction.
● Install the one with oil hol es onto the cylinder block and the
one without oil holes onto the main bearing cap.
● Before installing the bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
● When installing, align the bearing stopper to the notch.
● Insure the oil h oles on cyl inder bl ock and thos e on the c orre-
sponding bearing are aligned.
4. Install the pilot converter to the crankshaft.
● Using a drift approximately 35 mm (1.38 in) in outer diameter,
drive the pilot converter until its front end contacts the crankshaft.
● Press-fit the pilot co nv erter with its chamfering s id e fa ci ng the
crankshaft. (Refer to “Component parts illustration on former
page”.)
● It is acceptable to install it without the engine stand.
5. Install the crankshaft to the cylinder block.
● While turning the crankshaft by hand, check that it turns
smoothly.
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CYLINDER BLOCK
6. Inst all the main bearing caps.
● Align the identification number to the journal position to
install.
● Install the upper side of the identification number facing the
front of the engi ne. (The numb er shall be read c orrectly from
the rear of the engine.)
● Using a plastic hammer or similar tool, tap them lightly to seat
them on the installation position.
7. Follow the below steps to tighten each main bearing cap bolts.
a. Apply engine oil to threads and seating surface of bolts, and
tighten all bolts temporarily.
b. Tighten main bearing cap b olt (M12) to 36.3 to 4 2.1 N·m (3 .7 to
4.3 kg-m, 27 to 31 ft-lb) in order of 1 to 10.
c. Tighten main bea rin g cap su b bolt (M9) to 26.5 to 32.3 N· m (2.7
to 3.3 kg-m, 20 to 23 ft-lb) in order of 11 to 20.
d. Tighten main bearing cap bolt (M12) to 40 to 45° degrees (ideal
40 degrees) in order of 1 to 10.
e. Tighten main bearing cap sub bolt (M9) to 30 to 35° degrees
(ideal 30 degrees) in order of 11 to 20.
f. Tighten side bolt (M10) to 46.1 to 51.9 N·m (4.7 to 5.3 kg-m, 34 to 38 ft-lb) in order of 21 to 30.
g. Install cover of cylinder block right-rear side (next to starter motor housing).
CAUTION:
Measure tighten angle in step “d” and “e” with angle
wrench. Do not measure visually.
● Rotate crankshaft by hands after bolts are tightened. Check if
it rotates smoothly.
● Check the crankshaft end play. Refer to EM-87, "CRANK-
SHAFT END PLAY" .
PBIC0095E
PBIC0090E
PBIC0096E
8. Install rear oil seal to oil seal retainer.
● Tap until flatte ned with front edge of oil sea l retainer. Do not
damage or scratch outer circumference of oil seal.
PBIC0097E
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CYLINDER BLOCK
● Install new oil seal in the direction shown in the figure.
9. Install rear oil seal retainer.
● Apply liquid gasket thoroughly to rear oil seal retainer.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-46, "
RECOMMENDED CHEMICAL PRODUCTS AND
SEALANTS" .
● Apply new engine oil on lips of oil seal. Do not touch.
10. Install the piston to the connecting rod.
a. Using a sn ap ring pliers, in stall the snap ring to the grooves o f
the piston rear side.
● Insert it fully into groove to install.
b. Install the piston to the connecting rod.
● Using an industrial drier or similar tool, heat the piston until the piston pin can be pushed in by hand
without excess force [approx. 60 to 70 C° (140 to 158 °F)]. From the front to th e rear, insert the pis ton
pin into the piston and the connecting rod.
● Assemble so th at the fro nt mark on the pi ston crow n and the
oil holes and the cylind er No. on t he connec ting rod are positioned as shown in the figure.
c. Install the snap rings to the front of the piston.
● After installing, check that the connecting rod moves
smoothly.
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11. Using a piston ring expander, install the piston rings.
CAUTION:
Be careful not to damage the piston.
● Position each ring with the gap as shown in the figure, refer-
ring to the piston front mark.
● Install the top ring and the second ring with the stamped sur-
face facing upward.
Stamped mark : R (top ring)
: 2R (second ring)
PBIC0100E
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12. Install th e c onne ct in g r od b ea r ings to t he co nn ecti ng ro d an d t he
connecting rod cap.
● When installing th e connect ing rod bear ings, appl y engine oi l
to the bearing surface (insi de). Do no t apply en gine oil to the
back surface, but thoroughly clean it.
● When installing, align the connecting rod bearing stopper pro-
trusion with the notch of the connecting rod to install.
● Check the oil holes on the connect ing rod and those on the
corresponding bearing are aligned.
13. Install the piston and connecting rod assembly to the crankshaft.
● Position the c rankshaft pin corresponding to the connecting
rod to be installed onto the bottom dead center.
● Apply engine oil sufficiently to the cylinder bore, piston, and
crankshaft pin.
● Match the cylinder position with the cylinder No. on the con-
necting rod to install.
● Using a piston ring compressor, install the piston with the front
mark on the piston crown facing the front of the engine.
CAUTION:
Be careful not to damage th e cran kshaft pin, res ulting fro m
an interference of the connecting rod big end.
14. Install the connecting rod cap.
● Match the stamped cyli nder n umb er marks on th e con nec ting
rod with those on the cylinder cap to install.
PBIC0101E
PBIC0102E
15. Tighten the connecting rod nuts as follows:
a. Apply engine oil to the threads and seats of the connecting rod
bolts and nuts.
b. Tighten nuts to 13.7 to 15.7 N·m (1.4 to 1.6 kg-m, 10 to 12 ft-lb).
c. Put mating (with paint) on each nut and conne cting rod ca p, all
in the same direction (when using a protractor).
d. Then all nuts 60 to 65 degre es clockwise [target: 60 degrees]
(angle tightening).
CAUTION:
Always use either an angle wrench or protractor. Avoid
tightening based on visual check alone.
● After tightening the nuts, make sure that the crankshaft rotates smoothly.
● Check the connecting rod side clearance. Refer to EM-88, "CONNECTING ROD SIDE CLEARANCE" .
PBIC0103E
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CYLINDER BLOCK
16. Install knock sensor.
● Make sure that there is no foreign material on the cylinder
block mating surfac e and the back surfac e of the knock sensor.
● Install it with its connector facing the rear side.
● Do not tighten the mounting bolts while holding the connector.
● Make sure that the knock sensor does not interfere with other-
parts.
● Install the sub-harness with its shorter branch line to the RH
bank.
CAUTION:
If any impact by dropping is applied to the knock sensor, replace it with new one.
17. Install followings in reverse order of removal.
18. Remove engine assembly from engine stand.
19. Install drive plate.
● Align guide pin of cranks haft rear end with pin holes of each
parts to install.
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● Install drive plate, reinforcement plate and pilot converter (if
not installed in step 4) as shown in figure.
● Using drift of 33 mm (1.30 in) dia, push pilot converter into the
end.
● Face chamfered or rounded edge side to crankshaft.
How to Select Piston and Bearing EBS002MW
DESCRIPTION
Connecting points Connecting parts Selection items Selection methods
Determined by match of cylin-
der block bearing housing
Between cylinder block to
crankshaft
Between crankshaft to connecting rod
Between cylinder block to piston
*Between piston to connec t i ng
rod
Main bearing
Connecting rod bearing
Piston and piston pin assembly.
The piston is available together
with piston pin as an assembly.
———
Main bearing grade (bearing
thickness)
Connecting rod bearing grade
(bearing thickness)
Piston grade (piston outer
diameter)
grade (inner diameter of hous-
ing) and crankshaft journal
grade (outer diameter of jour-
nal)
Connecting rod bearing grade
= crankshaft pin grade (outer
diameter of pin). No grade
exists for inner diameter of con-
necting rod large end.
Piston grade = cylinder bore
grade (inner diameter of bore)
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*For the service parts, the grade for fitting cannot be selected between a piston pin and a connecting rod.
(Only 0 grade is available.) The informat ion at the shipment from the plant is described as a ref erence.
● Th e iden tifica tion grade s tamped o n each part is the g rade fo r the dimensi on me asure d in ne w condi tion.
This grade cannot apply to reused parts.
● Fo r reused or repaired parts, mea sure the dimens ion accurately. Determine the grad e by comparing the
measurement with the values of each selection table.
● For details of the measu rement met hod of ea ch p art, the reuse st a ndard s, an d the sel ecti on me thod of the
selective fitting parts, refer to the text.
HOW TO SELECT PISTON
Piston Selective Fitting When New Cylinder Block is Used:
Check the cy lin de r b ore g r ad e on th e rear upper sid e be tw ee n cy li nder block banks, and se le ct the pis ton of the sa me grad e.
PBIC0108E
When Cylinder Block is Reused:
1. Measure the cylinder block bore inner diameter.
2. Determine the bor e grad e by c omparin g the meas urem ent w ith th e va lues un der th e “Cy linde r bore inne r
diameter” of the piston selection table. Select the piston of the same grade.
Piston Selection T able
Unit: mm (in)
Grade number (Mark) 1 2 3
Inner diameter of cylinder bore 93. 000- 93. 010 (3.6614-3.6618) 93.010-93.020 (3.6618-3.6622) 93.020-93.030 (3.6622-3.6626)
Outer diameter of piston 92.980-92.990 (3.6606-3.6610) 92.990-93.000 (3.6610-3.6614) 93.000-93.010 (3.6614-3.6618)
NOTE:
● The piston is available together with piston pin as an assembly.
● The piston pin (pisto n pi n bo re) g rad e is p rovi d ed onl y f o r t he parts installe d at t h e p l an t. F o r se r vi ce p ar t s ,
no grades can be selected (Only 0 grade is available.).
PBIC0109E
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CYLINDER BLOCK
HOW TO SELECT CONNECTING ROD BEARING
When New Connecting Rod and Crankshaft are Used:
Compare the pin diamet er grade of the cranksh aft front surf ace with
the values of the selection table of connecting rod bearing.
NOTE:
There is no grading for connecting rod big end.
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When Crankshaft and Connecting Rod are Reused:
1. Measure the pin outer diameter of the crankshaft.
2. Compare the measurement with the values of the selection table of connecting rod bearing.
Selection Table of Connecting Rod Bearing
Connecting rod big end inner diameter 55.000 - 55.01 3 (2. 165 4 - 2.1 659)
Crankshaft pin outer diameter Grade (Mark) —(No gr ade)
51.968 - 51.974
(2.0460 - 2.0462)
51.962 - 51.968
(2.0457 - 2.0460)
51.956 - 51.962
(2.0455 - 2.0457)
0
1
2
NOTE:
(At shipment from the plant) For an engine, all the connecting rod
assemblies are in the same weight class. For service parts, no
weight grades can be selected.
Bearing grade No. 0
Bearing thickness range: 1.500 - 1.503 (0.00591 - 0.0592)
Color: No color
Bearing grade No.1
Bearing thickness range: 1.503 - 1.506 (0.0592 - 0.0593)
Color: Brown
Bearing grade No.2
Bearing thickness range: 1.506 - 1.509 (0.0593 - 0.0594)
Color: Green
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Undersize Bearings Usage Guide
● When the specifie d oil clearanc e is not obtained with standard size conne cting rod bearin gs, use under-
size (US) bearings.
● When using undersize bearings, measure the bearing inner diameters with bearings installed, and grind
the crankshaft pin so that the oil clearance satisfies the standard.
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Bearing undersize table
Unit: mm (in)
Undersize Thickness
US 0.25 (0.0098) 1.626 - 1.634 (0. 0640 - 0.06 43)
CAUTION:
In grinding the crankshaft pin to use undersize bearings, do not
damage the fillet R (All crankshaft pins).
HOW TO SELECT MAIN BEARING
When New Cylinder Block and Crankshaft are Used:
1. Apply main bearing housing grade on up per rear side between
cylinder block banks to row in main bearing selection table.
PBIC0111E
2. Apply journal diameter grade on crankshaft front to column in
main bearing selection table.
3. Find sign at crossing of row and column in main bearing selection table.
CAUTION:
● Initial clearance for No.1, 5 journal and No. 2, 3, 4 journal is different. Use two different selection
lists for each part.
● No.1, 5 journal and No. 2, 3 , 4 journa l have the same signs bu t different measures. Do not con -
fuse.
4. Apply sign at crossing in above step 3 to main bearing grade table.
NOTE:
● Grade list applies to all journals.
● Service parts is available as a set of both upper and lower.
PBIC0108E
PBIC0110E
When Cylinder Block and Crankshaft are Reused:
1. Measure inner diameter of cylinder block main bearing housing and outer diameter of cran kshaft journal.
2. Apply measurement in above step 1 to main bearing selection table.
3. Follow step 3 and later in “When new cylinder block and crankshaft are used”.
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Main Bearings Se lection Table (No.1 and No.5 journal)
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Main Bearings Selection Table (No.2, 3 and 4 journal)
Main Bearings Grade Table (All Journals)
Grade number Thickness
0 2.483 - 2.486 (0.0978 - 0.0979) Black
1 2.486 - 2.489 (0.0979 - 0.0980) Brown
2 2.489 - 2.492 (0.0980 - 0.0981) Gr een
3 2.492 - 2.495 (0.0981 - 0.0982) Yellow
4 2.495 - 2.498 (0.0982 - 0.0983) Bl ue
5 2.498 - 2.501 (0.0983 - 0.0985) Pink
6 2.501 - 2.504 (0.0985 - 0.0986) Purple
7 2.504 - 2.507 (0.0986 - 0.0987) White
8 2.507 - 2.510 (0.0987 - 0.0988) Red
Identification color
(UPR/LWR)
PBIC0113E
Unit: mm (in)
Remarks
Grade and color are the same
for upper and lower bearings.
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EM-86
CYLINDER BLOCK
01
12
23
34
45
56
67
78
UPR 2.4 83 - 2.486 ( 0.0 978 - 0.097 9)
LWR 2.486 - 2.489 ( 0.0 979 - 0.098 0)
UPR 2.4 86 - 2.489 ( 0.0 979 - 0.098 0)
LWR 2.489 - 2.492 ( 0.0 980 - 0.098 1)
UPR 2.4 89 - 2.492 ( 0.0 980 - 0.098 1)
LWR 2.492 - 2.495 ( 0.0 981 - 0.098 2)
UPR 2.4 92 - 2.495 ( 0.0 981 - 0.098 2)
LWR 2.495 - 2.498 ( 0.0 982 - 0.098 3)
UPR 2.4 95 - 2.498 ( 0.0 982 - 0.098 3)
LWR 2.498 - 2.501 ( 0.0 983 - 0.098 5)
UPR 2.4 98 - 2.501 ( 0.0 983 - 0.098 5)
LWR 2.501 - 2.504 ( 0.0 985 - 0.098 6)
UPR 2.5 01 - 2.504 ( 0.0 985 - 0.098 6)
LWR 2.504 - 2.507 ( 0.0 986 - 0.098 7)
UPR 2.504 - 2.507 (0.0986 - 0.0987)
LWR 2.507 - 2.510 (0.0987 - 0.0988)
Black/Brown
Brown/Green
Green/Yellow
Yellow/Blue
Blue/Pink
Pink/Purple
Purple/White
White/Red
Grade and color are different
for upper and lower bearings.
Use Undersize Bearing Usage Guide
● Use undersize (US) bearing when oil clearance with standard size main bearing is not within specification.
● When using un de rs iz e (U S) b ea ri ng , m ea su re i nn er di am eter o f be ar i ng i ns t al le d a nd g rin d j o urna l un t il oil
clearance falls within specificati on.
Bearing undersize table
Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.618 - 2.626 (0.1031 - 0.1034)
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CAUTION:
Do not damage fillet R when grinding crankshaft journal in
order to use undersized bearing (All journals).
Inspection After Disassembly EB S002MX
CRANKSHAFT END PLAY
● Using a dial gauge, measure the clearance between the thrust
bearings and th e crankshaft a rm when the cran kshaft is mov ed
fully forward or backward.
Standard : 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit : 0.30 mm (0.0118 in)
● If the measured value exceeds the repair limit, replace the thrust
bearings, an d measure again. If it still exceeds the repair limit,
replace the crankshaft also.
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CYLINDER BLOCK
CONNECTING ROD SIDE CLEARANCE
● Measure side clearance between connecting rod and crankshaft
arm with feel er gauge.
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)
Limit : 0.40 mm (0.0157 in)
● If th e measured v alue exce eds the repair l imit, replace t he con-
necting rod bearings, and measure again. If it still exceeds the
repair limit, replace the crankshaft also.
PISTON AND PISTON PIN CLEARANCE
Inner Diameter of Piston Pin
Measure the inner diameter of piston pin bore with an insidemicrometer.
Standard : 21.993 - 22.005 mm (0.8659 - 0.8663 in)
PBIC0115E
Outer Diameter of Piston Pin
Measure outer diame ter of pi sto n pin wi th a micr o me ter.
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
Piston and Piston Pin Clearance
(Piston pin clearance) = (Piston pin bore diameter) – (Outer diameter
of piston pin)
Standard : 0.002 - 0.006 mm (0.0001 - 0.0002 in)
● If clearance is exceeds specification, replace either or both of
piston/piston pin assembly and connecting rod assembly with
reference to specification of each parts.
● Refer to piston selection table to replace piston/piston pin
assembly. Refer to EM-82, "
● Refer to connecting rod bearing selection table to replace con-
necting rod. Refer to EM-83, "
ROD BEARING" .
HOW TO SELECT PISTON" .
HOW TO SELECT CONNECTING
PBIC0116E
PBIC0117E
PBIC0109E
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EM-88
CYLINDER BLOCK
NOTE:
● The connecting rod small end grad e and piston pi n hole (pis-
ton pin) grade are prov ided only for the parts installed at the
plant. For servi ce parts, no grades can be sele cted. (Only 0
grade is available.)
● Refer to EM-91, "Connecting Rod Bushing Oil Clearance (Small
End)" for the values for each grade at the plant.
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PISTON RING SIDE CLEARANCE
● Measure side clearance of piston ring and piston ring groove
with feeler gauge.
Standard:
Top ring 0.045 - 0.080 mm (0.0018 - 0.0031 in)
2nd ring 0.030 - 0.070 mm (0.0012 - 0.0028 in)
Oil ring 0.065 - 0.135 mm (0.0026 - 0.0053 in)
Limit:
Top ring 0.11 mm (0.0043 in)
2nd ring 0.10 mm (0.0039 in)
● If out of specification, replace pist on and/or piston ring assembly.
PISTON RING END GAP
● Check if inner diameter of cylinder bore is within specification.
Refer to EM-93, "
● Insert piston ring until middle of cylinder with piston, and mea-
sure gap.
Standard:
Top ring 0.22 - 0.32 mm (0.0087 - 0.0126 in)
2nd ring 0.22 - 0.32 mm (0.0087 - 0.0126 in)
Oil ring 0.20 - 0.60 mm (0.0079 - 0.0236 in)
Piston to Cylinder Bore Clearance" .
PBIC0103E
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Limit:
PBIC0118E
Top ring 0.56 mm (0.0220 in)
2nd ring 0.52 mm (0.0205 in)
Oil ring 0.96 mm (0.0378 in)
● If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylin-
der and use oversized piston and piston ring.
Revision; 2004 April 2003 Q45
EM-89
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CYLINDER BLOCK
CONNECTING ROD BEND AND TORSION
● Check with connecting rod aligner.
Bend:
Limit 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion:
Limit 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
● If it exceeds the limit, replace connecting rod assembly.
SEM003F
CONNECTING ROD BEARING (BIG END)
Install the connecting rod cap without the connecting rod bearing
installed. After tightening the connecting rod nut to the specified
torque, measure the connecti ng rod large en d inner diamet er using
an inside micrometer.
Standard : 55.000 - 55.013 mm (2.1654 - 2.1659 in)
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)
Inner Diameter of Connecting Rod (Small End)
Measure inner diameter of bushing.
Standard : 22.000 - 22.012 mm (0.8661 - 0.8666 in)
SEM038F
PBIC0119E
PBIC0120E
Revision; 2004 April 2003 Q45
EM-90
Outer Diameter of Piston Pin
Measure outer diameter of piston pin.
Standard : 21.989 - 22.001 mm (0.8657 - 0.8662 in)
CYLINDER BLOCK
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Connecting Rod Bushing Oil Clearance (Small End)
(Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) – (Outer diameter of piston pin)
Standard : 0.005 - 0.017 mm (0.0002 - 0.007 in)
● If the measured value exceeds the standard, replace the con-
necting rod assembly and/or piston and piston pin assembly.
● If replacin g th e pi st on a nd pi st o n pin a sse mb ly, refer to th e Table
for Selective Fi tti ng for P iston to select the p is to n c orre sp on di ng
to the applicable bore grade of the cylinder block to be used.
Refer to EM-82, "
HOW TO SELECT PISTON" .
Factory installed parts grading:
Service parts apply only to grade 0.
Unit: mm (in)
Grade 0 1
Connecting rod small end
inner diameter
Piston pin outer diameter
Piston pin bore diameter
22.000 - 22.006
(0.8661 - 0.8664)
21.989 - 21.995
(0.8657 - 0.8659)
21.993 - 21.999
(0.8659 - 0.8661)
22.006 - 22.012
(0.8664 - 0.8666)
21.995 - 22. 001
(0.8659 - 0.8662)
21.999 - 22.005
(0.8661 - 0.8663)
CYLINDER BLOCK DISTORTION
● Using a scrape r, remove gasket on the cylinder bloc k surface,
and also remove engine oil, scale, carbon, or other contamination.
CAUTION:
Be careful not to allow gasket flakes to e nter the engi ne oil
or engine coolant passages.
● Measure the distortion on the block upper face at some different
points in 6 directions.
PBIC0117E
PBIC0103E
PBIC0109E
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Limit : 0.1 mm (0.004 in)
● If out of the distortion limit, replace the cylinder block.
Revision; 2004 April 2003 Q45
EM-91
SEM123C
CYLINDER BLOCK
INNER DIAMETER OF MAIN BEARING HOUSING
● Install the main bearing caps with the main bearings removed,
and tighten the mounting bolts to the specified torque.
● Using a bore gauge, measure the inner diameter of the main
bearing housing.
Stan dar d : 68.944 - 68. 968 mm (2. 714 3 - 2.7 153 in )
● If ou t of the standa rd, replac e the cylin der blo ck and main bear-
ing caps as an assembly.
NOTE:
These components cannot be replaced as a single unit, because
they were processed together.
PISTON TO CYLINDER BORE CLEARANCE
Inner Diameter of Cylinder Bore
● Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper at 6 different po ints on each cylinder. (X and Y
directions at A , B and C)
NOTE:
When determining cylinder bore grade, measure cylinder bore at
B position.
PBIC0122E
Standard inner diameter:
93.000 - 93.030 mm (3.6614 - 3.6626 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (Difference between X and Y):
Less than 0.015 mm (0.0006 in)
Taper limit (Difference between A and C):
Less than 0.010 mm (0.0004 in)
● If the measured value exceeds the repair limit, or if there are
scratches and/or seizure on the cylinder inner wall, hone or bore the inner wall.
● An oversize piston is provided. When u sing an oversize piston, hone the cylinder so that the clearance
between the piston and cylinder satisfies the standard.
Oversize (OS) : 0.2 mm (0.008 in)
● If oversize piston is used, use it for all cylinders with oversize piston rings.
Outer Diameter of Piston
● Measure piston skirt diame ter.
Standard : 92.980 - 93.010 mm (3.6606 - 3.6618 in)
PBIC0123E
PBIC0124E
PBIC0125E
Revision; 2004 April 2003 Q45
EM-92
CYLINDER BLOCK
● Measure point “H”(Distance from the top): 42 mm (1.65 in)
Piston to Cylinder Bore Clearance
● Calculate by outer diameter of piston ski rt and inner diameter of cy linder (direction X, position B).
(Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt)
Standard : 0.010 - 0.030 mm (0.0004 - 0.0012 in)
Limit : 0.08 mm (0.0031 in)
● If it exceeds the limit, replace piston/piston pin assembly.
Reboring Cylinder Bore
1. Cylinder bore size is determined by adding piston-to-bore clearance to piston diameter “A”.
Rebored size calculation: D = A +B - C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston - to - bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
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PBIC0126E
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2. Install main b earin g ca ps, and t ighte n to t he specif ied torqu e. O therw ise, cyli nder b ores may be di storte d
in final assembly.
3. Cut cylinder bores.
NOTE:
● When any cylinder needs boring, all other cylinders must also be bored.
● Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a
time.
4. Hone cylinders to obtain specified piston-to-bore clearance.
5. Measure finished cylinder bore for out-of-round and taper.
NOTE:
Measurement sh ould be done after cylind er bore cools down.
OUTER DIAMETER OF CRANKSHAFT JOURNAL
Measure outer diameter of crankshaft journals.
Standard : 63.940 - 63.964 mm (2.5173 - 2.5183 in)
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Revision; 2004 April 2003 Q45
EM-93
CYLINDER BLOCK
OUTER DIAMETER OF CRANKSHAFT PIN
Measure outer diameter of crankshaft pin.
Standard : 51.956 - 51.974 mm (2.0455-2.0462 in)
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
● Using a micrometer, measure the dimensions at 4 different
points shown in the figure on each journal and pin.
● Out-of-roundness is indicated by the difference in dimension
between X and Y at A and B.
● Taper is indicated by the difference in dimens io n be tw ee n A an d
B at X and Y.
Limit:
Out-of-round (X-Y) : 0.015 mm (0.0006 in)
Taper (A-B) : 0.010 mm (0.0004 in)
PBIC0127E
PBIC0128E
CRANKSHAFT RUNOUT
● Place a V-block on a precise flat table to support the journals on
the both end of the crankshaft.
● Place a dial gauge straight up on the No. 3 journal.
● While rotating the crankshaft, read the movement of the pointer
on the dial gauge.
● Half of the movement shows the runout.
Limit: : 0.0 5 mm (0.00 2 in)
OIL CLEARANCE OF CONNECTING ROD BEARING
Method of Measurement
● Install the connect in g ro d b ea r ings to t he co nn ecti ng rod an d t he
cap, and tighten the connecting rod nut to the specified torque.
Using a inside micrometer measure the inner diameter of con-
necting rod bearing.
(Oil clearance) = (Inner diameter of connecting rod bearing) – (Outer
diameter of cra nkshaft pin)
Standard : 0.020 - 0.045 mm (0.0008 - 0.0018 in)
Limit : 0.055 mm (0.0 02 2 in)
● If clearance cannot be adjusted within the standard, grind crank-
shaft pin and use undersized bearing. Refer to EM-83, "
TO SELECT CONNECTING ROD BEARING" .
HOW
PBIC0129E
PBIC0119E
Revision; 2004 April 2003 Q45
EM-94
CYLINDER BLOCK
Method of Using Plastigauge
● Remove oil and dust on the cranks haft pin and the surfac es of
each bearing completely.
● Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes.
● Install the connecting rod bearings to the connecting rod and the
connecting rod be aring cap, and tig hten the connect ing rod nut
to the specified torque.
CAUTION:
Never rotate the crankshaft.
● Remove the connecting rod cap and bearings, and using the
scale on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the repair limit is same as that described in “Method of
Measurement”.
OIL CLEARANCE OF MAIN BEARING
Method of Measurement
● Install the main b earings to the cylinder bloc k and main bearing cap. Meas ure the main bearing inner
diameter with the bearing cap bolt tightened to the specified torque. Refer to EM-77, "
(Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal)
Standard:
No. 1 and 5 journals : 0.001 - 0.011 mm (0.0004 - 0.0004 in)
No. 2, 3, and 4 j ournals : 0.007 - 0.01 7 mm (0.0003 - 0.0007 in)
Limit:
No.1 and 5 journals : 0.021 mm (0.0008 in)
No. 2, 3, and 4 journals : 0.027 mm (0.0011 in)
ASSEMBLY" .
SBIA0409E
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● If the measured v alue exceeds the re pair limit, select main bearings referring to th e main bearing inn er
diameter and cr ankshaft jou rnal outer di ameter, so that the oil c learance satis fies the standa rd. Refer to
EM-84, "
Method of Using Plastigage
● Remove oil and dust on th e cranks haft jou rnal and th e surfac es
HOW TO SELECT MAIN BEARING" .
of each bearing completely.
● Cut a plastigage slightly shorter than the bearing width, and
place it in crankshaft axial direction, avoiding oil holes
● Install the main beari ngs to the cylin der block and ma in bearing
cap, and tighten the main bearing bolts to the specified torque.
CAUTION:
Never rotate the crankshaft.
● Remove the bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the repair limit is same as that described in “Method of
Measurement”.
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SBIA0410E
Revision; 2004 April 2003 Q45
EM-95
CYLINDER BLOCK
CRUSH HEIGHT OF MAIN BEARING
● Wh en the bearing cap is re moved after being tightene d to the
specified torque with main bearings installed, the tip end of bear-
ing must protrude.
Standard : There must be crush height
● If the standard is not met, replace main bearings.
SEM502G
Revision; 2004 April 2003 Q45
EM-96
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00030
Standard and Limit EBS003P5
GENERAL SPECIFICATIONS
Cylinder arrangement V-8
3
Displacement cm
Bore and stroke mm (in) 93 x 82.7 (3.66 x 3.256)
Valve arrangement DOHC
Firing order 1-8-7-3-6-5-4-2
Number of piston rings
Number of main bearings 5
Compression ratio 10.5
Compression pressure
kPa (kg/cm
2
(cu in)
, psi)/300 rpm
Compression 2
engine oil 1
Standard 1,320 (13.5, 191)
Minimum 1,130 (11.5, 164)
Differential limit
between cylinders
4,494 (274.22)
98 (1.0, 14)
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Cylinder number
SEM957C
Valve timing
PBIC0187E
abcdef
228 240 0 60 0 48
DRIVE BELTS
Tension of drive belts Auto adjustment by auto tensioner
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Unit: degree
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
Item Limit
Intake manifold upper 0.1 (0.004)
Surface distortion
Revision; 2004 April 2003 Q45
Intake manifold lower 0.1 (0.004)
Exhaust manifold 0.3 (0.012)
EM-97
SERVICE DATA AND SPECIFICATIONS (SDS)
SPARK PLUG (PLATINUM-TIPPED TYPE)
Make NGK
Standard PLFR5A-11
Type
CYLINDER HEAD
Items Limit
Head surface distortion 0.1 (0.004)
Hot PLFR4A-11
Cold PLFR6A-11
Plug gap (Nominal) 1.1 mm (0.043 in)
Unit: mm (in)
VALVE
Valve Dimensions
Valve head diameter “D”
Valve length “L”
Valve stem diameter “d”
Valve seat angle “α”
Val ve margin “T”
PBIC0183E
SEM188
Intake 36.0 - 36.3 (1.417 - 1.429)
Exhaust 31.2 - 31.5 (1.228 - 1.240)
Intake 96.57 (3.8020)
Exhaust 94.50 (3.720)
Intake 5.972 - 5.980 (0.2351 - 0.2354)
Exhaust 5.962 - 5.970 (0.2347 - 0.2350)
Intake
Exhaust
Intake 0.95 - 1.25 (0.0374 - 0.0492)
Exhaust 1.15 - 1.45 (0.0453 - 0.0571)
45°15′ - 45°45′
Unit: mm (in)
Revision; 2004 April 2003 Q45
EM-98
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Clearance
Items Cold* (reference data) Hot
Intake 0.26 - 0.34 (0.010 - 0.013) 0.32 - 0.40 (0.013 - 0.01 6)
Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.33 - 0.41 (0.013 - 0.016)
*: Approximately 20°C (68 °F)
Unit: mm (in)
A
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Available Shims
Thickness mm (in) Identification mark
2.32 (0.0913) 232
2.33 (0.0917) 233
2.34 (0.0921) 234
2.35 (0.0925) 235
2.36 (0.0929) 236
2.37 (0.0933) 237
2.38 (0.0937) 238
2.39 (0.0941) 239
2.40 (0.0945) 240
2.41 (0.0949) 241
2.42 (0.0953) 242
2.43 (0.0957) 243
2.44 (0.0961) 244
2.45 (0.0965) 245
2.46 (0.0969) 246
2.47 (0.0972) 247
2.48 (0.0976) 248
2.49 (0.0980) 249
2.50 (0.0984) 250
2.51 (0.0988) 251
2.52 (0.0992) 252
2.53 (0.0996) 253
2.54 (0.1000) 254
2.55 (0.1004) 255
2.56 (0.1008) 256
2.57 (0.1012) 257
2.58 (0.1016) 258
2.59 (0.1020) 259
2.60 (0.1024) 260
2.61 (0.1028) 261
2.62 (0.1031) 262
2.63 (0.1035) 263
2.64 (0.1039) 264
2.65 (0.1043) 265
2.66 (0.1047) 266
2.67 (0.1051) 267
2.68 (0.1055) 268
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Revision; 2004 April 2003 Q45
EM-99
SERVICE DATA AND SPECIFICATIONS (SDS)
Thickness mm (in) Identification mark
2.69 (0.1059) 269
2.70 (0.1063) 270
2.71 (0.1067) 271
2.72 (0.1071) 272
2.73 (0.1075) 273
2.74 (0.1079) 274
2.75 (0.1083) 275
2.76 (0.1087) 276
2.77 (0.1091) 277
2.78 (0.1094) 278
2.79 (0.1098) 279
2.80 (0.1102) 280
2.81 (0.1106) 281
2.82 (0.1110) 282
2.83 (0.1114) 283
2.84 (0.1118) 284
2.85 (0.1122) 285
2.86 (0.1126) 286
2.87 (0.1130) 287
2.88 (0.1134) 288
2.89 (0.1138) 289
2.90 (0.1142) 290
2.91 (0.1146) 291
2.92 (0.1150) 292
2.93 (0.1154) 293
2.94 (0.1157) 294
2.95 (0.1161) 295
SEM966E
Valve Spring
Free height mm (in) 46.35 - 46.85 (1.8247 - 1.8444)
Pressure N (kg, lb) at height mm (in)
Out-of-squ are mm (in) Limit 2.0 (0.079 )
Installation 165 - 189 (16.8 - 19.3, 37 - 42) at 33.8 (1.331)
Valve open 290 - 330 (29.6 - 33.7, 65 - 74) at 24.4 (0.961)
Valve Lifter
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.965 - 33.975 (1.3372 - 1.3776)
Lifter guide inner diameter 34.000 - 34.016 (1.3386 - 1.3392)
Clearance between lifter and lifter guide 0.025 - 0.051 (0.0010 - 0.0020)
Revision; 2004 April 2003 Q45
EM-100
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