Nissan ZD30 Y Service Manual
ENGINE MECHANICAL
B ENGINE
A
EM
SECTION
CONTENTS
KA24DE
PRECAUTIONS .......................................................... 5
Precautions for Drain Coolant .................................. 5
Precautions for Disconnecting Fuel Piping .............. 5
Precautions for Removal and Dis as sembly .............5
Precautions for Inspection, R epair and Replace-
ment ......................................................................... 5
Precautions for Assembly and Installation ...............5
Parts Requiring Angular Tightening ......................... 5
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET SEALING .......... 6
LIQUIDG ASKETAPPLICATIONPROCEDURE..... 6
PREPARATION ........................................................... 7
Special Service Tools ...............................................7
Commercial Service Tools ........................................ 8
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING .............................................. 10
NVH Troubleshooting —Engine Noise ................... 10
Use the Chart Below to Help You Find the Caus e
of the Symptom. ......................................................11
ENGINE ROOM COVER .......................................... 12
Removal and Installation of Engine Room Right
Side ........................................................................ 12
REMOVAL ........................................................... 12
INSTALLTION ..................................................... 12
Removal and Installation of Engine Room Rear
Cover ...................................................................... 12
REMOVAL ........................................................... 12
INSTALLATION ................................................... 13
DRIVE BELTS ........................................................... 14
Checking Drive Belts .............................................. 14
Tension Adjustment ................................................ 14
POWER STEERING PUMP BELT ...................... 14
AIR CONDITIONER COMPRESSOR BELT ....... 14
ALTERNATOR AND WATER PUMP BELT ......... 15
Removal and Installation ........................................ 15
REMOVAL ........................................................... 15
INSTALLATION ................................................... 15
AIR CLEANER AND AIR DUCT ............................... 16
Removal and Installation ........................................ 16
ENGINE MECHANICAL
REMOVAL ...........................................................1 6
INSTALLATION ...................................................17
Changing Air Cleaner Element ...............................1 8
REMOVAL ...........................................................1 8
INSTALLATION ...................................................18
THROTTLE BODY ....................................................1 9
Removal and Installation ........................................19
REMOVAL ...........................................................1 9
INSPECTION AFTER REMOVAL .......................20
INSTALLATION ...................................................20
Disassembly and Assembly ....................................20
DISASSEMBLY ...................................................20
ASSEMBLY .........................................................2 0
INTAKE MANIFOLD .................................................2 1
Removal and Installation ........................................21
REMOVAL ...........................................................2 1
INSPECTION AFTER REMOVAL .......................22
INSTALLATION ...................................................22
EXHAUST MANIFOLD .............................................23
Removal and Installation ........................................23
REMOVAL ...........................................................2 3
INSPECTION AFTER REMOVAL .......................24
INSTALLATION ...................................................24
INSPECTION AFTER INSTALLATION ................24
OIL PAN AND O IL STRAINER .................................25
Removal and Installation ........................................25
REMOVAL ...........................................................2 5
INSPECTION AFTER REMOVAL .......................25
INSTALLATION ...................................................25
INSPECTION AFTER INSTALLATION ................26
SPARK PLUG (CONVENTIONAL) ........................... 2 7
Removal and Installation ........................................27
REMOVAL ...........................................................2 7
INSPECTION AFTER REMOVAL .......................27
INSTALLATION ...................................................27
FUEL INJECTOR AND FUEL TUBE ........................28
Removal and Installation ........................................28
REMOVAL ...........................................................2 8
INSTALLATION ...................................................29
INSPECTION AFTER INSTALLATION ................29
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ROCKER COVER .....................................................30
Removal and Installation ........................................30
REMOVAL ...........................................................30
INSTALLATION ....................................................30
CAMSHAFT ............................................................... 32
Removal and Installation ........................................32
REMOVAL ...........................................................32
INSTALLATION ....................................................34
INSPECTION AFTER REMOVAL........................35
Valve Clearance ......................................................38
INSPECTION .......................................................38
ADJUSTMENT ....................................................38
SECONDARY TIMING CHAIN ..................................41
Removal and Installation ........................................41
REMOVAL ...........................................................41
INSPECTION AFTER REMOVAL........................44
INSTALLATION ....................................................45
PRIMARY TIMING CHAIN ........................................49
Removal and Installation ........................................49
REMOVAL ...........................................................50
INSPECTION AFTER REMOVAL........................51
INSTALLATION ....................................................51
CYLINDER HEAD .....................................................55
On-Vehicle Service .................................................55
CHECKING COMPRESSION PRESSURE .........55
Removal and Installation ........................................56
REMOVAL AND INSTALLATION .........................56
Disassemblyand Assembly ....................................57
DISASSEMBLY ...................................................57
ASSEMBLY .........................................................58
INSPECTION AFTER DISASSEMBLY ................58
ENGINE ASSEMBLY ................................................63
Removal and Installation ........................................63
REMOVAL ...........................................................64
INSTALLATION ....................................................65
INSPECTION AFTER INSTALLATION ................66
CYLINDER BLOCK ...................................................67
Disassemblyand Assembly ....................................67
DISASSEMBLY ...................................................68
ASSEMBLY .........................................................70
How to Select Piston and Bearing ..........................74
DESCRIPTION ....................................................74
HOW TO SELECT PISTON .................................75
HOW TO SELECT CONNECTING ROD BEAR-
ING ......................................................................75
HOW TO SELECT MAIN BEARING ....................76
Inspection After Disassembly .................................78
CRANKSHAFT SIDE CLEARANCE ....................78
CONNECTING ROD SIDE CL EARANCE ...........78
PISTON AND PISTON PIN CLEARANCE ..........78
PISTON RING SIDE CLEARANCE .....................79
PISTON RING END GAP ....................................79
CONNECTING ROD BEND AND TORSION .......80
CONNECTING R OD BEARING (BIG END) ........80
CONNECTING R OD BUSHING OIL CLE AR-
ANCE (SMALL END) ...........................................80
CYLINDER BLOCK DISTORTION ......................81
INNERDIAMETER OF MAINBEARING HOUS-
ING .......................................................................81
PISTON TO CYLINDER BORE CLEARANCE ....82
OUTER DIAMETER OF CRANK SHAFT JOUR-
NAL ......................................................................83
OUTER DIAMETER OF CRANKSHAFT PIN ......83
OUT-OF-ROUND A ND TAPER OF CRA NK-
SHAFT ................................................................. 83
CRANKSHAFT RUNOUT ....................................83
OIL CLEARANCE OF CONNECTING RO D
BEARING .............................................................84
OIL CLEARANCE OF MAIN BEARING ...............84
CRUSH HEIGHT OF MAIN BEARING ................85
OIL JET ................................................................85
OIL JET RELIEF VALVE ......................................85
FLY WHEEL RUNOUT ........................................86
SERVICE DATA AND SPECIFICATIONS (SDS) ......87
Standard and Limit ..................................................87
GENERAL SPECIFICATIONS .............................87
DRIVE BELTS ......................................................87
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD ...................................................................87
SPARK PLUG ......................................................88
SECONDARY TIMING CHAIN ............................88
CYLINDER HEAD ................................................88
VALVE ..................................................................88
CAMSHAFT AND CAMSHAFT BEARING ...........92
CYLINDER BLOCK ..............................................92
PISTON,PISTON RING AND PISTON PIN ........93
CONNECTING ROD ............................................94
CRANKSHAFT .....................................................94
MAIN BEARING ...................................................95
CONNECTING ROD BEARING ...........................95
FLYWHEEL ..........................................................96
Tightening Torque ...................................................96
ZD30DD
PRECAUTIONS .........................................................98
Precautions for Drain Coolant ................................. 98
Precautions for Disconnecting Fuel Piping ............. 98
Precautions for Removal and Disassembly ............98
Precautions for Inspection, Repair and Replace-
ment ........................................................................98
Precautions for Assembly and Installation ..............98
Parts Requiring Angular Tightening ........................98
Precautions for Liquid Gasket ................................. 99
REMOVAL OF LIQUID GASKET SEALING ........99
LIQUIDGASKETAP PLICATIONPROCEDURE...99
PREPARATION .......................................................100
Special Service Tools ............................................100
Commercial Service Tools ....................................102
NOISE, VIBRATION, AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................103
NVH Troubleshooting —Engine Noise ..................103
Use the Chart Below to Help You Find the Cause
of the Symptom. ....................................................104
ENGINE ROOM CO VER .........................................105
Removal and I ns tallation of Engine Room Right
EM-2
Side ...................................................................... 105
REMOVAL ......................................................... 105
INSTALLATION ................................................. 105
Removal and Installation of Engine Room Rear
Cover .................................................................... 105
REMOVAL ......................................................... 105
INSTALLATION ................................................. 106
DRIVE BELTS ......................................................... 107
Checking Drive Belt .............................................. 107
Tension Adjustment .............................................. 107
Removal and Installation ...................................... 107
WATER PUMP, ALTERNATOR AND A/C COM-
PRESSOR BELT ............................................... 107
Drive Belt Auto Tensioner ..................................... 109
REMOVAL ......................................................... 109
INSPECTION AFTER REMOVAL ..................... 109
INSTALLATION ................................................. 109
Dummy Pulley ...................................................... 109
REMOVAL ......................................................... 109
INSPECTION AFTER REMOVAL ..................... 109
INSTALLATION ................................................. 109
AIR CLEANER AND AIR DUCT ..............................110
Removal and Installation .......................................110
REMOVAL ..........................................................110
INSTALLATION .................................................. 111
Changing Air Cleaner Element ..............................112
REMOVAL ..........................................................112
INSTALLATION ..................................................112
INTAKE MANIFOLD COLLECTOR AND INTAKE
MANIFOLD ..............................................................113
Removal and Installation .......................................113
REMOVAL ..........................................................113
INSPECTION AFTER REMOVAL ......................115
INSTALLATION ..................................................115
EXHAUST MANIFOLD ............................................117
Removal and Installation .......................................117
REMOVAL ..........................................................117
INSPECTION AFTER REMOVAL ......................118
INSTALLATION ..................................................118
INSPECTION AFTER INSTALLATION ..............118
OIL PAN AND OIL STRAINER . ...............................119
Removal and Installation .......................................119
REMOVAL ..........................................................119
INSTALLATION ................................................. 120
INSPECTION AFTER INSTALLATION ............. 120
GLOW PLUG .......................................................... 121
Removal and Installation ...................................... 121
REMOVAL ......................................................... 121
INSTALLATION ................................................. 122
VACUUM PUMP ..................................................... 123
Removal and Installation ...................................... 123
REMOVAL ......................................................... 123
INSTALLATION ................................................. 123
INSPECTION AFTER INSTALLATION ............. 123
INJECTION TUBE AND INJE CT ION NOZZLE ......125
Removal and Installation ......................................125
REMOVAL .........................................................125
INSPECTION AFTER REMOVAL .....................127
INSTALLATION .................................................127
INSPECTION AFTER INSTALLATION ..............128
ELECTRONIC CO NTRO LFUEL INJECTIONPUMP.129
Removal and Installation ......................................129
REMOVAL .........................................................129
INSTALLATION .................................................132
INSPECTION AFTER INSTALLATION ..............134
ROCKER COVER ...................................................135
Removal and Installation ......................................135
REMOVAL .........................................................135
INSTALLATION .................................................136
CAMSHAFT ............................................................138
Removal and Installation ......................................138
REMOVAL .........................................................139
INSPECTION AFTER REMOVAL .....................139
INSTALLATION .................................................141
Valve Clearance ...................................................142
INSPECTION ....................................................142
ADJUSTMENTS ................................................144
TIMING CHAIN ........................................................147
Removal and Installation ......................................147
REMOVAL .........................................................147
INSPECTION AFTER REMOVAL .....................149
INSTALLATIO N .................................................149
TIMING GEAR .........................................................151
Removal and Installation ......................................151
REMOVAL .........................................................152
INSPECTION AFTER REMOVAL .....................155
INSTALLATIO N .................................................157
CYLINDER HEAD ...................................................160
On-Ve hicle Service ...............................................160
CHECKING COMPRESSION PRESSURE .......160
Removal and Installation ......................................161
REMOVAL .........................................................161
INSPECTION AFTER REMOVAL .....................162
INSTALLATIO N .................................................163
Disassembly and Assembly ..................................166
DISASSEMBLY .................................................166
ASSEMBLY .......................................................167
INSPECTION AFTER DISASSEMBLY ..............167
ENGINE ASSEMBLY ..............................................172
Removal and Installation ......................................172
REMOVAL .........................................................172
INSTALLATIO N .................................................174
INSPECTION AFTER INSTALLATION ..............175
CYLINDER BLOCK ................................................176
Disassembly and Assembly ..................................176
DISASSEMBLY .................................................177
ASSEMBLY .......................................................181
How to Select Piston ............................................184
DESCRIPTION ..................................................184
SELECTIVE PISTON COMBINATION ..............184
INSPECTION AFTER DISASSEMBLY ..............185
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SERVICE DATA AND SPECIFICATIONS (SDS ) ....194
Standard and Limit ................................................194
GENERAL SPECIFICATIONS ...........................194
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................194
DRIVE BELTS ...................................................194
CYLINDER HEAD .............................................195
VALVE ................................................................195
CAMSHAFT AND CAMSHAFT BEARING ........199
CYLINDER BLOCK ............................................199
PISTON,PISTON RING AND PISTON PIN ......200
CONNECTING ROD ..........................................201
CRANKSHAFT ...................................................201
AVAILABLE MAIN BEARING .............................202
AVAILABLE CONNECTING ROD BEARING .....202
MISCELLANEOUS COMPONENTS ..................202
Tightening torque ..................................................203
EM-4
PRECAUTIONS
[KA24DE]
[KA24DE]
PRECAUTIONS PFP:00001
Precautions for Drain Coolant
● Drain coolant when engine is cooled.
Precautions for Disconnecting Fuel Piping
● Before starting work, make sure no fire or spark producing items are in the work area.
● Release fuel pressure before disassembly.
● After disconnecting pipes, plug openings to stop fuel leakage.
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Precautions for Removal and Disassembly
● When instructed to use special service tools, use the specified tools. Always be careful to work safely,
EBS007JU
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 loosening nuts and bolts, as a basic rule, s tart with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loos ening is specified, do exactly as specified.
Precautions for Inspection, Repair and Replacement
● Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way,
EBS007JV
and replace if necessary.
Precautions for Assembly and Installation
● Use torque wrench to tighten bolts or nuts.
● When tightening nuts and bolts, as a basic rule, equall y tighten in several different steps starting with the
EBS007JW
ones in center, then ones on inside and outs ide diagonally in this orde r. If the order of tightening is specified, do exactly as specified.
● Replace with new ga sket, packing, oil seal or O-ring.
● Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
● Avoid damaging sliding or mating surfaces. Completely remove foreign materials suc h as cloth lint or dust.
Before assembly, oil sliding surfaces well.
● Release air within route after draining coolant.
● After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems
for leakage.
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Parts Requiring Angular Tightening
● Use an angle wrench for the final tightening of the following engi ne parts:
– Cylinder head bolts
– Connecting rod cap nuts
● Do not use a torque value for final tightening.
● The torque value for these parts are for a preliminary step.
● Ensure thread and seat su rfaces are clean and coated with engine oil.
EM-5
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PRECAUTIONS
[KA24DE]
Precautions for Liquid G asket
REMOVAL OF LIQUID GASKET SEALING
● After removing the mounting bolts and nuts, disconnect and
remove the liquid gasket se aling using a seal cutter.
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
gasket application surface and the mating surface.
● Remove the liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lig hting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
EBS007JY
PBIC0275E
4. Apply the gasket without breaks to the specified location with the
specified dimensions.
● If there is a groove for the liquid gasket application, apply the
gasket to the groove.
● As for the bolt holes, normally apply the gasket inside the hole s.
Occasionally, it should be applied outside the holes. Make sure
to read the text of service manual.
● Within five minutes of gasket applica tion, install the mating com-
ponent.
● If the liquid gasket protrudes, wipe it off immediately.
● Do not retighten after the installation.
● After 30 minutes or more have passed from the installation, fill the engine oil and coolant.
CAUTION:
If there are specific instructions in the service manual, observe them.
PBIC0003E
EMA0622D
EM-6
PREPARATION
[KA24DE]
PREPARATION PFP:00002
Special Service Tools
EBS007JZ
A
Tool number
Tool name
KV10111100
Seal cutter
KV10117100
Heated oxygen sensor wrench
KV10105800
Timing chain stopper
KV101151S0
Lifterstopper set
1 KV10115120
Lifter stopper
2 KV10115110
Camshaft pliers
ZZA0013D
ZZA1007D
ZZA1006D
Description
Removing steel oil pan and rear timing chain
case
Loosening or tightening heated oxygen
sensorswith 22 mm (0.87in) hexagon nut
Removingand installing idler sproket
Changing valve lifter shims
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KV10112100
Angle wrench
KV10116200
Valve spring compressor
KV10111200
Adapter
KV10116100
Valve oil seal puller
ZZA0103D
ZZA0120D
ZZA0993D
ZZA0015D
K
Tightening bolts for bearing cap, cylinder
head, etc.
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Disassembling and assembling valve
components
Removing valve oil seal
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PREPARATION
[KA24DE]
Tool number
Tool name
KV10116300
Valv e o il se al drift
ST0501S000
Enginestand assembly
KV10105001
Engineattachment
Description
Installing valve oil se al
a: 25 mm (0.98 in) dia.
b: 14.4 mm (0.567 in) dia.
c: 11.8 mm (0.465 in) dia.
d: 10 mm (0.39 in) dia.
e: 11mm (0.43 in)
f: 9 mm (0.35 in)
NT602
Engine overhaul
ZZA0022D
ZZA1061D
ST16610001
Pilot bushing puller
KV10114700
Main bearing cap remover
EM03470000
Piston ring compressor
WS39930000
Tube presser
Removingcrankshaft pilot bushing
(M/T model only)
ZZA0046D
ZZA0023D
Installing piston assembly into cylinder bore
S-NT04 4
Pressing the tube of liquid gasket
Commercial Service Tools
S-NT05 2
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EM-8
PREPARATION
[KA24DE]
Tool number
Tool name Description
Quick connector release Removingfuel tube quick connectorsin
engine room
(Available in SEC. 164 of PARTS
CATALOG: Part No. 16441 6N210)
PBIC0198E
Spark plu g wrench Removing a nd installing spark plug
S-NT04 7
Valve seat cutter set Finishing valve seat dimensions
S-NT04 8
Piston ring expander Removingand installing piston ring
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S-NT03 0
Valve guide drift Removingand installing valve guide
Intake & Exhaust:
a: 109.5 mm (0.413 in) dia.
b: 6.6 mm (0.260 in) dia.
S-NT01 5
Valve guide reamer 1: Reaming valve guide inner hole
2: Reaming hole for oversize valve guide
Intake & Exhaust:
1 : 7 .0 mm (0.276 in) dia.
d
2 : 11.175 mm (0.440 in) dia.
d
S-NT01 6
Rear oil seal drift Installing rear oil seal
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ZZA0025D
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NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[KA24DE]
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting —Engine Noise
PFP:00003
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PBIC0192E
NOISE, VIBRATION, AND HARSHNESS (NVH) TROUBLESHOOTING
[KA24DE]
Use the Chart Below to Help You Find the Cause of the Symptom.
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: Closelyrelated 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
Tappingor
ticking
Squeaking or fizzing
CreakingA B ABAB
Squall
Creak
Before
warm-
up
CA—AB—
—A—BB—
A ——BBA
A A—BBB
AB—B—C
A B—BAB
After
warm-
up
When
start-
ing
When
idling
When
racing
While
driving
Sourceof
Tappet
noise
Camshaft
bearing
noise
Pistonpin
noise
Piston
slap noise
Connecting rod
bearing
noise
Main
bearing
noise
Timing
chain and
chain tensioner
noise
Other
drivebelts
(Sticking
or slipping)
Other
drivebelts
(Slipping)
Water
pump
noise
noise
Checkitem
Valve clearance EM-38
Camshaftjournal clearance
Camshaft runout
Pistonand piston pin
clearance
Connecting rod bushing clearance
Piston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend
and torsion
Connecting rod bushing clearance (Small
end)
Connecting rod bearing clearance (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-21
EBS007K2
Refer-
ence page
EM-36
EM-35
EM-80
EM-80
EM-80
EM-79
EM-79
EM-80
EM-80
EM-80
EM-84
EM-83
EM-44
EM-51
EM-14
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EM-11
ENGINE ROOM COVER
[KA24DE]
ENGINE ROOM COVER
Removal and Installation of Engine Room Right Side
1. Engine room right side cover 2. Parking brake lever 3. Engineroom left side cover
4. Parking brake cable 5. Harness 6. Harness protector
PFP:14049
EBS00ALX
KBIA0741E
REMOVAL
1. Open engine compartment LH cover and secure it.
2. Remove RH seat. Refer to SE-4, "
FRONT SEAT" .
3. Partially remove floor carpet.
4. Disconnect harness protector secured together at front right. Disconnect harness connector to move harness routed on top of engine compartment RH cover aside.
5. Move parking brake lever and cable from engine compartment RH cover. Refer to PB-3, "
PARKING
BRAKE SYSTEM" .
6. Remove mounting bolts, and remove engine compartment RH cover.
CAUTION:
When taking it out of vehicle, do not allow it to interfere with vehicle.
INSTALLTION
● Install in reverse order of removal following instructions below.
1. Temporarily tighten bolt No. 1 shown in the figure.
2. Tighten bolt No. 2 shown in figure to specified torque.
3. Tighten other bolts except bolt “A” shown in the figure (bolt No. 1 is included) to specified torque in any
given order.
4. Close engine compartment LH cover.
5. Tighten bolt “A” shown in the figure to specifi ed torque.
Removal and Installation of Engine Room Rear Cover
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REMOVAL
1. Move folded seat on engine c ompartment rear cover side rearward, if applicable.
2. Partially remove floor carpet.
3. Remove mounting bolts, and remove engine compartment rear cover.
EM-12
ENGINE ROOM COVER
INSTALLATION
Following inst ruc tions below, install in reverse order of removal.
1. Tighten bolts No. 1 to No. 3 shown in the figure to specified
torque in this order.
2. Tighten other bolts to specified torque in any given order.
[KA24DE]
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DRIVE BELTS
[KA24DE]
DRIVE BELTS
Checking Drive Belts
WARNING:
Be sure to perform when the engine is stoppe d.
● Inspection should be done only when engine is cold, or over 30
minutes after engine is stopped.
● Measure belt tension with tension meter (special service tool) at
points marked shown in the figure.
● Measure belt deflection by applying load of 98.1 N {10 kg} to .
Unit: mm (in)
Deflection adjustment
Used belt
Limit After adjustment
Alternator 11 (0.43) 7 - 8 (0.28 - 0.31) 6 - 7 (0.24 - 0.28)
Air conditioner compressor 13 (0.51) 8 - 10 (0.31 - 0.39) 7 - 8 (0.28 - 0.31)
Powersteering oil pump 13 (0.51) 8 - 10 (0.31 - 0.39) 7 - 8 (0.28 - 0.31)
Appliedpushing force 98 N (10 kg, 72 lb)
New belt
PFP:02117
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PBIC0422E
Tension Adjustment
EBS00AM2
CAUTION:
● When belt is replaced with a new one, tighten it a little stronger than current one to accommodate
for insufficient adaptability with pulley grooves.
● When tension of belt being used exceeds ″Retightening limit″, adjust it to value for ″Used belt″.
● When installing belt, make sure that it is correctly engaged with pulley groove.
● Keep oil and water away from belt.
● Do not twist or bend belt excessively.
POWER STEERING PUMP BELT
1. Open and fix engine compartment LH cover.
2. Loosen idler pulley lock nut (A) and adjust tension by turning
adjusting bolt (B).
● For specified belt tension, refer to EM-14, "Checking Drive
Belts" .
3. Tighten nut (A ).
: 25.5 - 32.4 N·m (2.6 - 3.3 kg-m, 19 - 23 ft- lb)
EMK0571D
AIR CONDITIONER COMPRESSO R BELT
1. Open and fix engine compartment LH cover (passenger side for RHD models or driver-side for LHD models).
2. Loosen idler pulley lock nut (C) and adjust tension by turning adjusting bolt (D).
● For specified belt tension, refer to EM-14, "Checking Drive Belts" .
3. Tighten nut (C).
EM-14
DRIVE BELTS
[KA24DE]
: 25.5 - 32.4 N·m (2.6 - 3.3 kg-m, 19 - 23 ft-lb)
ALTERNATOR AND WATER PUMP BELT
1. Remove front-side under cover.
2. Remove RH seat. Refer to SE-4, "
3. Remove engine compartment RH cov er. Refer to EM-12, "
FRONT SEAT" .
ENGINE ROOM COVER" .
4. Loosen alternator mounting bolt (E) and adjuster lock bolt (F) , and adjust tension by turning adjusting nut
(G).
● For specified be lt tension, refer to EM-14, "Checking Drive Belts" .
5. Tighten bolts (E), (F) and (G).
: 45.1 - 59.8 N·m (4.6 - 6.1 kg-m, 34 - 44 ft-lb) for E bolt
: 15.7 - 20.6 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb) for F bolt
: 6.5 - 7.6 N·m (0.67 - 0.77 kg-m, 58 - 67 in-lb) for G bolt
Removal and Installation
EBS007K6
REMOVAL
● Loosen each belt while referring to "Adjustment", and re m ove them one by one starting from the one in
front.
INSTALLATION
1. Install belts to pulley in reverse order of removal.
2. Adjust belt tension.
CAUTION:
● When checking belt tension immediately after installation, first, adjust to specified value. Then,
after turning crankshaft more than two turns, re-adjust to specified value to avoid variation in
deflection between pulleys.
● Tighten idler pulley lock nut by hand and measure tension without looseness.
3. Tighten each adjusting bolt and nut to the specified torque.
4. Make sure that tension of each belt is within the standard.
A
EM
C
D
E
F
G
H
I
J
K
M
L
EM-15
AIR CLEANER AND AIR DUCT
[KA24DE]
AIR CLEANER AND AIR DUCT
Removal and Installation
PFP:16500
EBS007K8
1 PCV hose 2 Air duct 3 Collar
4Grommet 5Clamp 6Collar
7 Grommet 8 Resonator 9 Clamp
10 Resonator 11 Clamp 12 Air hose
13 Resonator 14 Clamp 15 Mass air flow meter
16 Air cleanercase 17 Grommet 18 Air cleaner element
19 Washer 20 Wing nut 21 Seal ring
22 Dust pan 23 Washer 24 Wing nut
25 Dust exhaust valve 26 Grille 27 Screw
28 Air duct 29 Grommet 30 Air duct
31 Resonator 32 Grommet 33 Collar
34 Resonator 35 Clamp
REMOVAL
1. Remove rear-side u nder cover.
2. Open and fix engine room LH cover.
3. Remove RH seat. Refer to SE-4, "
4. Remove engine room RH cover. Refer to EM-12, "
5. Remove floor cover behind RH seat.
6. Disconnect harness connector from airflow sensor.
FRONT SEAT" .
ENGINE ROOM COVER" .
KBIA0821E
EM-16
AIR CLEANER AND AIR DUCT
7. For correct installation, m ake matching marks on each connec tion.
8. Remove from engine side after separating the s ystem with the
following procedure.
a. Remove PCV hose (A).
b. Remove air duct (B).
c. Separate air hose (C) and resonator (D).
d. Remove resonator (E).
e. Remove air hose (C).
f. Remove resonator (D).
g. Remove mass ai r flo w sensor (F).
CAUTION:
● Handle with care, avoiding any shocks.
● Do not disassemble it.
● Do not touch sensor part.
h. After removing mud flap of front RH wheel, remove resonator
(G).
i. When removing following parts, remove EVAP canister, and set
it aside.
j. Remove resonator (H).
k. Remove air cleaner case (I).
9. When removing components inside vehicle on right-hand,
remove them with the following procedure.
a. Remove components up to air cleaner case (I), referring to step
8.
b. Remove intake grille from outside of vehicle.
c. Remove kicking plate on RH side, and lift up panel under RH
side seat belt anchor.
d. Lift up air duct (J) from vehicle opening, and separate it from a ir
duct (K).
e. Pull and remove air duct (K).
f. Remove air duct (J) from mounting hol e of air duct (K).
[KA24DE]
KBIA0822E
KBIA0902E
A
EM
C
D
E
F
G
H
I
J
K
INSTALLATION
Install in reverse order of removal, paying attention to points below.
● After aligning matching marks marked when rem oving, install each connection, and firmly tighten clamps.
● Install dust drain valve so that its opening is along circumfer-
ence.
KBIA0819E
EM-17
L
M
AIR CLEANER AND AIR DUCT
[KA24DE]
Changing Air Cleaner Element
REMOVAL
NOTE:
● Mark ″*″ in the figure shows part of lift arm.
● For replacement of air cleaner e lement, it is not necessary to lift
up vehicle.
1. Remove brake pipe protector under vehicle, behind front RH
wheel.
2. Remove 3 clips, and the cover at the bottom of air c leaner case.
3. Remove wing nut, dust pan under air cleaner case, and then air
cleaner element.
INSTALLATION
Install in the reverse order of removal.
EBS0096T
KBIA0749E
EM-18
THROTTLE BODY
[KA24DE]
THROTTLE BODY PFP:16298
Removal and Installation
EBS008X7
A
EM
C
D
E
F
G
1 Bracket 2 Throttle position sensorharness 3 Waterhose
4 Throttle body 5 Bracket 6 Water hose
7 Gasket 8 Intake manifold
REMOVAL
1. Remove RH seat. Refer to SE-4, "FR ONT SEAT" .
2. Remove engine compartment RH cov er. Refer to EM-12, "
3. Remove air duct on throttle body. Refer to EM-16, "
AIR CLEANER AND AIR DUCT" .
4. Disconnect accelerator cable, and set it aside.
5. Disconnect harness connector.
6. Disconnect water hose.
● After disconnection, plug the hose to prevent cool ant leaks.
7. Loosen mounting bolts in reverse order shown in the figure, and
remove throttle body.
ENGINE ROOM COVER" .
H
I
KBIA0823E
J
K
L
M
EM-19
PBIC0424E
THROTTLE BODY
[KA24DE]
INSPECTION AFTER REMOVAL
● If idle is rough when engine is cold or warmed up, check and adjus t the fas t idle cam (FIC). Refer to EC-
28, "Fast Idle Cam (FIC) Inspection and Adjustment" .
INSTALLATION
Install in reverse order of removal, paying attention to points below.
● For throttle body, tight en mounting bolts in two steps in the
numerical order shown in the figure.
● For adjustment of acce lerator cable, refer to ACC-3, "ACCEL-
ERATOR CON TRO L SYSTEM (KA24DE)" .
1st step : 8.8 - 10.8 N·m (0.9 - 1.1 kg-m, 78 - 95 in-lb)
2nd step : 17.7 - 21.6 N·m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
PBIC0424E
Disassembly and Assembly
1 Throttle body 2 Throttle position sensor 3 IACV-FICD solenoidvalve
4 Washer 5 Spring 6 plunger
7 Gasket 8 IACV-AAC valve
DISASSEMBLY
Disassemble referring to the component illustration.
EBS008X8
PBIC0425E
ASSEMBLY
Assemble in reverse order of disassembly, paying attention to points below.
● Insert throttle position sensor into throttle body, with connectors
positioned as shown in the figure. Then rotate it in the direction
shown by arrow and temporarily tighten mounting screws.
● While they are turned in direction shown by arrow, circumfer-
ence of sensor hits projection. Avoid hitting projection by giving
slight space, and insert projection into inside of mounting screw
long hole. (It is temporarily held in place by c ounter-action of
spring.)
● After adjustment on vehicle, tighten mounting screws.
For adjusting procedure, refer to EC-45, "
Basic Inspection" .
EM-20
PBIC0426E
INTAKE MANIFOLD
[KA24DE]
INTAKE MANIFOLD PFP:14003
Removal and Installation
EBS007K9
A
EM
C
D
E
F
G
1 Bracket 2 Grounding wire 3 Bracket
4 Vacuum hose 5 Intake manifold 6 Heater pipe
7 Waterhose 8 Water hose 9 Intake manifold support
10 Vacuum hose 11 Thermal transmitter 12 Water outlet
13 Gasket 14 Water hose 15 PCV hose
16 Gasket 17 Air relief plug 18 Gasket
19 Engine coolanttemperature sensor 20 Gasket
H
I
J
K
L
PBIC0427E
M
REMOVAL
1. Release fuel pressure. Refer to EC-27, "Fuel Pressure Release" .
2. Drain coolant. Refer to CO-9, "
3. Remove RH seat. Refer to SE-4, "
ENGINE COOLANT" .
FRONT SEAT" .
4. Remove engine compartment RH cov er and rear cover. Refer to EM-12, "
5. Remove floor cover behindRH seat.
EM-21
ENGINE ROOM COVER" .
INTAKE MANIFOLD
6. Move aside main harnes s above intake manifold.
7. Disconnect PCV hose between rocker cover and air duct.
8. Remove air duct between throttle body a nd mass air flow sensor. Refer to EM-16, "
AIR DUCT" .
9. Remove throttle body. Refer to EM-19, "
10. Remove fuel tube and injector assembly. Refer to EM-28, "
11. Disconnect radiator hose (upper).
12. Disconnect hoses connected to intake manifold.
NOTE:
Separate water hose and PCV hose behind intake manifold when removing intake manifold.
13. Remove intake manifold with the following procedure.
a. Loosen mounting bolts and nuts in reverse order shown in the
figure.
b. Pull out stud bolts on rear.
c. Di sconnect water hose and PCV hose on back side, and remove
intake manifold.
THROTTLE BODY" .
FUEL INJECTOR AND FUEL TUBE" .
[KA24DE]
AIR CLEANER AND
PBIC0428E
INSPECTION AFTER REMOVAL
Surface Distortion
● Using straightedge and feeler gauge, inspect surface d istortion
of intake manifold.
Limit : 0.1 mm (0.004 in)
INSTALLATION
Assemble in reverse order of removal, paying attention to the following.
Intake Manifold Bolts
● Tighten in numerical or der as shown in the figure.
: 15.7 - 18.6 N·m (1.6 - 1.8 kg-m, 12 - 13 ft-
lb)
PBIC0429E
Water Outlet
● Install ga sket so that identification mark face as shown in component parts drawing.
EM-22
PBIC0428E
EXHAUST MANIFOLD
[KA24DE]
EXHAUST MANIFOLD PFP:14004
Removal and Installation
EBS008RQ
A
EM
C
D
E
F
G
KBIA0825E
1 Exhaust manifold 2 Gasket 3 Heated oxygen sensor
4 Oil level gauge guide 5 Exhaust manifold cover 6 Bracket
REMOVAL
1. Remove under cover on rear side.
2. Remove exhaust front tube. Refer to EX-2, "
3. Open and fix engine compartment LH cover.
4. Remove heated oxygen sensor with the following procedure.
a. Remove engine compartment rear cover. Refer to EM-12, "
b. Disconnect heated oxygen s ensor harness connector from bracket on intake manifold No. 4 port, and
remove all harness clamps.
c. Using socket for heated oxygen sensor removal and installation
(special service tool), remove heated oxygen sensor.
5. Remove exhaust manifold cove r.
EXHAUST SYSTEM" .
ENGINE ROOM COVER" .
H
I
J
K
L
M
EM-23
KBIA0826E
EXHAUST MANIFOLD
6. Loosen m ounting nuts in reverse order shown in the figure, and
remove exhaust manifold.
INSPECTION AFTER REMOVAL
● Using straightedge and feeler gauge, inspect surface d istortion
of intake manifold.
Limit : 0.3 mm (0.012 in)
[KA24DE]
PBIC0430E
INSTALLATION
Install in the reverse order of removal, paying attention to the following.
● Tighten in numerical or der as shown in the figure.
: 37.3 - 48.1 N·m (3.8 - 4.9 kg-m, 28 - 35 ft-lb)
INSPECTION AFTER INSTALLATION
Start engine , and ch eck for exhaust gas leakage and unusual noise by increasing engine speed.
PBIC0431E
PBIC0430E
EM-24
OIL PAN AND OIL STRAINER
[KA24DE]
OIL PAN AND OIL STRAINER PFP:11110
Removal and Installation
EBS007KB
A
EM
C
D
E
F
1 Gasket 2 Oil strainer 3 Oil pan drain plug washer
4 Oil pan drain plug 5 Oil pan
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
1. Remove under covers on front-side, and rear-side.
2. Drain engine oil. Refer to LU-5, "
ENGINE OIL" .
3. Loosen mounting bolts in reverse order shown in the figure, and
remove them.
NOTE:
There are no screw holes in the area marked with on cylinder
block. (No mountin g bolts.)
4. Using a s eal cutter (special service tool), separate liquid gaske t,
and remove oil pan.
5. Remove oil strainer.
INSPECTION AFTER REMOVA L
Check oil strainer and clean it if any object attached.
PBIC0432E
SEM980F
G
H
I
J
K
L
M
INSTALLATION
Install in the reverse order of removal paying attention to the following.
EM-25
OIL PAN AND OIL STRAINER
Installing Oil Pan
1. Apply liquid gasket thoroughly as shown in illustration.
● Use Genuine Liquid Gasket or equiv alent.
2. Tighten mounting bolts in numerical order as shown in the figure.
NOTE:
There are no sc rew holes in the area marked with on cylinder
block. (No mounting bolts.)
[KA24DE]
PBIC0433E
Installing Drain Plug Washer
Refer to illustration of com ponent parts for installation direction.
INSPECTION AFTER INSTALLATION
Check for leakage of engine oil when engine is warmed.
SEM985F
EM-26
SPARK PLUG (CONVENTIONAL)
[KA24DE]
SPARK PLUG (CONVENTIONAL) PFP:22401
Removal and Installation
REMOVAL
1. Open and fix engine compartment LH cover.
2. Disconnect high-tension cables from rocker cover.
3. Remove spark plugs with a spark plug wrench (comme rcial service tool).
● Remove and i nstall No. 4 cylinder by conne cting exte nsion
bar of 75 mm and universal socket to spark plug wrench.
EBS008YM
SMA581C
A
EM
C
D
E
INSPECTION AFTER REMOVA L
Check spark plug gap. Adjust or replace if necessary.
Standard : 1.0 - 1.1 mm (0.039 - 0.043 in)
Spark plug:
Make NGK
Standard type BKR5E-11
Cold type
● Use a wire brush for cleaning, if necessary.
BKR6E-11
BKR7E-11
INSTALLATION
Install in the reverse order of removal, paying attention to the following.
Spark plug:
: 20 - 29 N·m ( 2.0 - 3.0 Kg-m, 14 - 22 ft-lb)
● Refer to EM-30, "ROCKER COVER" for installation of spark plug cap and high-tension cables.
F
G
H
I
SMA476
J
K
L
M
EM-27
FUEL INJECTOR AND FUEL TUBE
[KA24DE]
FUEL INJECTOR AND FUEL TUBE
Removal and Installation
PFP:16600
EBS007KE
1 Fuel tube 2 Vacuum hose 3 Fuel feed hose
4 Clip 5 O-ring 6 Fuel injector
7 Fuel returnhose 8 Vacuum hose 9 O-ring
10 Fuel pressureregulator
CAUTION:
● Apply new engine oil when installing the parts that specified to do so in the figu re.
REMOVAL
1. Release fuel pressure. Refer to EC-27, "Fuel Pressure Release" .
2. Remove RH seat. Refer to SE-4, "
3. Remove engine compartment RH cover. Refer to EM -12, "
4. Disconnect PCV hose between rocker cover and air duct.
5. Remove air duct on throttle body. Refer to EM-16, "
6. Disconnect fuel injector harness connector.
7. Move aside main harnes s above intake manifold.
8. Disconnect vacuum hose from fuel tube.
9. Disconnect fuel feed hose and fuel return hose.
CAUTION:
Plug hoses to prevent fuel from draining.
10. Remove fuel tube and injector assembly.
CAUTION:
Do not incline it, or remaining fuel in pipes may drain from pipes.
FRONT SEAT" .
ENGINE ROOM COVER" .
AIR CLEANER AND AIR DUCT" .
KBIA0827E
EM-28
FUEL INJECTOR AND FUEL TUBE
[KA24DE]
11. Expand and remove clips securing fuel injectors.
12. Extractfuel injectors straight from fuel tubes.
● Be careful not to damage injector nozzles during
removal.
● Do not bump or drop fuel injectors.
● Do not disassemble.
PBIC0227E
INSTALLATION
1. Careful ly install O-rings, including the one used with the pressure regulator.
● Lubricate O-rings by smearing new engine oil.
● Be careful not t o 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 clipsin grooves on fuel injectors.
● Make sure that p r otrusions of fuel injectors are aligned with
cutouts of clips after installation.
3. Align protrusions of fuel tubes with those of fuel injectors.
4. Do not incline it, or remaining fuel in pipes m ay drain from pipes.
● Insert hose until its end touches bulge on fuel tube. Install
clamp, avoiding bulge, and securely tighten i t.
5. Tighten fuel tube assembly mounting bolts alternatively in two
steps.
PBIC0227E
1st step : 7.8 - 10.8 N·m (0.8 - 1.1 kg-m, 69 - 95 ft-lb)
A
EM
C
D
E
F
G
H
I
2nd step :15.7 - 18.6 N·m (1.6 - 1.8 kg-m, 12 - 13 ft-lb)
6. Conne ct fuel feed nose and fuel return hose.
● Insert hose until its end touches bulge on fuel tube. Install clamp, avoiding bulge, and securely tighten
it.
7. Install all removed parts in the reverse o rder of removal.
INSPECTION AFTER INSTAL LATION
Check on Fuel Le akage
1. Start the engine, and run it for a few minutes with engine at idle.
2. Stop the engine, and check for fuel leakage both visually and by odor of gasoline.
NOTE:
Use mirrors for checking on invisible points.
CAUTION:
Do not touch the engine immediately after stopped, as engine becomes extremely hot.
J
K
L
M
EM-29
ROCKER COVER
[KA24DE]
ROCKER COVER
Removal and Installation
PFP:13264
EBS007KF
1 PCV hose 2 Oil filler cap 3 Rocker cover
4 Gasket 5 Gasket
REMOVAL
1. Open and fix engine compartment LH cover.
2. Remove engine compartment rear cover. Refer to EM-12, "
ENGINE ROOM COVER" .
3. Disconnect PCV hose.
4. Disconnect spark plug cap and high-tension cables, and set them aside.
5. Loosen mounting bolts in reverse order s hown in the figure, and
remove rocker cover.
INSTALLATION
Install in the reverse order of removal, paying attention to the following.
KBIA0828E
PBIC0434E
EM-30
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