Em PDF

ENGINE
SECTION
ENGINE MECHANICAL
EM EM
E
CONTENTS
QR25DE AIR CLEANER AND AIR DUCT ....................... 19 F
Component ..............................................................19
SERVICE INFORMATION ............................ 5 Removal and Installation .........................................19
Changing Air Cleaner Filter .....................................21 G
PRECAUTIONS ................................................... 5
Precaution for Supplemental Restraint System INTAKE MANIFOLD ......................................... 22
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Component ..............................................................22
SIONER" ................................................................... 5 Removal and Installation .........................................22 H
Precaution for Drain Engine Coolant and Engine
Oil .............................................................................. 5 EXHAUST MANIFOLD AND THREE WAY
Precaution for Disconnecting Fuel Piping ................. 5 CATALYST ........................................................ 26 I
Precaution for Removal and Disassembly ................ 5 Component ..............................................................26
Precaution for Inspection, Repair and Replace- Removal and Installation .........................................26
ment .......................................................................... 5 J
Precaution for Assembly and Installation .................. 5 OIL PAN AND OIL STRAINER ......................... 28
Precaution for Angle Tightening ................................ 6 Component ..............................................................28
Precaution for Liquid Gasket ..................................... 6 Removal and Installation .........................................28
K
PREPARATION ................................................... 8 IGNITION COIL, SPARK PLUG AND ROCK-
Special Service Tool ................................................. 8 ER COVER ........................................................ 31
Commercial Service Tool .......................................... 9 Component ..............................................................31
L
Removal and Installation .........................................31
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................12 FUEL INJECTOR AND FUEL TUBE ................ 34
NVH Troubleshooting - Engine Noise ..................... 12 Component ..............................................................34 M
Use the Chart Below to Help You Find the Cause Removal and Installation .........................................34
of the Symptom ....................................................... 12 CAMSHAFT ....................................................... 39
Component ..............................................................39 N
ENGINE ROOM COVER ....................................14
Component .............................................................. 14 Removal and Installation .........................................39
Removal and Installation of Engine Room Right Valve Clearance ......................................................48
Side Cover .............................................................. 14 O
TIMING CHAIN .................................................. 51
Removal and Installation of Engine Room Rear
Component ..............................................................51
Cover ....................................................................... 14
Removal and Installation .........................................51
P
DRIVE BELTS ....................................................16 OIL SEAL .......................................................... 60
Component .............................................................. 16 Removal and Installation of Valve Oil Seal ..............60
Tension Adjustment ................................................ 16 Removal and Installation of Front Oil Seal ..............60
Removal and Installation ......................................... 16 Removal and Installation of Rear Oil Seal ...............61
Removal and Installation of Drive Belt Auto Ten-
sioner ...................................................................... 17 CYLINDER HEAD ............................................. 63
Revision: 2007 November EM-1 E25

On-Vehicle Service ................................................. 63 Removal and Installation ....................................... 128
Component ............................................................. 64
Removal and Installation ........................................ 64 TURBOCHARGER AND THREE WAY CATA-
Component ............................................................. 67 LYST (ZD30DDTi) ............................................ 129
Disassembly and Assembly .................................... 67 Component ........................................................... 129
Inspection After Disassembly ................................. 69 Removal and Installation ....................................... 129
ENGINE ASSEMBLY ......................................... 74 EXHAUST MANIFOLD (ZD30DD) .................... 131

Component ............................................................. 74 Component ........................................................... 131
Removal and Installation ........................................ 74 Removal and Installation ....................................... 131
CYLINDER BLOCK ........................................... 78 EXHAUST MANIFOLD (ZD30DDTi) ................ 132

Component ............................................................. 78 Component ........................................................... 132
Disassembly and Assembly .................................... 79 Removal and Installation ....................................... 132
How to Select Piston and Bearing .......................... 87
Inspection After Disassembly ................................. 94
OIL PAN AND OIL STRAINER ........................ 133
Component ........................................................... 133
SERVICE DATA AND SPECIFICATIONS Removal and Installation ....................................... 133
(SDS) ................................................................ 105
GLOW PLUG .................................................... 134
Standard and Limit ................................................105
Component ........................................................... 134
ZD30 WITHOUT COMMON RAIL
VACUUM PUMP ............................................... 135
SERVICE INFORMATION .......................... 116 Component ........................................................... 135
PRECAUTIONS ............................................... 116 INJECTION TUBE AND INJECTION NOZZLE.. 136
Precaution for Supplemental Restraint System Component ........................................................... 136
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ................................................................116 ELECTRONIC CONTROL FUEL INJECTION
Precaution for Drain Coolant .................................116 PUMP ................................................................ 137
Precaution for Disconnecting Fuel Piping ..............116 Component ........................................................... 137
Precaution for Removal and Disassembly .............116 Removal and Installation ....................................... 137
Precaution for Inspection, Repair and Replace-
ment .......................................................................116 ROCKER COVER ............................................. 142
Precaution for Assembly and Installation ..............116 Component ........................................................... 142
Parts Requiring Angular Tightening .......................117
Precaution for Liquid Gasket .................................117
CAMSHAFT ...................................................... 143
Component ........................................................... 143
PREPARATION ............................................... 118
Special Service Tool ..............................................118
TIMING CHAIN ................................................. 145
Component ........................................................... 145
Commercial Service Tool ......................................120
Removal and Installation ....................................... 145
ENGINE ROOM COVER .................................. 121
Component ............................................................121
TIMING GEAR .................................................. 150
Component ........................................................... 150
Removal and Installation of Engine Room Right
Side Cover .............................................................121
Removal and Installation of Engine Room Rear CYLINDER HEAD ............................................. 159
Cover .....................................................................121 Component (Removal and Installation) ................. 159
AIR CLEANER AND AIR DUCT (ZD30DD) .... 123 Component (Disassembly and Assembly) ............ 160
Inspection After Assembly and Disassembly ........ 160
Component ............................................................123
AIR CLEANER AND AIR DUCT (ZD30DDTi) . 124 ENGINE ASSEMBLY ....................................... 162
Component ........................................................... 162
Component ............................................................124
CHARGE AIR COOLER [ZD30DDTi] .............. 125
Layout ....................................................................125
CYLINDER BLOCK .......................................... 163
Component ............................................................126 Component ........................................................... 163
Inspection After Disassembly (ZD30DD) .............. 164
INTAKE MANIFOLD COLLECTOR AND IN-
SERVICE DATA AND SPECIFICATIONS
TAKE MANIFOLD ............................................ 127
Component ............................................................127
(SDS) ................................................................ 165

Standard and Limit ................................................ 165 EGR SYSTEM ................................................. 196
Tightening Torque ................................................. 174 Component ............................................................ 196 A
ZD30 WITH COMMON RAIL Removal and Installation ....................................... 196
SERVICE INFORMATION ......................... 175 TURBOCHARGER AND THREE WAY CATA-

EM
LYST (ZD30DDTi) ........................................... 198
MODIFICATION NOTICE ................................. 175 Component ............................................................ 198
Major Modification Item ......................................... 175 Removal and Installation ....................................... 198
C
PRECAUTIONS ................................................ 176 EXHAUST MANIFOLD .................................... 204
Precaution for Supplemental Restraint System Component ............................................................ 204
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- Removal and Installation ....................................... 204 D
SIONER" ............................................................... 176
Precaution for Drain Engine Coolant ..................... 176 OIL PAN AND OIL STRAINER ....................... 206
Precaution for Disconnecting Fuel Piping ............. 176 Component ............................................................ 206
Precaution for Removal and Disassembly ............ 176 Removal and Installation ....................................... 206 E
Precaution for Inspection, Repair and Replace-
ment ...................................................................... 176 GLOW PLUG ................................................... 209
Precaution for Assembly and Installation .............. 176 Component ............................................................ 209
F
Parts Requiring Angular Tightening ...................... 176 Removal and Installation ....................................... 209
Precaution for Liquid Gasket ................................. 177 VACUUM PUMP .............................................. 211
PREPARATION ................................................ 178 Component ............................................................ 211 G
Special Service Tool ............................................. 178 Removal and Installation ....................................... 211
Commercial Service Tool ...................................... 179 FUEL INJECTOR AND FUEL TUBE .............. 213
H
NOISE, VIBRATION AND HARSHNESS Component ............................................................ 213
(NVH) TROUBLESHOOTING .......................... 181 Removal and Installation ....................................... 213
NVH Troubleshooting - Engine Noise ................... 181 FUEL SUPPLY PUMP ..................................... 218 I
Use the Chart Below to Help You Find the Cause Component ............................................................ 218
of the Symptom ..................................................... 181 Removal and Installation ....................................... 218
ENGINE COVERS ............................................ 183 ROCKER COVER ........................................... 220 J
Component ............................................................ 183 Component ............................................................ 220
Removal and Installation of Engine Room Right Removal and Installation ....................................... 220
Side Cover ............................................................ 183 K
Removal and Installation of Engine Room Rear CAMSHAFT ..................................................... 223
Cover ..................................................................... 183 Component ............................................................ 223
DRIVE BELTS .................................................. 185 L
Valve Clearance .................................................... 228
Checking Drive Belt ............................................... 185
Tension Adjustment .............................................. 185 TIMING CHAIN ................................................ 232
Removal and Installation ....................................... 185 Component ............................................................ 232 M
Drive Belt Auto Tensioner ..................................... 186 Removal and Installation ....................................... 232
AIR CLEANER AND AIR DUCT ...................... 187 TIMING GEAR ................................................. 236
Component ............................................................ 187 Component ............................................................ 236 N
Removal and Installation ....................................... 188 Removal and Installation ....................................... 237
Changing Air Cleaner Filter ................................... 189
OIL SEAL ........................................................ 243 O
CHARGE AIR COOLER ................................... 190 Removal and Installation of Valve Oil Seal ............ 243
Layout ................................................................... 190 Removal and Installation of Front Oil Seal ............ 243
Component ............................................................ 191 Removal and Installation of Rear Oil Seal ............. 244
Removal and Installation ....................................... 191 P
CYLINDER HEAD ........................................... 246
INTAKE MANIFOLD ......................................... 193 On-Vehicle Service ................................................ 246
Components .......................................................... 193 Component (Removal and Installation) ................. 247
Removal and Installation ....................................... 193 Removal and Installation ....................................... 247
Components .......................................................... 195 Component (Disassembly and Assembly) ............. 251
Disassembly and Assembly .................................. 195 Disassembly and Assembly ................................... 251

ENGINE ASSEMBLY ....................................... 257 How to Select Piston ............................................. 269
Component ............................................................257 Inspection After Disassembly ................................ 270
Removal and Installation .......................................257
SERVICE DATA AND SPECIFICATIONS
CYLINDER BLOCK ......................................... 261 (SDS) ................................................................ 280
Component ............................................................261 Standard and Limit ................................................ 280
Disassembly and Assembly ...................................262

PRECAUTIONS
< SERVICE INFORMATION > [QR25DE]
SERVICE INFORMATION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000003470881
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along C
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING: D
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer. E
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
F
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
G
Precaution for Drain Engine Coolant and Engine Oil INFOID:0000000003397060
Drain engine coolant and engine oil when the engine is cooled.
H
Precaution for Disconnecting Fuel Piping INFOID:0000000003397061
• Before starting work, check no fire or spark producing items are in the work area.
I
• Release fuel pressure before disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and Disassembly INFOID:0000000003397062
J
• When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid
forceful or uninstructed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces. K
• Cover openings of engine system with a tape or the equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally L
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.
Precaution for Inspection, Repair and Replacement INFOID:0000000003397063 M
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
N
Precaution for Assembly and Installation INFOID:0000000003397064
• Use torque wrench to tighten bolts or nuts to specification. O

• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring. P
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• Release air within route when refilling after draining engine coolant.

PRECAUTIONS
• Before starting the engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine
stopped). Then check there are no leaks at fuel line connections.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Precaution for Angle Tightening INFOID:0000000003397065
• Use the angle wrench [SST: KV10112100] for the final tightening of the following engine parts.
- Cylinder head bolts
- Lower cylinder block bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
- Balancer unit
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step.
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000003397066
REMOVAL OF LIQUID GASKET

• After removing the mounting nuts and bolts, separate the mating
surface using a seal cutter (SST) and remove the old liquid gasket
sealing.
CAUTION:
Be careful not to damage the mating surfaces.
• Tap seal cutter (SST) to insert it, and then slide it by tapping on the
side as shown in the figure.
• In areas where the seal cutter (SST) is difficult to use, use plastic
hammer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason a tool such as screwdriver is
PBIC0275E
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0003E
3. Attach liquid gasket tube to the tube presser (commercial ser-

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

PRECAUTIONS
• As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the holes. A
Check to read the text of service manual.
• Within 5 minutes of liquid gasket application, install the mating
component.
EM
• If the liquid gasket protrudes, wipe it off immediately.
• Do not retighten mounting nuts or bolts after the installation.
• Wait 30 minutes or more after installation before refilling
engine oil and engine coolant. C
CAUTION:
If there are instructions in this manual, observe them.
SEM159F

PREPARATION
PREPARATION
Special Service Tool INFOID:0000000003397067
Tool number
Description
Tool name
KV10111100 Removing oil pan and front cover, etc.
Seal cutter
S-NT046
KV10116200 Disassembling valve mechanism

Valve spring compressor Part (1) is a component of KV10116200, but
1. KV10115900 Part (2) is not so.
Attachment
2. KV10109220
Adapter
PBIC1650E
KV10112100 Tightening bolts for connecting rod bearing

Angle wrench cap, cylinder head, etc. in angle
NT014
KV10117100 Loosening or tightening heated oxygen sen-

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

Valve oil seal puller
NT011
KV10115600 Installing valve oil seal

Valve oil seal drift
NT024

PREPARATION
Tool number
Description
Tool name A
EM03470000 Installing piston assembly into cylinder bore
Piston ring compressor
EM
C
NT044
ST16610001 Removing pilot bush

Pilot bushing puller D
NT045
F
— Removing fuel tube quick connectors in en-
Quick connector release gine room
(Available in SEC. 164 of PARTS CATALOG:
part No. 16441 6N210) G
H
PBIC0198E
Commercial Service Tool INFOID:0000000003397068
Tool name Description

Tube presser Pressing the tube of liquid gasket J
NT052 L
Power tool Loosening nuts and bolts
N
PBIC0190E
Spark plug wrench Removing and installing spark plug

O
PBIC2982E

PREPARATION
Pulley holder Removing and installing crankshaft pulley
ZZA1010D
Pulley puller Removing crankshaft pulley
NT676
1. Compression tester Checking compression pressure

2. Adapter
ZZA0008D
Cylinder head bolt wrench Loosening and tightening cylinder head bolt,
and used with the angle wrench [SST:
KV10112100]
a: 13 (0.51) dia.
b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)
NT583
Valve seat cutter set Finishing valve seat dimensions
S-NT048
TORX socket Removing and installing flywheel

Size: T55
PBIC1113E
Piston ring expander Removing and installing piston ring
S-NT030

PREPARATION
A
Valve guide drift Removing and installing valve guide
Intake and Exhaust:
a: 9.5 mm (0.374 in) dia.
b: 5.5 mm (0.217 in) dia. EM
C
S-NT015
Valve guide reamer 1: Reaming valve guide inner hole

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

before installing a new heated oxygen sensor
(Use with anti-seize lubricant shown below.)
a: 18 mm (0.71 in) dia. for zirconia heated
oxygen sensor G
b: 12 mm (0.47 in) dia. for titania heated ox-
ygen sensor
AEM488
H
Anti-seize lubricant i.e.: (Permatex TM Lubricating oxygen sensor thread cleaning
133AR or equivalent meeting MIL tool when reconditioning exhaust system
specification MIL-A-907) threads
I
J
AEM489
Manual lift table caddy Removing and installing the engine

K
ZZA1210D

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting - Engine Noise INFOID:0000000003397069
PBIC5378E
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000003397070
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 A

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
EM
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-48
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
EM-39
C
Cylinder Rattle C A — A B C bearing clearance
EM-39
head noise Camshaft runout
Piston to piston pin oil D

Slap or Piston pin clearance EM-94
— A — B B —
knock noise Connecting rod bushing EM-94
oil clearance
E
Piston to cylinder bore
Crank- clearance
EM-94
shaft pul- Piston ring side clear-
Slap or Piston EM-94
ley A — — B B A ance F
rap slap noise EM-94
Cylinder Piston ring end gap
EM-94
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
G
Oil pan ing rod oil clearance EM-94
Knock A B C B B B
bearing Connecting rod bearing EM-94
noise oil clearance H
Main bearing oil clear-
Main bear- EM-94
Knock A B — A B C ance
ing noise EM-94
Crankshaft runout
I
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-51
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-51 J
sioner
er operation
noise
Drive belt
Squeak-
(Sticking K
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-16
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B L
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-17
Creak M
noise
A: Closely related B: Related C: Sometimes related —: Not related

ENGINE ROOM COVER
ENGINE ROOM COVER
Component INFOID:0000000003397071
PBIC4646E
1. Engine room right side cover 2. Parking brake lever 3. Engine room left side cover
4. Parking brake cable 5. Harness 6. Harness protector
Removal and Installation of Engine Room Right Side Cover INFOID:0000000003397072
REMOVAL
1. Open engine compartment left side cover and secure it.
2. Remove front RH seat. Refer to SE-2.
3. Partially remove floor carpet.
4. Remove harness protector secured together at front right. Disconnect harness connector to move har-
ness routed on top of engine compartment right side cover aside.
5. Move parking brake lever and cable from engine compartment right side cover. Refer to PB-4, "Compo-
nent".
6. Remove mounting bolts, and remove engine compartment right side cover.
CAUTION:
When taking it out of vehicle, never allow it to interfere with vehicle.
INSTALLATION
Install in the reverse order of removal following instructions below.
1. Temporarily tighten bolt (B) shown in the figure.
: Vehicle front
2. Tighten bolt (C) shown in the figure to specified torque.

3. Tighten other bolts except bolt (A) shown in the figure [bolt (B) is
included] to specified torque in any given order.
4. Close engine compartment left side cover.
5. Tighten bolt (A) shown in the figure to specified torque.
PBIC5379E
Removal and Installation of Engine Room Rear Cover INFOID:0000000003397073
REMOVAL
1. Move folded seat on engine room rear cover side rearward, if applicable.

ENGINE ROOM COVER
3. Remove mounting bolts, and remove engine room rear cover.
A
EM
G
KBIA0742E
INSTALLATION
Following instructions below, install in the reverse order of removal. H
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. I
KBIA0742E

DRIVE BELTS
DRIVE BELTS
PBIC5347E
1. Water pump 2. Fan pulley 3. Power steering oil pump

4. Alternator 5. Idler pulley 6. Crankshaft pulley
7. Idler pulley 8. A/C compressor 9. Drive belt auto-tensioner pulley
Range when new drive belt is in-
A. Indicator B. C. Possible use range
stalled
: Engine front
• Refer to GI-8, "Component" for symbol marks in the figure.

Checking Drive Belt
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (A) (notch on fixed side) of drive belt auto-tensioner is within the possible use range
(C).
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the fig-
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.
Tension Adjustment INFOID:0000000003397075
Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Removal and Installation INFOID:0000000003397076
REMOVAL
1. Remove undercover.
2. Remove radiator shroud (lower). Refer to CO-9, "Component".

DRIVE BELTS
3. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han- A
dle in the direction of arrow (loosening direction of tensioner).
CAUTION:
• Avoid placing hand in a location where pinching may
EM
occur if the holding tool accidentally comes off.
• Never loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Never turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto- C
tensioner must be replaced as a unit, including the pulley.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as PBIC2169E
short-length screwdriver into the hole of the retaining boss to fix D
drive belt auto-tensioner pulley.
5. Loosen drive belt from water pump pulley in sequence, and remove it.
INSTALLATION E
1. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han-
dle in the direction of arrow (loosening direction of tensioner). F
CAUTION:
• Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off. G
• Never loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Never turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto-
tensioner must be replaced as a unit, including the pulley. H
2. Insert a rod approximately 6 mm (0.24 in) in diameter such as PBIC2627E
short-length screwdriver into the hole of retaining boss to fix
drive belt auto-tensioner pulley. I
3. Hook drive belt onto all pulleys except for drive belt auto-tensioner pulley, and then onto drive belt auto-
tensioner pulley finally. J
CAUTION:
• Confirm drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
K
pulley groove.
4. Release drive belt auto-tensioner, and apply tension to drive belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley. L
6. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-16, "Component".
Removal and Installation of Drive Belt Auto Tensioner INFOID:0000000003397077 M
REMOVAL
CAUTION: N
The complete drive belt auto-tensioner must be replaced as a unit, including the pulley.
2. Remove drive belt. Refer to EM-16, "Removal and Installation". O

DRIVE BELTS
3. Remove drive belt auto-tensioner (2).
1 : Idler pulley
3 : Idler pulley
CAUTION:
Never loosen the hexagonal part in center of drive belt auto-ten-
sioner pulley (Never turn it counterclockwise). If turned coun-
terclockwise, the complete drive belt auto-tensioner must be
replaced as a unit, including the pulley.
PBIC5430E
INSTALLATION
Note the following, and install in the reverse order of removal.
• When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
CAUTION:
If there is damage greater than peeled paint, replace drive belt auto-tensioner.

AIR CLEANER AND AIR DUCT
A
EM
J
PBIC5348E
1. PCV hose 2. Clamp 3. Air duct K

4. Clamp 5. Mass air flow meter 6. Air cleaner case
7. Collar 8. Grommet 9. Grille
10. Air duct (inlet) 11. Air duct 12. Collar L
13. Grommet 14. Resonator 15. Resonator
16. Grommet 17. Collar 18. Clamp
19. Air cleaner element 20. Washer 21. Wing nut M
22. Seal ring 23. Dust pan 24. Washer
25. Wing nut 26. Dust exhaust valve 27. Clamp
A. To rocker cover B. To electric throttle control actuator N

Removal and Installation INFOID:0000000003397079 O
REMOVAL
1. Remove undercover. P
2. Open and fix engine room left side cover. Refer to EM-14, "Component".
4. Remove engine room right side cover. Refer to EM-14.
5. Remove floor cover behind front RH seat.
6. Disconnect harness connector from mass air flow meter.

7. For correct installation, make matching marks on each connection.
8. Remove from engine side after separating the system with the
following procedure.
1 : Air duct (inlet)

2 : Air duct
: Vehicle front
a. Remove PCV hose (6).

b. Remove air duct (7).
c. Remove mass air flow meter (8).
CAUTION:
• Handle with care, avoiding any shocks.
• Never disassemble mass air flow meter.
• Never touch sensor part.
d. After removing mud flap of front RH wheel, remove resonator
(4).
e. When removing following parts, remove EVAP canister, and set
it aside.
f. Remove resonator (3).
g. Remove air cleaner case (5).
PBIC5349E
9. When removing components inside vehicle on right-hand, remove them with the following procedure.
a. Remove components up to air cleaner case, 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. Refer to EI-15.
d. Lift up air duct (J) from vehicle opening, and separate it from air
duct (K).
e. Pull and remove air duct.
f. Remove air duct from mounting hole of air duct.
KBIA0902E
INSTALLATION
Install in the reverse order of removal, paying attention to points below.
• After aligning matching marks marked when removing, install each connection, and firmly tighten clamps.
• Install dust drain valve so that its opening is along circumference.
KBIA0819E

Changing Air Cleaner Filter INFOID:0000000003397080
A
REMOVAL
1. Remove brake pipe protector under vehicle, behind front RH wheel.
EM
2. Remove 3 clips, and the cover at the bottom of air cleaner case.
NOTE:
• Mark “*” in the figure shows part of lift arm.
• For replacement of air cleaner element, it is not necessary to C
lift up vehicle.
3. Remove wing nut, dust pan, and then air cleaner element.
D
E
KBIA0749E
INSTALLATION
Install in the reverse order of removal. F

INTAKE MANIFOLD
INTAKE MANIFOLD
PBIC5425E
1. Electric throttle control actuator 2. Gasket 3. PCV hose

4. Clamp 5. PCV hose 6. Gasket
7. Intake manifold 8. Gasket 9. Intake manifold collector
10. Intake manifold support 11. Clamp 12. Vacuum hose
EVAP canister purge volume control
13. Vacuum hose 14. Bracket 15.
solenoid valve
16. Bracket
A. To rocker cover B. To heater outlet C. To water pipe
D. To brake booster E. To EVAP canister

CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
2. Remove RH seat. Refer to SE-2, "Component Parts Drawing".
3. Remove engine room right side cover. Refer to EM-14, "Component".
4. Release fuel pressure. Refer to EC-37, "Fuel Pressure Check".
5. Remove air duct. Refer to EM-19.

INTAKE MANIFOLD
6. Remove quick connector caps, and disconnect quick connector
at the engine side. Refer to EM-34. A
EM
PBIC2175E
D
7. Remove electric throttle control actuator with the following procedure:
a. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-6, "Changing Engine Coolant". E
CAUTION:
• Perform this step when engine is cold.
• Never spill engine coolant on drive belt.
F
b. Disconnect water hoses from electric throttle control actuator. When engine coolant is not drained from
radiator, attach plug to water hoses to prevent engine coolant leakage.
c. Disconnect harness connector.
G
d. Loosen mounting bolts in reverse order as shown in the figure,
and remove electric throttle control actuator and gasket.
CAUTION:
• Handle carefully to avoid any shock to electric throttle H
control actuator.
• Never disassemble.
I
J
PBIC5351E
8. Remove intake manifold support.

K
9. Disconnect harness, vacuum hoses and PCV hose from intake manifold, and move them aside.
10. Disconnect harness connector from fuel injector. Refer to EM-34.
11. Loosen mounting nuts and bolts in reverse order as shown in L
the figure, and remove intake manifold and gasket.
: Engine front
M
CAUTION:
Cover engine openings to avoid entry of foreign materials.
NOTE:
Disregard No. 6 when loosening. N
PBIC5352E
O
12. Remove fuel tube and fuel injector assembly from intake manifold. Refer to EM-34.

INTAKE MANIFOLD
13. Loosen mounting nuts and bolts in reverse order as shown in
the figure, and remove intake manifold collector and gasket from
intake manifold.
: Engine front
CAUTION:
NOTE:
Disregard No. 7 when loosening.
PBIC5353E
INSPECTION AFTER REMOVAL

Surface Distortion
• Using a straightedge (A) and a feeler gauge (B), check the surface
distortion of both the intake manifold collector mating surface and
the intake manifold mating surfaces.
Limit : 0.1 mm (0.004 in)

NOTE:
This figure shows intake manifold as an example.
• If it exceeds the limit, replace intake manifold and/or intake mani-
fold collector.
PBIC5354E
INSTALLATION
Intake Manifold
• If stud bolts were removed, install them and tighten to the specified torque below.
: 10.8 N·m (1.1 kg-m, 8 ft-lb)

• Tighten in numerical order as shown in the figure.
: Engine front
NOTE:
No. 6 means double tightening of bolt No. 1.
PBIC5352E
Intake Manifold Collector

• If stud bolts were removed, install them and tighten to the specified torque below.
: 10.8 N·m (1.1 kg-m, 8 ft-lb)

INTAKE MANIFOLD
A
: Engine front
NOTE:
No. 7 means double tightening of bolt No. 1. EM
PBIC5353E
D
Electric Throttle Control Actuator
• Tighten mounting bolts equally and diagonally in several steps and
in numerical order as shown in the figure.
• Perform the “Throttle Valve Closed Position Learning” when har- E
ness connector of electric throttle control actuator is disconnected.
Refer to EC-33, "Basic Inspection".
• Perform the “Idle Air Volume Learning” and “Throttle Valve Closed F
Position Learning” when electric throttle control actuator is
replaced. Refer to EC-33, "Basic Inspection".
G
PBIC5351E
INSPECTION AFTER INSTALLATION H

Check on fuel leakage.
1. Turning ignition switch “ON” (with the engine stopped). With fuel pressure to fuel piping check there are no
fuel leaks at connection points. I
NOTE:
Use mirrors for checking on invisible points.
2. Start the engine. With engine speed increased, check again there are no fuel leaks at connection point.
J
CAUTION:
Never touch the engine immediately after stopped as the engine becomes extremely hot.

EXHAUST MANIFOLD AND THREE WAY CATALYST
PBIC5355E
Exhaust manifold and three way cat-

1. Exhaust manifold cover 2. Gasket 3.
alyst assembly
4. Washer 5. Exhaust manifold support 6. Heated oxygen sensor 1

REMOVAL
3. Remove exhaust front tube. Refer to EX-3, "Component".
4. Disconnect harness connector of heated oxygen sensor 1, and harness from bracket and middle clamp.
5. Using the heated oxygen sensor wrench (SST), remove heated
oxygen sensor 1.
CAUTION:
• Be careful not to damage heated oxygen sensor.
• Discard heated oxygen sensor 1 which has been dropped
onto a hard surface such as a concrete floor. Replace with
a new one.
KBIA0094E
6. Remove exhaust manifold support.

7. Remove exhaust manifold cover.

8. Loosen nuts in reverse order as shown in the figure to remove
exhaust manifold and three way catalyst assembly. A
: Engine front
EM
9. Remove gasket.
CAUTION:
C
PBIC5356E
D
Surface Distortion
• Using a straightedge and a feeler gauge, check the surface distor- E
tion of exhaust manifold and three way catalyst assembly mating
surface.
Limit : 0.1 mm (0.004 in) F
• If it exceeds the limit, replace exhaust manifold and three way cat-
alyst assembly.
G
KBIA0046E H
INSTALLATION
I
Exhaust Manifold
If stud bolts were removed, install them and tighten to the specified torque below.
J
: 14.7 N·m (1.5 kg-m, 11 ft-lb)
1. Tighten nuts in numerical order as shown in the figure (tempo-
rarily).
K
: Engine front
2. Tighten nuts in numerical order as show in the figure (specified L

torque).
3. Install exhaust manifold support with the following procedure:
a. Tighten the mounting bolt to the exhaust manifold and three way M
catalyst assembly side.
b. Tighten the mounting nut to the engine side. PBIC5356E
N
Heated Oxygen Sensor 1
CAUTION:
• Before installing new heated oxygen sensor 1, clean exhaust system threads using a heated oxygen
sensor thread cleaner (commercial service tool) and apply anti-seize lubricant (commercial service O
tool).
• Never over torque heated oxygen sensor 1. Doing so may cause damage to heated oxygen sensor 1,
resulting in the “MIL” coming on. P

OIL PAN AND OIL STRAINER
PBIC5357E
1. Oil pan 2. Drain plug 3. Washer

A. Oil pan side

REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
2. Drain engine oil. Refer to LU-5, "Changing Engine Oil".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine oil on drive belt.
3. Remove gusset. Refer to MT-28, "Removal and Installation".
4. Remove dust cover. Refer to MT-28, "Removal and Installation".
5. Remove suspension cross member. Refer to FSU-6, "Component".
6. Remove oil pan with the following procedure:
a. Loosen mounting bolts in reverse order shown in the figure with
power tool.
: Engine front
PBIC5358E

b. Insert the seal cutter (SST) between oil pan and lower cylinder
block. A
CAUTION:
• Be careful not to damage the mating surfaces.
• Never insert a screwdriver, this will damage the mating
EM
surfaces.
c. Slide seal cutter (SST) by tapping on the side of the tool with a
hammer. Remove oil pan.
C
SEM365EA
D
Clean oil strainer if any object attached.
INSTALLATION E
1. Install oil pan with the following procedure:
a. Use a scraper to remove old liquid gasket from mating surfaces.
• Also remove old liquid gasket from mating surface of oil pan F
and lower cylinder block.
• Remove old liquid gasket from the bolt holes and thread.
CAUTION:
G
Never scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
PBIC0003E
I
b. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) as shown in the figure.
J
a : 4.0 - 5.0 mm (0.157 - 0.197 in)
CAUTION: K
Attaching should be done within 5 minutes after coating.
L
JPBIA1966ZZ
c. Tighten bolts in numerical order as shown in the figure. M
: Engine front
PBIC5358E
P
2. Install oil pan drain plug.
• Refer to the figure of components of former page for installation direction of washer. Refer to EM-28,
"Component".
3. Install in the reverse order of removal after this step.
NOTE:
Pour engine oil at least 30 minutes after oil pan is installed.

INSPECTION AFTER INSTALLATION
1. Check the engine oil level, and adjust the level. Refer to LU-4.
2. Start the engine, and check there is no leaks of engine oil.
3. Stop the engine and wait for 10 minutes.
4. Check the engine oil level again. Refer to LU-4.

IGNITION COIL, SPARK PLUG AND ROCKER COVER
A
EM
G
PBIC5431E
1. Fresh air hose 2. Clamp 3. Oil filler cap

4. PCV hose 5. Clamp 6. Hose connector
H
7. PCV hose 8. Ignition coil 9. Spark plug
10. PCV valve 11. O-ring 12. Rocker cover
13. Rocker cover gasket
I
A. To air duct B. To intake manifold C. Refer to EM-31
Removal and Installation INFOID:0000000003397088 J
REMOVAL
1. Open and fix engine room left side cover. Refer to EM-14, "Component". K
2. Remove engine room rear cover. Refer to EM-14, "Component".
3. Disconnect harness connector from ignition coil.
L
4. Remove ignition coil.
CAUTION:
Never drop or shock ignition coil.
5. Remove spark plug with a spark plug wrench (commercial service tool). M
CAUTION:
Never drop or shock spark plug.
6. Disconnect PCV hose from rocker cover. N
7. Remove PCV valve and O-ring from rocker cover, if necessary.
8. Remove oil filler cap from rocker cover, if necessary.
O
9. Loosen bolts in reverse order shown in the figure.
: Engine front
P
10. Remove rocker cover gasket from rocker cover.
11. Use scraper to remove all traces of liquid gasket from cylinder
head and camshaft bracket (No. 1).
CAUTION:
Never scratch or damage the mating surface when cleaning
off old liquid gasket.
PBIC5414E

Use standard type spark plug for normal condition.
Make NGK
Standard type DILKAR6A-11
Gap (Nominal) : 1.1 mm (0.043 in)

CAUTION:
• Never drop or shock spark plug.
• Never use wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be
used.
Cleaner air pressure:

Less than 588 kPa (6 kg/cm2, 85 psi)
Cleaning time:
Less than 20 seconds
SMA773C
• Checking and adjusting plug gap is not required between

change intervals.
SMA806CA
INSTALLATION
1. Apply liquid gasket to the position shown in the figure with the
following procedure:
a. Refer to figure “a” to apply liquid gasket to joint part of camshaft
bracket (No. 1) and cylinder head.
b. Refer to figure “b” to apply liquid gasket in 90 degrees to figure
“a”.
CAUTION:
Attaching should be done within 5 minutes after liquid gas-
ket application.
WBIA0164E

2. Install rocker cover gasket to rocker cover.
3. Install rocker cover. A
• Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
4. Tighten bolts in two steps separately in numerical order as
shown in the figure. EM
: Engine front
C
1st step: 2.0 N·m (0.2 kg-m, 18 in-lb)
2nd step: 8.4 N·m (0.86 kg-m, 74 in-lb) D
PBIC5414E
E

FUEL INJECTOR AND FUEL TUBE
PBIC5361E
1. Fuel tube 2. Fuel feed hose 3. Quick connector cap

4. Clip 5. O-ring (green) 6. Fuel injector
7. O-ring (black) 8. Intake manifold
: Engine front

CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the work shop.
• Be sure to work in a well ventilated area and furnish work shop with a CO2 fire extinguisher.
• Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
2. Remove RH seat. Refer to SE-2.
5. Remove air duct from electric throttle control actuator. Refer to EM-19.
6. Disconnect quick connector with the following procedure: as follows, and remove fuel feed hose.
CAUTION:
Disconnect quick connector by using the quick connector release, not by picking out retainer
tabs.

a. Remove quick connector cap.
A
EM
KBIA0701E
D
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 E
contacts and goes no further. Hold quick connector release on
that position.
CAUTION:
Inserting quick connector release hard will not disconnect F
quick connector. Hold quick connector release where it
contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube. G
CAUTION:
• Pull quick connector holding “A” position in the figure.
• Never pull with lateral force applied. O-ring inside quick KBIA0702E H
connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks.
• Keep parts away from heat source. Especially, be careful when welding is performed around I
them.
• Never expose parts to battery electrolyte or other acids.
• Never bend or twist connection between quick connector and fuel feed hose during installation/ J
removal.
• To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar. K
PBIC2205E
7. Remove EVAP canister purge volume control solenoid valve and bracket assembly. Refer to EM-22. N
8. Disconnect harness connector from electric throttle control actuator.
9. Disconnect harness from fuel tube.
O
10. Remove PCV hose between rocker cover and intake manifold. Refer to EM-22, "Component".

11. Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
12. Remove fuel tube and fuel injector assembly and insulators.
CAUTION:
• When removing, be careful to avoid any interference with
fuel injector.
• Use a shop cloth to absorb any fuel leaks from fuel tube.
PBIC5362E
13. Remove fuel injector from fuel tube with the following procedure:
a. Open and remove clip (3).
b. Remove fuel injector (2) from fuel tube (1) by pulling straight.
CAUTION:
• Be careful with remaining fuel that may go out from fuel
tube.
• Be careful not to damage fuel injector nozzle during
removal.
• Never bump or drop fuel injector.
• Never disassemble fuel injector.
PBIC5363E
INSTALLATION
1. Note the following, and install O-rings to fuel injector.
CAUTION:
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Black

Nozzle side : Green
• Handle O-ring with bare hands. Never wear gloves.
• Lubricate O-ring with new engine oil.
• Never clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
• Insert O-ring straight into fuel tube. Never decenter or twist it.
2. Install fuel injector to fuel tube with the following procedure:
a. Insert clip into clip attachment groove on fuel injector.

• Insert clip so that protrusion “A” of fuel injector matches cutout
“A” of clip. A
CAUTION:
• Never reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
EM
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion “B” of fuel tube matches C
cutout “B” of clip.
• Check that fuel tube flange is securely fixed in flange fixing
groove on clip. D
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
• Check that protrusions of fuel injectors are aligned with cut- E
outs of clips after installation.
G
PBIC2651E
3. Install fuel tube and fuel injector assembly with the following procedure:
CAUTION: H
When installing, be careful to avoid any interference with fuel injector.
a. Insert the tip of each fuel injector into intake manifold.
b. Tighten mounting bolts in numerical order as shown in the fig- I
ure.
: Engine front J
4. Note the following, and connect quick connectors to install fuel

feed hose.
K
a. Check the connection for foreign material and damage.
L
PBIC5362E
b. Align center to insert quick connector straightly into fuel tube.

• Insert quick connector to fuel tube until the top spool on fuel M
tube is inserted completely and the second level spool is posi-
tioned slightly below quick connector bottom end.
CAUTION:
• Hold “A” position in the figure when inserting fuel tube N
into quick connector.
• Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector. O
• Insert until you hear a “click” sound and actually feel
the engagement.
KBIA0272E
• To avoid misidentification of engagement with a similar
P
sound, be sure to perform the next step.
c. Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding “A” position.
Check it is completely engaged (connected) so that it does not come out from fuel feed tube.
d. Install quick connector cap to quick connector connection. (Both on the engine side and the vehicle side)

• Install so that the arrow mark on the side faces up.
CAUTION:
• Check that quick connector and fuel tube are securely fit
into quick connector cap installation groove.
• If quick connector cap cannot be installed smoothly,
quick connector may have not been installed correctly.
Check the connection again.
5. Install fuel feed hose to hose clamp.
PBIC2348E

Check on Fuel Leaks
1. Apply fuel pressure to fuel lines with turning ignition switch “ON” (with the engine stopped). Then check
there are no fuel leaks at connections.
NOTE:
Use mirrors for checking on invisible points.
2. Start the engine. With engine speed increased, check again there are no fuel leaks at connections.
CAUTION:
Never touch the engine immediately after stopped as the engine becomes extremely hot.

CAMSHAFT
CAMSHAFT
A
EM
J
PBIC5364E
1. Camshaft bracket (No. 2 to 5) 2. Seal washer 3. Camshaft bracket (No. 1) K

4. front cover 5. Chain guide 6. Chain tensioner
7. Spring 8. Chain tensioner plunger 9. O-ring
Intake valve timing control solenoid L
10. 11. O-ring 12. Intake valve timing control cover
valve
13. O-ring 14. Camshaft sprocket (INT) 15. camshaft sprocket (EXH)
16. O-ring 17. Valve lifter 18. Camshaft (INT) M
19. Camshaft (EXH) 20. O-ring 21. Camshaft position sensor (PHASE)
22. Cylinder head
A. Refer to EM-39 N
Removal and Installation INFOID:0000000003397092 O
REMOVAL
NOTE: P
This section describes removal/installation procedure of camshaft without removing front cover. If front cover
is removed or installed, removal of camshaft bracket (No. 1) is easier before step 9 and installation is easier
after step 4. Regarding removal and installation of front cover, refer to EM-51.
2. Remove RH seat. Refer to SE-2.

CAMSHAFT
4. Remove drive belt. Refer to EM-16, "Removal and Installation".
5. Remove radiator shroud. Refer to CO-9, "Component".
6. Remove cooling fan. Refer to CO-16, "Component".
7. Remove ignition coil and rocker cover. Refer to EM-31, "Component".
8. Remove cam shaft position sensor (PHASE).
9. Remove intake valve timing control cover with the following procedure:
a. Disconnect intake valve timing control solenoid valve harness connector.
b. Disconnect ground cables and remove harness clip.
c. Remove intake valve timing control solenoid valve, if necessary.
CAUTION:
• Never drop or shock intake valve timing control solenoid valve.
• Never disassembly intake valve timing control solenoid valve.
d. Loosen bolts in reverse order as shown in the figure.
e. Use the seal cutter [SST: KV10111100] or suitable tool to cut liq-
uid gasket for removal.
CAUTION:
KBIA0085E
10. Pull chain guide between camshaft sprockets out through front cover.
11. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley clockwise and align TDC mark (B) to
timing indicator (A) on front cover.
C : Grooved line (white)
PBIC5365E
b. At the same time, check that the mating marks on camshaft

sprockets are located as shown in the figure.
• If not, rotate crankshaft pulley one more turn to align mating
marks to the positions in the figure.
PBIC2351E
12. Remove camshaft sprockets with the following procedure:

a. Put indelible paint marks on the timing chain link plates aligning with the mating marks on camshaft
sprockets.

CAMSHAFT
b. Push in chain tensioner plunger. Insert a stopper pin into hole on
chain tensioner body to secure chain tensioner plunger and A
remove chain tensioner.
CAUTION:
Be careful not to drop mounting bolts inside front cover.
EM
NOTE:
Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
C
KBIA0048E
D
c. Secure hexagonal part of camshaft with a wrench. Loosen cam-
shaft sprocket mounting bolts and remove camshaft sprockets.
CAUTION:
E
• Never loosen the mounting bolts with securing anything
other than the camshaft hexagonal part or with tensioning
timing chain.
• Never rotate crankshaft or camshaft while timing chain is F
removed. It causes interference between valve and piston.
NOTE:
Chain tension holding work is not necessary. Crankshaft
G
sprocket and timing chain do not disconnect structurally while
KBIA0049E
front cover is attached.
13. Remove camshaft position sensor (PHASE) from cylinder head back side.
CAUTION: H
• Handle carefully to avoid dropping and shocks.
• Never allow metal powder to adhere to magnetic part at sensor tip. I
• Never place the sensor in a location where it is exposed to magnetism.
14. Loosen mounting bolts in reverse order as shown in the figure,
and remove camshaft brackets. J
• Remove camshaft bracket (No. 1) by slightly tapping it with a
plastic hammer.
K
SBIA0255E
M
15. Remove camshafts.
16. Remove valve lifters.
• Identify installation positions, and store them without mixing them up. N
Camshaft Runout
O
1. Put V-block on a precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations. P

CAMSHAFT
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on the dial indicator. (Total indicator reading)
Standard: Less than 0.02 mm (0.0008 in).

4. If out of the standard, replace camshaft.
PBIC2499E
Camshaft Cam Height

1. Measure the camshaft cam height with a micrometer.
Standard:
Intake : 45.015 - 45.205 mm (1.7722 - 1.7797 in)
Exhaust : 43.975 - 44.165 mm (1.7313 - 1.7388 in)
Cam wear limit
: 0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.
PBIC0039E
Camshaft Journal Oil Clearance

CAMSHAFT JOURNAL DIAMETER
Measure the outer diameter of camshaft journal with a micrometer.
Standard:
No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in)
No. 2, 3, 4, 5 : 23.435 - 23.455 mm (0.9226 - 0.9234 in)
PBIC0040E
CAMSHAFT BRACKET INNER DIAMETER

• Tighten camshaft bracket bolts with the specified torque. Refer to EM-39, "Removal and Installation" for the
tightening procedure.
• Measure inner diameter “A” of camshaft bracket with a bore gauge.
Standard:
No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in)
No. 2, 3, 4, 5 : 23.500 - 23.521 mm (0.9252 - 0.9260 in)
PBIC1645E
CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter)
Standard : 0.045 - 0.086 mm (0.0018 - 0.0034 in)

CAMSHAFT
• If out of the standard, replace either or both camshaft and cylinder head.
NOTE: A
Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder
head. Replace whole cylinder head assembly.
Camshaft End Play EM
1. Install camshaft in cylinder head. Refer to EM-39, "Removal and Installation" for tightening procedure.
2. Install a dial indicator in thrust direction on front end of camshaft.
Measure the camshaft end play on the dial indicator when cam- C
shaft is moved forward/backward (in direction to axis).
Standard : 0.115 - 0.188 mm (0.0045 - 0.0074 in) D
PBIC2446E
F
• Measure the following parts if out of the standard.
- Dimension “A” for camshaft No. 1 journal
G
Standard : 25.800 - 25.848 mm (1.0157 - 1.0176 in)
- Dimension “B” for cylinder head No. 1 journal bearing
H
Standard : 25.660 - 25.685 mm (1.0102 - 1.0112 in)
• Refer to the standards above, and then replace camshaft and/
or cylinder head. I
KBIA2426J
Camshaft Sprocket Runout

J
1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations. K
2. Measure the camshaft sprocket runout with a dial indicator.
(Total indicator reading)
L
Limit : 0.15 mm (0.0059 in)
• If it exceeds the limit, replace camshaft sprocket. M
N
PBIC0930E
Valve Lifter O
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-48,
"Valve Clearance".
P
KBIA0182E

CAMSHAFT
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter with a micrometer.
Standard : 33.977 - 33.987 mm (1.3377 - 1.3381 in)
JEM798G
VALVE LIFTER HOLE DIAMETER

Measure the diameter of valve lifter hole of cylinder head with an
inside micrometer.
Standard : 34.000 - 34.021 mm (1.3386 - 1.3394 in)
PBIC0043E
VALVE LIFTER CLEARANCE

• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
Standard : 0.013 - 0.044 mm (0.0005 - 0.0017 in)

• If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diame-
ter, replace either or both valve lifter and cylinder head.
INSTALLATION
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
• Distinction between intake and exhaust camshafts is per-
formed with the different shapes of rear end.
Intake : Signal plate shape for camshaft position

sensor (PHASE)
Exhaust : Cone end shape
KBIA0246E

CAMSHAFT
• Install camshafts so that camshaft dowel pins on the front side
are positioned as shown in the figure. A
EM
KBIA0051E
D
3. Install camshaft brackets with the following procedure:
a. Remove foreign material completely from camshaft bracket backside and from cylinder head installation
face. E
b. Install camshaft brackets (No. 2 to 5) aligning the identification
marks on upper surface as shown in the figure.
NOTE:
F
Install so that identification mark can be correctly read when
viewed from the exhaust side.
H
SBIA0256E
c. Install camshaft bracket (No. 1) with the following procedure: I

i. Apply liquid gasket to camshaft bracket (No. 1) as shown in the
figure.
CAUTION: J
After installation, be sure to wipe off any excessive liquid
gasket leaking from part “A”.
K
L
PBIC2579E
ii. Apply liquid gasket to camshaft bracket (No. 1) contact surface

on the front cover backside. M
• Apply liquid gasket to the outside of bolt hole on front cover.
N
SBIA0258E
P

CAMSHAFT
iii. Locate camshaft bracket (No. 1) near installation position, and
install it without disturbing the liquid gasket applied to the sur-
faces.
PBIC2641E
4. Tighten mounting bolts of camshaft brackets in the following

steps, in numerical order as shown in the figure.
a. Tighten No. 9 to 11 in numerical order.
: 1.96 N·m (0.2 kg-m, 1 ft-lb)

b. Tighten No. 1 to 8 in numerical order.
: 1.96 N·m (0.2 kg-m, 1 ft-lb)

c. Tighten all bolts in numerical order. SBIA0255E
: 5.88 N·m (0.6 kg-m, 4 ft-lb)

d. Tighten all bolts in numerical order.
: 10.4 N·m (1.1 kg-m, 8 ft-lb)

CAUTION:
After tightening mounting 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 (When installed without front cover)
5. Install camshaft position sensor (PHASE).
6. Install camshaft sprockets.
• Install them by aligning the mating marks on each camshaft
sprocket with the paint marks on the timing chain link plates
during removal.
CAUTION:
• Aligned mating marks could slip. Therefore, after match-
ing them, hold the timing chain in place by hand.
• Before and after installing chain tensioner, check again
that mating marks have not slipped.
NOTE:
Before installation of chain tensioner, it is possible to re-match
the marks on timing chain with the ones on each sprocket.
PBIC2351E
7. Install chain tensioner.
CAUTION:
After installation, pull the stopper pin off completely, and check that chain tensioner plunger is
released.
8. Install chain guide.
9. Install intake valve timing control cover with the following procedure:
a. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control
cover.
b. Install O-ring to front cover.

CAMSHAFT
c. Apply liquid gasket with the tube presser (commercial service
tool) to intake valve timing control cover as shown in the figure. A
EM
SBIA0260E
D
d. Tighten mounting bolts in numerical order as shown in the fig-
ure.
E
G
KBIA0085E
e. Install intake valve timing control solenoid valve to intake valve timing control cover if removed.
H
f. Connect ground cables, and install harness clip.
10. Check and adjust valve clearance. Refer to EM-48, "Valve Clearance".
11. Install in the reverse order of removal after this step. I
Inspection of Camshaft Sprocket (INT) Oil Groove J
CAUTION:
• Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-78, "Description".
• Check when the engine is cold so as to prevent burns from any splashing engine oil. K
1. Check the engine oil level. Refer to LU-4.
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking. L
a. Release fuel pressure. Refer to EC-37, "Fuel Pressure Check".
b. Disconnect ignition coil and injector harness connectors.
M
3. Remove intake valve timing control solenoid valve. Refer to EM-39.
4. Crank the engine, and then check that engine oil comes out
from intake valve timing control cover oil hole. End crank after
checking. N
WARNING:
Be careful not to touch rotating parts (drive belt, idler pul-
ley, and crankshaft pulley, etc.). O
CAUTION:
Engine oil may squirt from intake valve timing control sole-
noid valve installation hole during cranking. Use a shop P
cloth to prevent the engine components and the vehicle.
Never allow engine oil to get on rubber components such PBIC2723E
as drive belt or engine mount insulators. Immediately wipe
off any splashed engine oil.
• Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not
come out from intake valve timing control cover oil hole. Refer to LU-3.

CAMSHAFT
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-3.
6. After inspection, install removed parts.
Valve Clearance INFOID:0000000003397093
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Warm up engine thoroughly. Then, stop it.
2. Remove rocker cover. Refer to EM-31, "Component".
4. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley clockwise and align TDC mark (B) to
PBIC5365E
• At the same time, check that both intake and exhaust cam noses of No. 1 cylinder face outside as
shown in the figure.
• If they do not face outside, rotate crankshaft pulley once more (360 degrees) and align as shown in the
figure.
b. Use a feeler gauge, measure the clearance between valve lifter

and camshaft.
SEM139D
Valve clearance:
Unit: mm (in)
Cold (reference data) Hot *

Intake 0.24 - 0.32 (0.009 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*:Approximately 80°C (176°F)
• By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table
below (locations indicated with black arrow in the figure) with a feeler gauge.

CAMSHAFT
• No. 1 cylinder compression TDC
A
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
No. 1 cylinder at INT × ×

compression TDC EXH × × EM
PBIC2624E
D
c. Rotate crankshaft pulley one revolution (360 degrees) and align
TDC mark (B) to timing indicator (A) on front cover.
C : Grooved line (white) E
G
PBIC5365E
• By referring to the figure, measure the valve clearance at locations marked “×” as shown in the table
H
below (locations indicated with black arrow in the figure) with a feeler gauge.
• No. 4 cylinder compression TDC

I
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
No. 4 cylinder at INT × ×

J
compression TDC EXH × ×
PBIC2625E
L
5. If out of standard, perform adjustment. Refer to "ADJUSTMENT".
ADJUSTMENT
• Perform adjustment depending on selected head thickness of valve lifter. M
1. Remove camshaft. Refer to EM-39, "Removal and Installation".
2. Remove valve lifters at the locations that are out of the standard.
N
3. Measure the center thickness of the removed valve lifters with a
micrometer.
O
KBIA0057E
4. Use the equation below to calculate valve lifter thickness for replacement.

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

t = Valve lifter thickness to be replaced
t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.28 mm (0.011 in)
Exhaust : 0.30 mm (0.012 in)
• Thickness of new valve lifter can be identified by stamp mark
on the reverse side (inside the cylinder).
Stamp mark “696” indicates 6.96 mm (0.2740 in) in thickness.
KBIA0119E
NOTE:
Available thickness of valve lifter: 26 sizes range 6.96 to 7.46 mm (0.2740 to 0.2937 in) in steps of 0.02
mm (0.0008 in) (when manufactured at factory). Refer to EM-105, "Standard and Limit".
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-39, "Removal and Installation".
7. Manually rotate crankshaft pulley a few rotations.
8. Check that valve clearances for cold engine are within specifications by referring to the specified values.
Refer to "INSPECTION".
9. Install all removed parts in the reverse order of removal.
10. Warm up the engine, and check for unusual noise and vibration.

TIMING CHAIN
TIMING CHAIN
A
EM
L
PBIC5366E
1. Camshaft sprocket (INT) 2. Camshaft sprocket (EXH) 3. Chain tensioner M

4. Spring 5. Chain tensioner plunger 6. Timing chain slack guide
7. Timing chain 8. Front cover 9. Chain guide
Intake valve timing control solenoid N
10. Intake valve timing control cover 11. 12. O-ring
valve
13. O-ring 14. O-ring 15. Crankshaft pulley bolt
16. Crankshaft pulley 17. Front oil seal 18. Balancer unit timing chain
O
19. Balancer unit sprocket 20. Balancer unit 21. O-ring
22. Timing chain tension guide 23. Balancer unit timing chain tensioner 24. Oil pump drive spacer
25. Crankshaft sprocket 26. O-ring 27. O-ring
P
A. Refer to EM-51

REMOVAL
1. Remove the following parts.

TIMING CHAIN
• Undercover
• Engine room right side cover: Refer to EM-14, "Component".
• PCV hose: Refer to EM-22.
• Ignition coil: Refer to EM-31, "Component".
• Remove A/C compressor and bracket: Refer to MTC-69, "Removal and Installation for Compressor".
• Rocker cover: Refer to EM-31, "Component".
• Drive belt: Refer to EM-16, "Removal and Installation".
• Radiator shroud: Refer to CO-9, "Component".
• Cooling fan and fan pulley bracket: Refer to CO-16, "Component".
• Drive belt auto-tensioner and idler pulley: Refer to EM-17, "Removal and Installation of Drive Belt Auto
Tensioner".
CAUTION:
Perform this step when the engine is cold.
3. Remove power steering oil pump with piping connected, and secure it to the vehicle side temporarily.
Refer to PS-16, "Component".
4. Remove oil pan. Refer to EM-28.
5. Remove intake valve timing control cover. Refer to EM-39, "Component".
6. Pull chain guide between camshaft sprockets out through front cover.
7. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley clockwise and align TDC mark (B) to
PBIC5365E
b. At the same time, check that the mating marks on camshaft

sprockets are located as shown in the figure.
• If not, rotate crankshaft pulley once more (360 degrees) to
align mating marks to the positions in the figure.
PBIC2351E
8. Remove crankshaft pulley with the following procedure:

a. Fix crankshaft pulley with a pulley holder (commercial service
tool), loosen crankshaft pulley bolt, and locate bolt seating sur-
face at 10 mm (0.39 in) from its original position.
PBIC2434E

TIMING CHAIN
b. Attach a pulley puller (commercial service tool) in the M 6 thread
hole on crankshaft pulley, and remove crankshaft pulley. A
EM
PBIC2709E
D
9. Remove front cover with the following procedure:
a. Loosen mounting bolts in reverse order as shown in the figure.
b. Use the seal cutter [SST: KV10111100] or suitable tool to cut liq- E
uid gasket for removing front cover.
CAUTION:
F
c. Pull out downward front cover.
K
PBIC5367E
10. Remove front oil seal from front cover using suitable tool.
CAUTION: L
Be careful not to damage front cover.
11. Remove timing chain with the following procedure:
a. Push in chain tensioner plunger. Insert a stopper pin into hole on M
chain tensioner body to secure chain tensioner plunger and
remove chain tensioner.
NOTE: N
Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a
stopper pin.
KBIA0048E P

TIMING CHAIN
b. Secure hexagonal part of camshaft with a wrench. Loosen cam-
shaft sprocket mounting bolts and remove timing chain and
camshaft sprockets.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.
12. Remove timing chain slack guide, timing chain tension guide
and oil pump drive spacer.
13. Remove balancer unit timing chain tensioner with the following
procedure:
KBIA0049E
a. Press stopper tab (A) in the direction shown in the figure to push
the timing chain slack guide (B) toward timing chain tensioner
(for oil pump) (1).
• The slack guide is released by pressing the stopper tab. As
the result, the slack guide can be moved.
b. Insert a stopper pin (D) into tensioner body hole (C) to secure
the timing chain slack guide.
NOTE:
Use a hard metal pin with the diameter of approximately 1.2 mm
(0.047 in) as a stopper pin.
c. Remove balancer unit timing chain tensioner.
• When the holes on lever and tensioner body cannot be
aligned, align these holes by slightly moving the slack guide.
PBIC5368E
14. Remove balancer unit timing chain and crankshaft sprocket.

15. Loosen mounting bolts in reverse order as shown in the figure,
and remove balancer unit.
: Engine front
CAUTION:
Never disassemble balancer unit.
PBIC5369E

Timing Chain

TIMING CHAIN
Check timing chain for cracks and any excessive wear at the roller
links of timing chain. Replace timing chain if necessary. A
EM
PBIC0282E
D
Balancer Unit Mounting Bolt Outer Diameter
• Measure outer diameters (“d1”, “d2”) at two positions as shown in
the figure.
• If reduction appears in “A” range, regard it as “d2”. E
Limit (“d1” – “d2”) : 0.15 mm (0.0059 in)

• If it exceeds the limit (large difference in dimensions), replace bal- F
ancer unit mounting bolt with a new one.
G
PBIC1137E
INSTALLATION H
NOTE:
The figure shows the relationship between the mating mark on each
timing chain and that on the corresponding sprocket, with the com-
ponents installed. I
1. Check that crankshaft key points straight up.
J
PBIC3029E
O

TIMING CHAIN
2. Tighten mounting bolts in numerical order as shown in the figure
with the following procedure to install balancer unit.
: Engine front
CAUTION:
If mounting bolts are reused, check their outer diameter
before installation. Refer to EM-51, "Removal and Installa-
tion".
a. Apply new engine oil to threads and seat surfaces of mounting
bolts.
PBIC5369E
b. Tighten No. 1 to No. 4 bolts.
: 48.1 N·m (4.9 kg-m, 35 ft-lb)
c. Turn No. 1 to No. 4 bolts 100 degrees clockwise (angle tighten-

ing).
1 : Balancer unit
CAUTION:
Check tightening angle with the angle wrench [SST:
KV10112100] (A) or a protractor. Never make judgment by
visual check alone.
d. Completely loosen.
PBIC5383E
: 0 N·m (0 kg-m, 0 ft-lb)
CAUTION:
In this step, loosen bolts in reverse order as shown in the figure.
e. Tighten No. 1 to No. 4 bolts.
: 48.1 N·m (4.9 kg-m, 35 ft-lb)
f. Turn them another 100 degrees clockwise (angle tightening).

g. Tighten No. 5 to No. 6 bolts.
: 30.9 N·m (3.2 kg-m, 23 ft-lb)

3. Install crankshaft sprocket and balancer unit timing chain.
• Check that crankshaft sprocket is positioned with mating
marks on cylinder block and crankshaft sprocket meeting at
the top.
• Install it by aligning mating marks on each sprocket and bal-
ancer unit timing chain.
PBIC2183E
4. Install balancer unit timing chain tensioner.

• Be careful not to let mating marks of each sprocket and timing chain slip.
• After installation, check the mating marks have not slipped, then remove stopper pin and release ten-
sioner sleeve.
5. Install timing chain and related parts.

TIMING CHAIN
• Install by aligning mating marks on each sprocket and timing
chain. A
• Before and after installing chain tensioner, check again to
check that mating marks have not slipped.
• After installing chain tensioner, remove stopper pin, and check
EM
that tensioner moves freely.
CAUTION:
• For the following note, after the mating marks are
aligned, keep them aligned by holding them with a hand. C
• To avoid skipped teeth, never rotate crankshaft and
camshaft until front cover is installed.
NOTE: D
Before installing chain tensioner, it is possible to change the
position of mating mark on timing chain for that on each
sprocket for alignment.
E
G
PBIC3029E
6. Install front oil seal to front cover. Refer to EM-60, "Removal and Installation of Front Oil Seal".
H
7. Install front cover with the following procedure:
a. Install O-rings to cylinder head and cylinder block.
b. Apply a continuous bead of liquid gasket with the tube presser
I
(commercial service tool) to front cover as shown in the figure.
NOTE:
Application instruction differs depending on the position. J
A : Cross over the start of the application and the

end. K
B : Apply liquid gasket outside of bolt holes. (For all
bolt holes other than B, apply to the inside.)
C : Between here only application. L
d : 2.6 - 3.6 mm (0.102 - 0.142 in)
e : 295.6 mm (11.64 in)
M
f : 5.0 mm (0.197 in)
g : 4.5 - 5.5 mm (0.177 - 0.217 in)
N
O
PBIC5370E
c. Check that mating marks of timing chain and each sprocket are still aligned. Then install front cover.
P
• When installing, align flat faces at oil pump drive spacer and oil pump inner rotor.
CAUTION:
Be careful not to damage front oil seal by interference with front end of crankshaft.

TIMING CHAIN
d. Tighten mounting bolts in numerical order as shown in the fig-
ure.
• Refer to the following for locating M6 bolts.
Bolt length: Bolt position

45 mm (1.77 in) : 5, 10, 14, 17
20 mm (0.79 in) : Except the above (Except 1 to 4)
• At the same time, install RH engine mounting bracket. (Bolt
positions 1 to 4 in the figure)
e. After all bolts are tightened, retighten them to the specified
torque in numerical order as shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket leaking to
surface for fitting oil pan (upper).
PBIC5367E
8. Install chain guide between camshaft sprockets.

9. Install intake valve timing control cover with. Refer to EM-39, "Component".
a. Install intake valve timing control solenoid valve to intake valve timing control cover if removed.
b. Connect ground cables, and install harness clip.
10. Insert crankshaft pulley by aligning with crankshaft key.
• When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Install protecting front oil seal lip section from any damage.
11. Tighten crankshaft pulley bolt with the following procedure.
• Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley
bolt.
a. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
b. Tighten crankshaft pulley bolt.
: 42.1 N·m (4.3 kg-m, 31 ft-lb)

c. Put a paint mark on crankshaft pulley, mating with any one of six
easy to recognize angle marks on bolt flange.
d. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
SEM751G
12. Install all removed parts in the reverse order of removal.

Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

TIMING CHAIN
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "Fluids and Lubricants". A
• Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
EM
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may C
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including D
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary. E
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
F
Engine oil Level Leakage Level

Other oils and fluid* Level Leakage Level G
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
* Transmission/transaxle, power steering fluid, brake fluid, etc. H

OIL SEAL
OIL SEAL
Removal and Installation of Valve Oil Seal INFOID:0000000003397096
REMOVAL
1. Remove camshafts. Refer to EM-39.
2. Remove valve lifters. Refer to EM-39.
3. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder.
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
4. Remove valve collet.
• Compress valve spring with the valve spring compressor, the
attachment and the adapter (SST). Remove valve collet with a
magnet hand.
CAUTION:
When working, be careful not to damage valve lifter holes.
PBIC1791E
5. Remove valve spring retainer and valve spring.

CAUTION:
Never remove valve spring seat from valve spring.
6. Remove valve oil seal with the valve oil seal puller (SST).
SEM093F
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the height “H” shown in the figure with
the valve oil seal drift (SST).
Height “H” : 11.8 - 12.4 mm (0.465 - 0.488 in)
KBIA1999J

Removal and Installation of Front Oil Seal INFOID:0000000003397097
REMOVAL

OIL SEAL
• Undercover A
• Drive belt: Refer to EM-16.
• Cooing fan: Refer to CO-16, "Component".
EM
• Crankshaft pulley: Refer to EM-51.
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft. C
INSTALLATION
D
1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in
the figure.
E
SEM715A
H
• Press-fit front oil seal until it is flush with front end surface of
front cover with a suitable tool.
CAUTION:
• Be careful not to damage front cover and crankshaft. I
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
J
K
SBIA0266E

L
Removal and Installation of Rear Oil Seal INFOID:0000000003397098
REMOVAL M
1. Remove transaxle assembly. Refer to MT-28, "Removal and Installation".
2. Remove clutch cover and clutch disk. Refer to CL-11, "Removal and Installation".
3. Remove flywheel. Refer to EM-78. N
4. Remove rear oil seal with a suitable tool.
CAUTION:
Be careful not to damage crankshaft and cylinder block. O
INSTALLATION
1. Apply new engine oil to new rear oil seal joint surface and seal lip. P

OIL SEAL
2. Install rear oil seal so that each seal lip is oriented as shown in
the figure.
SEM715A
• Press in rear oil seal to the position as shown in the figure.
SBIA0281E
• Press-fit rear oil seal with a suitable drift [outside diameter 102
mm (4.02 in), inside diameter 86 mm (3.39 in)].
CAUTION:
• Be careful not to damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt-
ing.
• Never touch grease applied onto oil seal lip.
SBIA0280E

CYLINDER HEAD
CYLINDER HEAD
A
On-Vehicle Service INFOID:0000000003397099
CHECKING COMPRESSION PRESSURE EM

3. Disconnect fuel pump fuse to avoid fuel injection during measurement. Refer to EC-47, "Engine Control C
Component Parts Location" (TYPE 1) or EC-173, "Engine Control Component Parts Location" (TYPE 2).
4. Remove ignition coil and spark plug from each cylinder. Refer to EM-31, "Component".
D
5. Connect an engine tachometer (not required in use of CONSULT-III).
6. Install a compression tester with an adapter (commercial service
tool) onto spark plug hole.
E
KBIA0130E
H
• Use the adapter whose picking up end inserted to spark plug
hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it
may be caught by cylinder head during removal.
I
K
SBIA0533E
7. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each L
cylinder.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/rpm
M
Standard Minimum Differential limit between cylinders

1,412 (14.1, 14.4, 204.7)/250 1,216 (12.2, 12.4, 176.3)/250 100 (1.0, 1.0, 14.5)/250 N
CAUTION:
Always use fully a charged battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine O
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 the compression pressure again. P
• If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole
of the cylinder to recheck it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.

CYLINDER HEAD
• If two adjacent cylinders have respectively low compression pressure and their compression remains
low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder
head gasket.
8. After inspection is completed, install removed parts.
9. Start the engine, and confirm that the engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-38, "Trouble Diagnosis Introduction".
PBIC2185E
1. Cylinder head assembly 2. Cylinder head gasket 3. Cylinder head bolt
REMOVAL
2. Drain engine coolant and engine oil. Refer to CO-6, "Changing Engine Coolant" and LU-5, "Changing
Engine Oil".
CAUTION:
• Perform this step when the engine is cold.
• Never spill engine coolant and engine oil on drive belt.
3. Remove the following components and related parts.
• Exhaust manifold and three way catalyst assembly: Refer to EM-26.
• Intake manifold and fuel tube assembly: Refer to EM-22.
• Heater outlet: Refer to CO-17, "Component".
NOTE:
Can be removed and installed even when assembled with cylinder head.
4. Remove front cover and timing chain. Refer to EM-51.
5. Remove camshafts. Refer to EM-39.

CYLINDER HEAD
6. Remove cylinder head loosening bolts in reverse order as
shown in the figure. A
7. Remove cylinder head gasket.
EM
KBIA0058E
D
Cylinder Head Bolts Outer Diameter
• Cylinder head bolts are tightened by plastic zone tightening E
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with a new one.
Limit (“d1” – “d2”): 0.23 mm (0.0091 in) F
• If reduction of outer diameter appears in a position other than “d2”,

use it as “d2” point.
G
SBIA0269E H
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-94, "Inspec- I
tion After Disassembly".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION: J
Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions. K
Limit : 0.1 mm (0.004 in)
• If it exceeds the limit, replace cylinder head. L
PBIC0075E
N
INSTALLATION
1. Install new cylinder head gasket.
2. Tighten cylinder head bolts in numerical order as shown in the O
figure with the following procedure to install cylinder head.
CAUTION:
If cylinder head bolts are reused, check their outer diame- P
ters before installation. Refer to EM-64, "Removal and
Installation".
a. Apply new engine oil to threads and seating surfaces of mount-
ing bolts.
b. Tighten all bolts.
KBIA0058E

CYLINDER HEAD
: 50.0 N·m (5.1 kg-m, 37 ft-lb)

c. Turn all bolts 60 degrees clockwise (angle tightening).
CAUTION:
Check and confirm the tightening angle by using the angle
wrench (SST) or protractor. Avoid judgment by visual
inspection without the tool.
d. Completely loosen.
: 0 N·m (0 kg-m, 0 ft-lb)

CAUTION:
In this step, loosen bolts in reverse order of that indicated
in the figure.
e. Tighten all bolts. KBIA0059E
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
f. Turn all bolts 75 degrees clockwise (angle tightening).

g. Turn all bolts 75 degrees clockwise again (angle tightening).
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "Fluids and Lubricants".
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
* Transmission/transaxle, power steering fluid, brake fluid, etc.

CYLINDER HEAD
EM
PBIC5433E
I
1. Valve collet 2. Valve spring retainer 3. Valve spring (with valve spring seat)
4. Valve oil seal 5. Valve guide (EXH) 6. Valve guide (INT)
7. Cylinder head 8. Valve seat (INT) 9. Valve (INT) J
10. Valve (EXH) 11. Valve seat (EXH) 12. Spark plug tube

K
Disassembly and Assembly INFOID:0000000003397103
DISASSEMBLY L
1. Remove spark plug with a spark plug wrench (commercial service tool).
2. Remove valve lifter.
• Identify installation positions, and store them without mixing them up. M
3. Remove valve collet.
attachment and the adapter (SST). Remove valve collet with a N
magnet hand.
CAUTION:
O
PBIC1791E
4. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
5. Push valve stem to combustion chamber side, and remove valve.

CYLINDER HEAD
• Identify installation positions, and store them without mixing them up.
6. Remove valve oil seal with the valve oil seal puller (SST).
SEM093F
7. When valve seat must be replaced, refer to EM-69, "Inspection After Disassembly" to removal.
8. When valve guide must be replaced, refer to EM-69, "Inspection After Disassembly" to removal.
9. Remove spark plug tube, if necessary.
• Using pliers, remove it from cylinder head.
CAUTION:
• Be careful not to damage cylinder head.
• Never remove spark plug tube if not necessary. Once removed, spark plug tube cannot be
reused because of deformation.
ASSEMBLY
1. Install valve guide if removed. Refer to EM-69, "Inspection After Disassembly".
2. Install valve seat if removed. Refer to EM-69, "Inspection After Disassembly".
3. Install valve oil seal.
• Install with the valve oil seal drift (SST) to match dimension in
the figure.
Height “H” : 11.8 - 12.4 mm (0.465 - 0.488 in)
KBIA1999J
4. Install valve.
• Install larger diameter to intake side.
5. Install valve spring (with valve spring seat).
• Install smaller pitch (valve spring seat side) to cylinder head
side.
• Confirm identification color of valve spring.
Intake : Pink
Exhaust : Yellowish green
PBIC0525E
6. Install valve spring retainer.

7. Install valve collet.

CYLINDER HEAD
attachment and the adapter (SST). Install valve collet with a A
magnet hand.
CAUTION:
EM
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
PBIC1791E
D
8. Install valve lifter.
9. Install spark plug tube if removed.
• Press-fit it into cylinder head with the following procedure: E
a. Remove old sealant from cylinder head side installation hole.
b. Apply sealant all round on spark plug tube within approximately
12 mm (0.47 in) width from edge of spark plug tube on the F
press-fit side.
Use high strength thread locking sealant or equivalent.
c. Using a drift, press-fit spark plug tube so that height is as same G
as “H” shown in the figure.
Standard press-fit height “H”:

H
41.2 - 42.2 mm (1.622 - 1.661 in)
CAUTION: PBIC2713E
• When press-fitting, be careful not to deform spark plug I
tube.
• After press-fitting, wipe off any protruding sealant on top surface of cylinder head.
10. Install spark plug with a spark plug wrench (commercial service tool). J
Inspection After Disassembly INFOID:0000000003397104
VALVE DIMENSIONS K
• Check dimensions of each valve. For dimensions, refer to EM-105,
"Standard and Limit".
• If dimensions are out of the standard, replace valve. L
N
SEM188A
VALVE GUIDE CLEARANCE

O
Valve Stem Diameter

CYLINDER HEAD
Measure the diameter of valve stem with a micrometer.
Standard
Intake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in)
SEM938C
Valve Guide Inner Diameter

Measure the inner diameter of valve guide with a bore gauge.
Standard
Intake and Exhaust
: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
Valve Guide Clearance
(Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter).
Valve guide clearance:

Standard
Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in)
Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in)
Limit
Intake : 0.08 mm (0.0031 in)
Exhaust : 0.09 mm (0.0035 in)
• If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced, refer to "VALVE
GUIDE REPLACEMENT".
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.
SEM008A
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.0 lmp
ton) force] or hammer and valve guide drift (commercial service
tool).
WARNING:
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
SEM931C

CYLINDER HEAD
3. Ream cylinder head valve guide hole with a valve guide reamer
(commercial service tool). A
Valve guide hole diameter (for service parts):

Intake and exhaust EM
: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
D
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil.
E
G
SEM008A
5. Using a valve guide drift (commercial service tool), press valve H

guide from camshaft side to dimensions as shown in the figure.
Projection “H”:
I
Intake : 10.1 - 10.3 mm (0.398 - 0.406 in)
Exhaust : 10.0 - 10.4 mm (0.394 - 0.409 in)
WARNING: J
Cylinder head contains heat, when working, wear protective
equipment to avoid getting burned.
PBIC2187E
K
6. Apply reamer finish to valve guide with a valve guide reamer

(commercial service tool). L
Standard
Intake and exhaust: M
6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
VALVE SEAT CONTACT O

• After confirming that the dimensions of valve guides and valves are within specifications, perform this proce-
dure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve P
contact on the surface.

CYLINDER HEAD
• Check if the contact area band is continuous all around the circum-
ference.
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has NG conditions even after the recheck, replace
valve seat. Refer to "VALVE SEAT REPLACEMENT".
SBIA0322E
VALVE SEAT REPLACEMENT

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-105, "Standard and Limit".
CAUTION:
Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat.
Oversize [0.5 mm (0.020 in)]

Intake : 37.000 - 37.016 mm (1.4567 - 1.4573 in)
Exhaust : 32.000 - 32.016 mm (1.2598 - 1.2605 in)
• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
SEM795A
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil.
SEM008A
4. Provide valve seats cooled well with a dry ice. Press-fit valve seats into cylinder head.
WARNING:
Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
CAUTION:
Avoid directly to touching cold valve seats.
5. Using a valve seat cutter set (commercial service tool) or a valve

seat grinder, finish valve seat to the specified dimensions. For
dimensions, refer to EM-105, "Standard and Limit".
CAUTION:
When using a valve seat cutter, firmly grip the cutter handle
with both hands. Then, press on the contacting surface all
around the circumference to cut in a single drive. Improper
pressure on with the cutter or cutting many different times
may result in stage valve seat.
SEM934C

CYLINDER HEAD
6. Using compound, grind to adjust valve fitting.
A
7. Check again for normal contact. Refer to "VALVE SEAT CONTACT".
VALVE SPRING SQUARENESS
• Set a try square along the side of valve spring and rotate valve EM
spring. Measure the maximum clearance between the top of valve
spring and try square.
CAUTION:
Never remove valve spring seat from valve spring. C
Limit : 1.9 mm (0.075 in)

• If it exceeds the limit, replace valve spring (with valve spring seat). D
PBIC0080E E
VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD
• Check valve spring pressure with valve spring seat installed at the
specified spring height. F
CAUTION:
G
SEM113
I
Standard:
Items Intake Exhaust
Free height 43.72 - 43.92 mm (1.7213 - 1.7291 in) 45.29 - 45.49 mm (1.7831 - 1.7909 in) J
Installation height 35.30 mm (1.3898 in) 35.30 mm (1.3898 in)
Installation load 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb) 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb)
K
Height during valve open 25.30 mm (0.9961 in) 26.76 mm (1.0535 in)
Load with valve open 351 - 394 N (35.8 - 40.2 kg, 79 - 89 lb) 318 - 362 N (32.4 - 36.9 kg, 71 - 81 lb)
Identification color Pink Yellowish green L
• If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring
seat).
M

ENGINE ASSEMBLY
ENGINE ASSEMBLY
PBIC5371E
1. Rear engine mounting insulator 2. Rear engine mounting bracket 3. Engine mounting bracket (RH)
4. Engine mounting insulator (RH) 5. Engine mounting bracket (LH) 6. Engine mounting insulator (LH)

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.
• Never start working until exhaust system and engine coolant are cool enough.
• For work items that are not covered by the engine main body section, refer to the applicable sec-
tions.
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking points, refer to GI-34, "Garage Jack and Safety Stand".
REMOVAL
Outline
Remove engine and transmission assembly with suspension member downwards. Then separate engine from
transmission.
Preparation
1. Remove floor cover behind RH and LH seats. Refer to EI-17, "Component".

ENGINE ASSEMBLY
2. Open and fix engine compartment left side cover and secure it. Refer to EM-14, "Component".
3. Remove front RH seat. Refer to SE-2. A
4. Remove engine compartment right side cover. Refer to EM-14.
EM
6. Open fuel filler cap, and release internal pressure of fuel tank.
7. Disconnect battery negative terminal.
8. Drain engine coolant. Refer to CO-6, "Changing Engine Coolant". C
9. Remove following parts.
• Undercover
• Front wheels (RH and LH)
• Drive belts. Refer to EM-16, "Removal and Installation". D
• Reservoir tank, radiator shroud, and radiator. Refer to CO-9.
10. Disconnect engine harness at ECM side. Temporarily fix it on engine upper side.
E
Engine room LH
11. Disconnect harness between vehicle and engine.
Engine room RH
F
12. Disconnect PCV hose and air duct. Refer to EM-19, "Component".
13. Disconnect fuel feed hose on engine side, and move them aside. Refer to EM-34, "Component".
CAUTION: G
Plug disconnected hoses to prevent fuel leakage.
14. Disconnect heater hose from heater pipe, and plug hose to prevent engine coolant leakage. Refer to CO-
17, "Component".
H
15. Disconnect all hoses (vacuum hose, water hose, EVAP hose and others) connected to vehicle at engine
side.
16. Remove power steering oil pump from engine. Temporarily fix it on vehicle with rope in a manner in which
I
excessive load is applied to piping. Refer to PS-16, "Component".
Engine room RR
17. Disconnect S and B terminals from starter motor, and move harness to vehicle. Refer to SC-26, "Removal J
and Installation (QR25DE)".
18. Disconnect engine ground attached to upper front end of transmission, at vehicle side.
Vehicle underbody K
19. Remove power steering piping bracket. Refer to PS-16, "Component".
20. Remove air conditioner compressor from bracket, and temporarily fix it aside. Refer to MTC-68.
21. Remove exhaust front tube, and bracket on transmission side. Refer to EX-3, "Component". L
22. Remove rear propeller shaft. Refer to PR-2.
23. Remove air breather hose from transmission. Refer to MT-27, "Removal and Installation".
24. Remove clutch operating cylinder from transmission, and temporarily fix it aside. Refer to CL-9. M
25. Remove shift control wires from transmission, and temporarily fix them aside. Refer to MT-7.
26. Disconnect engine coolant piping for rear heater between vehicle and engine and transmission assembly
(vehicle with rear heater). N
27. Remove brake caliper from steering knuckle. Temporarily secure brake hose on body with rope to avoid
putting a load on it. Refer to BR-17.
28. Remove stabilizer from vehicle. Refer to FSU-6, "Component". O
29. Remove suspension lower arm on suspension member side and damper lower end side, to free it
together with steering knuckle. Refer to FSU-6, "Component".
P
Removal
30. Securely support bottom surface of engine and transmission with two transmission jacks.
CAUTION:
• Make lifting height minimal where work under vehicle can be performed. Reserve gap for lifting
up (height where engine upper part protrudes above vehicle bottom).
• Take fixing measures as necessary so that jack does not slip from supporting surface. (The fig-
ure shows fixing with a rope as an example.)

ENGINE ASSEMBLY
31. Pull out rear engine mounting through-bolt from upper surface of transmission.
32. Remove suspension member mounting bolts. Refer to FSU-6, "Component".
33. Carefully lift up vehicle, and remove engine and transmission assembly from vehicle.
NOTE:
The figure shows an example with the vehicle front and rear
supported by a 2-pole lift and using two transmission jacks.
(Vehicle rear is not shown in the figure.)
CAUTION:
• Check that no part interferes with vehicle.
• Check that every part is connected.
• Check that vehicle does not fall off by shifting of center of
gravity of vehicle, or counter-action. (Refer to “CAUTION
EM-74, "Removal and Installation"” in the beginning.)
[Disassemble work]
• On level ground, separate engine and transmission in the following KBIA0893E
procedure.
CAUTION:
During operation, securely support engine by placing pieces of wood under engine oil pan, transmis-
sion oil pan, and suspension member, and suspend engine slings from a hoist.
34. Install engine slingers into front left of cylinder head and rear right of cylinder head.
• Use alternator bracket mounting bolt holes for the front side.
Slinger bolts
Cylinder head side : 28.0 N·m (2.9 kg-m, 21 ft-lb)
Front cover side : 45.0 N·m (4.6 kg-m, 33 ft-lb)
35. Remove engine and transmission assembly from suspension
member.
CAUTION:
Securely support engine by placing pieces of wood under
SBIA0271E
bottom surface.
36. Remove starter motor. Refer to SC-22.
37. Separate engine and transmission. Refer to MT-9.
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.
• Do not allow oil to adhere to mount insulators. Be careful not to damage mount insulators.
• Be sure that each mount insulator is not twisted, and has uneven thickness at right and left when it is
installed.
The following are procedures for checking fluids leak, lubricates leak exhaust gases leak.
• Before starting engine, check the levels of engine coolant, engine oil, working fluid, and of air conditioner
refrigerant. If less than required quantity, fill to the specified level.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
• Warm up engine thoroughly to check there is no leakage of engine coolant, engine oil, working fluid, fuel and
exhaust gas.
• Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
• After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to

ENGINE ASSEMBLY
Inspection:
Items Before starting engine Engine running After engine stopped A
EM
Working fluid Level Leakage Level
Fuel Leakage Leakage –
Exhaust gas – Leakage – C

CYLINDER BLOCK
CYLINDER BLOCK
PBIC5373E
1. Oil level gauge guide 2. Oil level gauge 3. O-ring

4. Lower cylinder block 5. Lower cylinder block mounting bolt 6. Snap ring
7. Connecting rod 8. Connecting rod bearing 9. Connecting rod bearing cap
10. Connecting rod bolt 11. Piston 12. Oil ring
13. Second ring 14. Top ring 15. Piston pin
16. Thrust bearing 17. Main bearing (upper) 18. Crankshaft
19. Crankshaft key 20. Main bearing (lower) 21. Flywheel
22. Rear oil seal 23. Pilot bush 24. Signal plate
25. Cylinder block 26. O-ring 27. Crankshaft position sensor (POS)
28. Knock sensor 29. Oil pressure switch 30. Water drain plug
A. Refer to EM-79

CYLINDER BLOCK
A
DISASSEMBLY
NOTE:
Explained here is how to disassemble with an engine stand supporting mating surface of transmission. When EM
using different type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transmission assembly from the vehicle, and separate the transmission
assembly from the engine. Refer to EM-74. C
2. Remove the parts that may restrict installation of engine to widely use engine stand.
NOTE:
The procedure is described assuming that you use widely use engine holding the surface, to which trans- D
mission is installed.
a. Remove flywheel.
• Secure crankshaft with a stopper plate, and remove mounting
E
bolts.
CAUTION:
Be careful not to damage or scratch contact surface for
clutch disc of flywheel. F
NOTE:
The flywheel, two block construction, allows movement in
response to transmission side pressure, or when twisted in its
G
rotational direction. Therefore, some amount of noise is normal.
PBIC1753E
H
b. Lift the engine with a hoist to install it onto widely use engine
stand.
CAUTION: I
• Use the engine stand that has a load capacity [approxi-
mately 150 kg (331 lb) or more] large enough for support-
ing the engine weight. J
• Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.
NOTE:
The figure shows an example of widely use engine stand that K
can support mating surface of transmission with flywheel
PBIC0085E
removed.
3. Drain engine oil. Refer to LU-5, "Changing Engine Oil". L
4. Drain engine coolant by removing water drain plug from inside of
the engine.
M
O
PBIC2716E
5. Remove cylinder head. Refer to EM-63. P

6. Remove knock sensor.
CAUTION:
Carefully handle knock sensor avoiding shocks.

CYLINDER BLOCK
7. Remove crankshaft position sensor (POS).
CAUTION:
• Avoid impacts such as a dropping.
• Keep it away from metal particles.
• Never place the sensor in a location where it is exposed to
magnetism.
PBIC2191E
8. Remove piston and connecting rod assembly with the following procedure:
• Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to
EM-94, "Inspection After Disassembly".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.
PBIC0259E
9. Remove connecting rod bearings.

CAUTION:
Identify installation positions, and store them without mixing them up.
10. Remove piston rings form piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-94, "Inspection After
Disassembly".
• Use a piston ring expander (commercial service tool).
CAUTION:
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
them excessively.
PBIC0087E
11. Remove piston from connecting rod with the following procedure:

CYLINDER BLOCK
a. Using snap ring pliers, remove snap rings.
A
EM
PBIC1638E
D
b. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use
drier or equivalent.
E
G
PBIC1639E
c. Push out piston pin with a stick of outer diameter approximately

H
19 mm (0.75 in).
PBIC0262E
K
12. Remove lower cylinder block mounting bolts.
• Before loosening lower cylinder block mounting bolts, measure crankshaft end play. Refer to EM-94,
"Inspection After Disassembly". L
• Loosen them in reverse order as shown in the figure, and
remove them.
M
: Engine front
NOTE:
Use TORX socket (size E14) for bolts No. 1 to 10. N
O
PBIC5374E
13. Remove lower cylinder block. P

• Use the seal cutter [SST: KV10111100] or suitable tool to cut liquid gasket for removal.
CAUTION:
Be careful not to damage the mounting surface.
14. Remove crankshaft.
CAUTION:

CYLINDER BLOCK
• Be careful not damage or deform signal plate mounted on
crankshaft.
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
• Never remove signal plate unless it is necessary to do so.
NOTE:
When removing or installing signal plate, use TORX socket (size
T30).
15. Pull rear oil seal out from rear end of crankshaft.
NOTE: SBIA0275E
When replacing rear oil seal without removing lower cylinder
block, use a screwdriver to pull the oil seal installed between crankshaft and cylinder block out.
CAUTION:
Be careful not to damage crankshaft and cylinder block.
16. Remove main bearings and thrust bearings from cylinder block and lower cylinder block.
CAUTION:
Identify installation positions, and store them without mixing them up.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to
remove any foreign material.
CAUTION:
Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure.
• Apply liquid gasket to the thread of water drain plug “A”.
NOTE:
Do not apply liquid gasket to the thread of plug “B”.
PBIC2770E
• Tighten each plug as specified below.
Part Washer Tightening torque

A No 9.8 N·m (1.0 kg-m, 87 in-lb)
B Yes 53.5 N·m (5.5 kg-m, 39 ft-lb)
3. Install main bearings and thrust bearings with the following procedure:
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and lower cylinder
block.
b. Install thrust bearings to the both sides of the No. 3 journal hous-
ing on cylinder block.
• Install thrust bearings with the oil groove facing crankshaft arm
(outside).
PBIC0264E
c. Install the main bearings paying attention to the direction.

CYLINDER BLOCK
• Main bearing with an oil hole and groove goes on cylinder
block. The one without them goes on lower cylinder block. A
• Only main bearing (on cylinder block) for No. 3 journal has dif-
ferent specifications.
• Before installing main bearings, apply new engine oil to the
EM
bearing surface (inside). Do not apply engine oil to the back
surface, but thoroughly clean it.
• When installing, align main bearing stopper to the notch.
• Ensure the oil holes on cylinder block and those on the corre- C
sponding bearing are aligned.
PBIC2193E
D
4. Install signal plate to crankshaft if removed.
A : Signal plate
E
B : Crank shaft
C : Dowel pin (used to position the signal plate)
a. Position crankshaft and signal plate using dowel pin, and tighten F
mounting bolts.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each. If dowel pin is not available (when reusing crankshaft and G
signal plate), use M6 bolt [length 10 mm (0.39 in) or more] as a PBIC4436J
substitute.
b. Remove dowel pin. H
CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block. I
• While turning crankshaft by hand, check that it turns smoothly.
CAUTION:
Never install rear oil seal yet. J
6. Inspect outer diameter of lower cylinder block mounting bolts. Refer to EM-94, "Inspection After Disas-
sembly".
7. Install lower cylinder block with the following procedure: K
a. Apply liquid gasket with the tube presser (commercial service
tool) to lower cylinder block as shown in the figure.
L
B : Apply liquid gasket to an end
a : 3.5 - 4.0 mm (0.138 - 0.157 in)
: Engine front
M
CAUTION:
After liquid gasket is applied, rear oil seal installation must N
be finished within 5 minutes. Therefore, the following pro- PBIC5375E
cedure must be performed quickly.
NOTE:
Lower cylinder block cannot be replaced as a single part, because it is machined together with cylinder O
block.
b. Tighten lower cylinder block mounting bolts with the following procedure:
i. Apply new engine oil to threads and seat surfaces of the mounting bolts. P

CYLINDER BLOCK
ii. Tighten M8 bolts in numerical order from No. 11 to 22 in the fig-
ure.
: Engine front
: 25.1 N·m (2.6 kg-m, 19 ft-lb)

CAUTION:
Wipe off completely any protruding liquid gasket on rear oil
seal installation surface.
NOTE: PBIC5374E
There are more processes to complete the tightening of mount-

ing bolts. However stop procedure here to install rear oil seal.
c. Install rear oil seal. Refer to EM-61, "Removal and Installation of Rear Oil Seal".
d. Restart tightening of lower cylinder block mounting bolts with the following procedure:
i. Tighten M10 bolts in numerical order from No. 1 to 10 in the fig-
ure.
: Engine front
: 39.2 N·m (4.0 kg-m, 29 ft-lb)
PBIC5374E
ii. Turn M10 bolts 60 degrees clockwise (angle tightening) in numerical order from No. 1 to 10 in the figure.
CAUTION:
PBIC2959J
• After installing the mounting bolts, check that crankshaft can be rotated smoothly by hand.
• Wipe off completely any protruding liquid gasket on front side of the engine.
• Check crankshaft end play. Refer to EM-94, "Inspection After Disassembly".
8. Install piston to connecting rod with the following procedure:
a. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
b. Assemble piston to connecting rod.
• Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without
excess force [approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into
piston and connecting rod.

CYLINDER BLOCK
• Assemble so that the front mark on the piston head and the oil
holes and the cylinder number on connecting rod are posi- A
tioned as shown in the figure.
c. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install. EM
• After installing, check that connecting rod moves smoothly.
PBIC2194E
D
9. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION:
• Be careful not to damage piston.
E
• Be careful not to damage piston rings by expanding them excessively.
• Position each ring with the gap as shown in the figure referring
to the piston front mark.
• Install second ring with the stamped surface facing upward. F
Stamped mark:
Top ring :— G
Second ring : 2 ND
NOTE:
H
If there is no stamped mark on piston ring, no specific orienta-
tion is required for installation. PBIC2195E
10. Inspect outer diameter of connecting rod bolts. Refer to EM-94, "Inspection After Disassembly". I
11. Install connecting rod bearings to connecting rod and connecting rod cap.
• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not
apply engine oil to the back surface, but thoroughly clean it. J
• When installing, align the connecting rod bearing stopper pro-
trusion with the cutout of connecting rod and connecting rod
cap to install.
• Ensure the oil hole on connecting rod and that on the corre- K
sponding bearing are aligned.
M
PBIC2067E
12. Install piston and connecting rod assembly to crankshaft.

N
• Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
• Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin.
• Match the cylinder position with the cylinder number on connecting rod to install.
• Using the piston ring compressor (SST) or suitable tool, install O
piston with the front mark on the piston head facing the front of
the engine.
CAUTION:
P
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
PBIC1619E

CYLINDER BLOCK
13. Install connecting rod cap.
• Match the stamped cylinder number marks on connecting rod
with those on connecting rod cap to install.
PBIC2196E
14. Tighten connecting rod bolt with the following procedure:

a. Apply new engine oil to the threads and seats of connecting rod bolts.
b. Tighten bolts.
: 27.4 N·m (2.8 kg-m, 20 ft-lb)

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

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

e. Then turn all bolts 90 degrees clockwise (angle tightening).
CAUTION:
PBIC2961J
• After tightening connecting rod bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-94, "Inspection After Disassembly".
15. Install flywheel.

CAUTION:
Check that dowel pin is installed at the rear end of crankshaft.
• When installing flywheel to crankshaft, check that align crankshaft side dowel pin with flywheel side
dowel pin hole correctly.
- If these are not aligned correctly, engine runs roughly and “MIL” turns on.
• Secure crankshaft with a stopper plate, and tighten mounting bolts crosswise over several times.
16. Install knock sensor.

CYLINDER BLOCK
• Install knock sensor with connector facing lower left by 45
degrees as shown in the figure. A
CAUTION:
• Never tighten mounting bolt while holding the connector.
• If any impact by dropping is applied to knock sensor,
EM
replace it with a new one.
NOTE:
• Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor. C
• Check that knock sensor does not interfere with other parts.
17. Install crankshaft position sensor (POS). KBIA0069E
18. Assemble in the reverse order of disassembly after this step. D
How to Select Piston and Bearing INFOID:0000000003397109
E
DESCRIPTION
Selection points Selection parts Selection items Selection methods

F
Determined by match of cylin-
der block bearing housing
Between cylinder block and Main bearing grade (bearing grade (inner diameter of hous-
Main bearing
crankshaft thickness) ing) and crankshaft journal G
grade (outer diameter of jour-
nal)
Combining service grades for H
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection. I
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston skirt diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.) J
Between piston and connecting
— — —
rod*
*For the service parts, the grade for fitting cannot be selected between piston pin and connecting rod. (Only grade “0” is available.) The K
information at the shipment from the plant is described as a reference.
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts. L
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text. M
HOW TO SELECT PISTON
When New Cylinder Block Is Used N
• Check the cylinder bore grade on rear-left side of cylinder block,
and select piston of the same grade.
• If there is a corrected stamp mark on cylinder block, use it as a cor-
O
rect reference.
SBIA0283E
When Cylinder Block Is Reused

1. Measure the cylinder bore inner diameter. Refer to EM-94, "Inspection After Disassembly".

CYLINDER BLOCK
2. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner
diameter of the “Piston Selection Table”.
3. Select piston of the same grade.
A : Piston grade number

B : Identification code
C : Front mark
D : Piston pin grade number
PBIC5376E
Piston Selection Table

Unit: mm (in)
Grade number (Mark) 2 (or no mark) 3
Cylinder bore Inner diameter 89.010 - 89.020 (3.5043 - 3.5047) 89.020 - 89.030 (3.5047 - 3.5051)
Piston skirt diameter 88.990 - 89.000 (3.5035 - 3.5039) 89.000 - 89.010 (3.5039 - 3.5043)
NOTE:
• There is no piston grade “1”.
• Piston is available together with piston pin as an assembly.
• The piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.)
HOW TO SELECT CONNECTING ROD BEARING

When New Connecting Rod and Crankshaft Are Used
1. Apply connecting rod big end diameter grade stamped on con-
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
PBIC2196E
2. Apply crankshaft pin journal diameter grade stamped on crank-

shaft front side to the column in the “Connecting Rod Bearing
Selection Table”.
PBIC2198E
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
When Crankshaft and Connecting Rod Are Reused

CYLINDER BLOCK
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-94, "Inspection After Disassembly" and EM-94, "Inspection After Disassembly". A
2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”. EM
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
Connecting Rod Bearing Selection Table
C
M
PBIC5377E
Connecting Rod Bearing Grade Table

Unit: mm (in) N
Grade number Thickness Identification color Remarks
0 1.493 - 1.496 (0.0588 - 0.0589) Black
O
1 1.496 - 1.499 (0.0589 - 0.0590) Brown
Grade and color are the same for
2 1.499 - 1.502 (0.0590 - 0.0591) Green
upper and lower bearings.
3 1.502 - 1.505 (0.0591 - 0.0593) Yellow P
4 1.505 - 1.508 (0.0593 - 0.0594) Blue

CYLINDER BLOCK
UPR 1.493 - 1.496 (0.0588 - 0.0589) Black
01
LWR 1.496 - 1.499 (0.0589 - 0.0590) Brown
UPR 1.496 - 1.499 (0.0589 - 0.0590) Brown
12
LWR 1.499 - 1.502 (0.0590 - 0.0591) Green Grade and color are different for
UPR 1.499 - 1.502 (0.0590 - 0.0591) Green upper and lower bearings.
23
LWR 1.502 - 1.505 (0.0591 - 0.0593) Yellow
UPR 1.502 - 1.505 (0.0591 - 0.0593) Yellow
34
LWR 1.505 - 1.508 (0.0593 - 0.0594) Blue
Undersize Bearings Usage Guide

• When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod
bearings, use undersize (US) bearings.
• When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing
installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft pin to use undersize bearings, keep the
fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
PBIC2200E
Bearing undersize table

Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 1.622 - 1.630 (0.0639 - 0.0642)
HOW TO SELECT MAIN BEARING

When New Cylinder Block and Crankshaft Are Used
1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear-left side of cylinder block.
• If there is a corrected stamp mark on cylinder block, use it as a
correct reference.
SBIA0283E

CYLINDER BLOCK
2. Apply main journal diameter grade stamped on crankshaft front
side to column in the “Main Bearing Selection Table”. A
EM
PBIC2198E
D
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and
E
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE: F
Service part is available as a set of both upper and lower.
When Cylinder Block and Crankshaft Are Reused
G
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-94, "Inspection After Disassembly" and EM-94, "Inspection After
Disassembly".
H
2. Apply the measured dimension to the “Main Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”.
CAUTION:
There are two main bearing selection tables. One is for odd-numbered journals (No. 1, 3 and 5) and I
the other is for even-numbered journals (No. 2 and 4). Make certain to use the appropriate table.
This is due to differences in the specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing. J
NOTE:
Service part is available as a set of both upper and lower.
K

CYLINDER BLOCK
Main Bearing Selection Table (No. 1, 3 and 5 Journals)
PBIC2201E

CYLINDER BLOCK
Main Bearing Selection Table (No. 2 and 4 Journals)
A
EM
PBIC2202E
K
Main Bearing Grade Table (All Journals)

Unit: mm (in)
L
0 1.973 - 1.976 (0.0777 - 0.0778) Black
1 1.976 - 1.979 (0.0778 - 0.0779) Brown M
2 1.979 - 1.982 (0.0779 - 0.0780) Green
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow Grade and color are the same
N
4 1.985 - 1.988 (0.0781 - 0.0783) Blue for upper and lower bearings.
5 1.988 - 1.991 (0.0783 - 0.0784) Pink

6 1.991 - 1.994 (0.0784 - 0.0785) Purple O
7 1.994 - 1.997 (0.0785 - 0.0786) White

CYLINDER BLOCK
UPR 1.973 - 1.976 (0.0777 - 0.0778) Black
01
LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown
UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown
12
LWR 1.979 - 1.982 (0.0779 - 0.0780) Green
UPR 1.979 - 1.982 (0.0779 - 0.0780) Green
23
LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
Grade and color are different
UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow for upper and lower bearings.
34
LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue
UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue
45
LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink
UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink
56
LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple
UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple
67
LWR 1.994 - 1.997 (0.0785 - 0.0786) White
Use Undersize Bearing Usage Guide

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under-
size (US) bearing.
• When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and
grind main journal so that the main bearing oil clearance satisfies the standard.
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)].
PBIC2200E
Bearing undersize table

Unit: mm (in)
Size Thickness
US 0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832)
CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).
Standard : 0.10 - 0.26 mm (0.0039 - 0.0102 in)

Limit : 0.3 mm (0.012 in)
• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft
also.
PBIC3252J
CONNECTING ROD SIDE CLEARANCE

CYLINDER BLOCK
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge. A
Standard : 0.20 - 0.35 mm (0.0079 - 0.0138 in)

Limit : 0.5 mm (0.020 in) EM
• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also. C
KBIA0071E
D
PISTON TO PISTON PIN OIL CLEARANCE
Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole with an inside E
micrometer.
Standard: 19.993 - 20.005 mm (0.7871 - 0.7876 in)

F
PBIC0116E H
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer.
I
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E
L
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
M
Standard: 0.002 - 0.006 mm (0.0001 - 0.0002 in)
• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly, refer to "PISTON TO CYLINDER BORE CLEARANCE".
N
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.) O
PISTON RING SIDE CLEARANCE
P

CYLINDER BLOCK
• Measure the side clearance of piston ring and piston ring groove
with a 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:
SEM024AA
Top ring : 0.11 mm (0.0043 in)
2nd ring : 0.10 mm (0.0039 in)
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
replace piston also.
PISTON RING END GAP
• Check that cylinder bore inner diameter is within the specification.
Refer to "Cylinder Bore Inner Diameter".
• Lubricate with new engine oil to piston and piston ring, and then
insert piston ring until middle of cylinder with piston, and measure
piston ring end gap with a feeler gauge.
Standard:
Top ring : 0.21 - 0.31 mm (0.0083 - 0.0122 in)
2nd ring : 0.37 - 0.57 mm (0.0146 - 0.0224 in)
Oil ring (rail ring) : 0.20 - 0.60 mm (0.0079 - 0.0236 in) SEM822B
Limit:
Top ring : 0.50 mm (0.0197 in)
2nd ring : 0.63 mm (0.0248 in)
Oil ring (rail ring) : 0.91 mm (0.0358 in)
• If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit,
re-bore cylinder inner wall and use oversized piston and piston rings.
CONNECTING ROD BEND AND TORSION

CYLINDER BLOCK
• Check with a connecting rod aligner.
A
Bend:
Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length
Torsion: EM
Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length
• If it exceeds the limit, replace connecting rod assembly. C
G
PBIC2077E
CONNECTING ROD BIG END DIAMETER

• Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to H
the specified torque. Refer to EM-79, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of connecting rod big end with an
inside micrometer.
I
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 in)
• If out of the standard, replace connecting rod assembly. J
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE L
Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with an inside
micrometer. M
Standard: 20.000 - 20.012 mm (0.7874 - 0.7879 in)

N
PBIC0120E
P

CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer.
Standard: 19.989 - 20.001 mm (0.7870 - 0.7874 in)
PBIC0117E
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)

• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly, refer to "PISTON TO CYLINDER BORE CLEARANCE".
• If replacing connecting rod assembly, refer to "CONNECTING
ROD BEARING OIL CLEARANCE" to select connecting rod bear-
ing.
PBIC2196E
Factory installed parts grading:

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

B : Identification code
C : Front mark
D : Piston pin grade number
Unit: mm (in)
Grade 0 1
Connecting rod bushing 20.000 - 20.006 20.006 - 20.012
inner diameter* (0.7874 - 0.7876) (0.7876 - 0.7879) PBIC5376E
19.993 - 19.999 19.999 - 20. 005

Piston pin hole diameter
(0.7871 - 0.7874) (0.7874 - 0.7876)
19.989 - 19.995 19.995 - 20.001
Piston pin outer diameter
(0.7870 - 0.7872) (0.7872 - 0.7874)
*: After installing in connecting rod.
CYLINDER BLOCK DISTORTION

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

CYLINDER BLOCK
• Measure the distortion on the cylinder block upper face at some
different points in six directions with a straight edge and a feeler A
gauge.
Limit: 0.1 mm (0.004 in) EM

• If it exceeds the limit, replace cylinder block and lower cylinder
block assembly.
NOTE: C
Cylinder block cannot be replaced as a single, because it is
machined together with lower cylinder block.
PBIC0121E
D
MAIN BEARING HOUSING INNER DIAMETER
• Install lower cylinder block without main bearings installed, and
tighten lower cylinder block mounting bolts to the specified torque.
Refer to EM-79, "Disassembly and Assembly" for the tightening E
procedure.
• Measure the inner diameter of main bearing housing with a bore
gauge. F
Standard: 58.944 - 58.968 mm (2.3206 - 2.3216 in)

• If out of the standard, replace cylinder block and lower cylinder G
block assembly.
NOTE: PBIC2012E
Cylinder block cannot be replaced as a single, because it is H

machined together with lower cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter I
• Using a bore gauge, measure the cylinder bore for wear, out-of-
round and taper at six different points on each cylinder. (“X” and
“Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of J
the engine)
NOTE:
When determining cylinder bore grade, measure cylinder bore at
“B” position. K
Standard inner diameter:

L
89.010 - 89.030 mm (3.5043 - 3.5051 in)
Wear limit: SBIA0284E
0.2 mm (0.008 in) M

Out-of-round (Difference between “X” and “Y”):
0.015 mm (0.0006 in)
Taper limit (Difference between “A” and “C”): N
0.01 mm (0.0004 in)
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, O
hone or re-bore the cylinder inner wall.
• Oversize piston is provided. When using oversize piston, re-bore the cylinder so that the clearance of the
piston to cylinder bore satisfies the standard.
CAUTION: P
When using an oversize piston, use oversize pistons for all cylinders with oversize piston rings.
Oversize (O/S): 0.2 mm (0.008 in)

Piston Skirt Diameter

CYLINDER BLOCK
Measure the outer diameter of piston skirt with a micrometer.
Measure point
: Distance from the top 42.98 mm (1.6921 in)
Standard
: 88.990 - 89.010 mm (3.5035 - 3.5043 in)
PBIC0125E
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”).
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)
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 and piston pin assembly. Refer to EM-87, "How to Select Piston and
Bearing".
Re-boring Cylinder Bore
1. Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter.
Re-bored size calculation: D = A + B - C

where,
A: Piston diameter as measured
B: Piston - to - cylinder bore clearance (standard value)
C: Honing allowance 0.02 mm (0.0008 in)
D: Bored diameter
2. Install lower cylinder block, and tighten mounting bolts to the specified torque. Otherwise, cylinder bores
may be distorted in final assembly. Refer to EM-79, "Disassembly and Assembly" for the tightening proce-
dure.
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 the specified piston to cylinder bore clearance.
5. Measure the finished cylinder bore for out-of-round and taper.
NOTE:
Measurement should be done after cylinder bore cools down.
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a
micrometer.
Standard: 54.955 - 54.979 mm (2.1636 - 2.1645 in) dia.

• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to "MAIN BEARING OIL
CLEARANCE".
PBIC0270E

CYLINDER BLOCK
CRANKSHAFT PIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft pin journal with a micrometer. A
Standard: 44.956 - 44.974 mm (1.7699-1.7706 in) dia.

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer EM
to EM-87, "How to Select Piston and Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT
C
• Measure the dimensions at four different points as shown in the
figure on each main journal and pin journal with a micrometer.
• Out-of-round is indicated by the difference in dimensions between
“X” and “Y” at “A” and “B”. D
• Taper is indicated by the difference in dimension between “A” and
“B” at “X” and “Y”.
E
Limit:
Out-of-round (Difference between “X” and “Y”)
: 0.005 mm (0.0002 in) F
PBIC2203E
Taper (Difference between “A” and “B”)
: 0.005 mm (0.0002 in)
G
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to "MAIN BEARING OIL CLEARANCE" and/or "CON-
NECTING ROD BEARING OIL CLEARANCE". H
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on the both end of crankshaft.
I
• Place a dial indicator straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
dial indicator. (Total indicator reading)
J
Limit : 0.05 mm (0.0020 in)
• If it exceeds the limit, replace crankshaft.
K
L
PBIC2541E
CONNECTING ROD BEARING OIL CLEARANCE

Method by Calculation M
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-79, "Disassembly and Assembly" for tightening procedure.
• Measure the inner diameter of connecting rod bearing with an N
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter)
O
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in)
Limit : 0.1 mm (0.004 in)
P
• If the clearance exceeds the limit, select proper connecting rod
bearing according to connecting rod big end diameter and crank-
shaft pin journal diameter to obtain the specified bearing oil clear-
PBIC1642E
ance. Refer to EM-87, "How to Select Piston and Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely.

CYLINDER BLOCK
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified
torque. Refer to EM-79, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC1149E
MAIN BEARING OIL CLEARANCE

Method by Calculation
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting
bolts to the specified torque. Refer to EM-79, "Disassembly and Assembly" for the tightening procedure.
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
Standard:
No. 1, 3 and 5 journals
: 0.012 - 0.022 mm (0.0005 - 0.0009 in)
No. 2 and 4 journals
: 0.018 - 0.028 mm (0.0007 - 0.0011 in)
PBIC2204E
Limit : 0.1 mm (0.004 in)
• If the clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to EM-87, "How to
Select Piston and Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block mounting
bolts to the specified torque. Refer to EM-79, "Disassembly and Assembly" for the tightening procedure.
CAUTION:
• Remove lower cylinder block and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
PBIC1149E
MAIN BEARING CRUSH HEIGHT

CYLINDER BLOCK
• When lower cylinder block is removed after being tightened to the
specified torque with main bearings installed, the tip end of bearing A
must protrude. Refer to EM-79, "Disassembly and Assembly" for
the tightening procedure.
EM
Standard: There must be crush height.
• If the standard is not met, replace main bearings.
C
SEM502G
D
CONNECTING ROD BEARING CRUSH HEIGHT
• When connecting rod bearing cap is removed after being tightened
to the specified torque with connecting rod bearings installed, the
tip end of bearing must protrude. Refer to EM-79, "Disassembly E
and Assembly" for the tightening procedure.
Standard: There must be crush height. F

• If the standard is not met, replace connecting rod bearings.
PBIC1646E
LOWER CYLINDER BLOCK MOUNTING BOLT OUTER DIAMETER H

• Perform only with M10 bolts.
• Measure the outer diameters (“d1”, “d2”) at two positions as shown
in the figure.
I
• If reduction appears in “A” range, regard it as “d2”.
Limit (“d1” – “d2”): 0.13 mm (0.0051 in)

J
• If it exceeds the limit (a large difference in dimensions), replace
lower cylinder block mounting bolt with a new one.
K
PBIC0911E
CONNECTING ROD BOLT OUTER DIAMETER L

• Measure the outer diameter “d” at position as shown in the figure.
• If reduction appears in a position other than “d”, regard it as “d”.
M
Limit: 7.75 mm (0.3051 in)
• When “d” falls below the limit (when it becomes thinner), replace
connecting rod bolt with a new one. N
O
PBIC0912E
FLYWHEEL DEFLECTION
P

CYLINDER BLOCK
• Measure the deflection of flywheel contact surface to clutch with a
dial indicator.
• Measure the deflection at 210 mm (8.27 in) dia.
Standard : 0.45 mm (0.0177 in) or less.

• If measured value is out of the standard, replace flywheel.
CAUTION:
When measuring, keep magnetic fields (such as dial indicator
stand) away from signal plate of the rear end of crankshaft.
PBIC2168E
MOVEMENT AMOUNT OF FLYWHEEL

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

Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install a bolt to clutch cover mounting hole, and place a torque wrench on the extended line of the flywheel
center line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it from loosening.
2. Put a matching mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points).
3. Apply a force of 9.8 N·m (1.0 kg-m, 87 in-lb) in each direction,
and mark the movement amount on the mass on the transaxle
side.
4. Measure the dimensions of movement amounts “A” and “B” on
circumference of flywheel on the transaxle side.
Standard: 35.2 mm (1.386 in) or less.

PBIC1263E

SERVICE DATA AND SPECIFICATIONS (SDS)
A
Standard and Limit INFOID:0000000003397111
GENERAL SPECIFICATIONS EM
Cylinder arrangement In-line 4

Displacement cm3 (cu in) 2,488 (151.82) C
Bore and stroke mm (in) 89.0 x 100.0 (3.504 x 3.937)
Valve arrangement DOHC
D
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1 E
Compression ratio 9.5
Standard 1,412 (14.1, 14.4, 204.7)
Compression pressure F
2 Minimum 1,216 (12.2, 12.4, 176.3)
kPa (bar, kg/cm , psi)/250 rpm
Differential limit between cylinders 100 (1.0, 1.0, 14.5)
DRIVE BELT G
Tension of drive belt Auto adjustment by auto-tensioner

H
INTAKE MANIFOLD AND EXHAUST MANIFOLD
Unit: mm (in)
Items Limit I
Intake manifold collector 0.1 (0.004)
Surface distortion Intake manifold 0.1 (0.004)
J
Exhaust manifold and three way catalyst assembly 0.1 (0.004)
SPARK PLUG
Unit: mm (in) K
Make NGK
Standard type DILKAR6A-11
L
Gap (Nominal) 1.1 (0.043)
CYLINDER HEAD
Unit: mm (in) M
Items Limit
Head surface distortion 0.1 (0.004)
N
PBIC0283E
VALVE

Valve Timing
Valve timing
PBIC0187E
Unit: degree
a b c d e f
224 236 4 (−33) 60 (23) 7 37
( ): Valve timing control “ON”
Valve Dimensions
Unit: mm (in)
SEM188A
Intake 35.5 - 35.8 (1.398 - 1.409)

Valve head diameter “D”
Exhaust 30.5 - 30.8 (1.201 - 1.213)
Intake 97.16 (3.8252)
Valve length “L”
Exhaust 98.82 (3.8905)
Intake 5.965 - 5.980 (0.2348 - 0.2354)
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 1.3 (0.051)
Valve Clearance
Unit: mm (in)
Items Cold (reference data) Hot*

Intake 0.24 - 0.32 (0.009 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.26 - 0.34 (0.010 - 0.013) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
Available Valve Lifter

Unit: mm (in)
Thickness Identification mark A
EM
KBIA0119E
E
6.96 (0.2740) 696
6.98 (0.2748) 698
7.00 (0.2756) 700
F
7.02 (0.2764) 702
7.04 (0.2772) 704
7.06 (0.2780) 706 G
7.08 (0.2787) 708
7.10 (0.2795) 710
H
7.12 (0.2803) 712
7.14 (0.2811) 714
7.16 (0.2819) 716 I
7.18 (0.2827) 718
7.20 (0.2835) 720
J
7.22 (0.2843) 722
7.24 (0.2850) 724
7.26 (0.2858) 726 K
7.28 (0.2866) 728
7.30 (0.2874) 730
L
7.32 (0.2882) 732
7.34 (0.2890) 734
7.36 (0.2898) 736 M
7.38 (0.2906) 738
7.40 (0.2913) 740
7.42 (0.2921) 742 N
7.44 (0.2929) 744
7.46 (0.2937) 746
O
Valve Spring
Items Intake Exhaust P

Free height 43.72 - 43.92 mm (1.7213 - 1.7291 in) 45.29 - 45.49 mm (1.7831 - 1.7909 in)
Installation load 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb) 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb)
Height during valve open 25.30 mm (0.9961 in) 26.76 mm (1.0535 in)

Load with valve open 351 - 394 N (35.8 - 40.2 kg, 79 - 89 lb) 318 - 362 N (32.4 - 36.9 kg, 71 - 81 lb)
Identification color Pink Yellowish green
Unit: mm (in)
Limit
Items
Intake Exhaust
Squareness 1.9 (0.075)
Valve Lifter
Unit: mm (in)
Items Standard
Valve lifter outer diameter 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter hole diameter 34.000 - 34.021 (1.3386 - 1.3394)
Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)
Valve Guide
Unit: mm (in)
PBIC0184E
Items Standard Oversize (Service) [0.2 (0.008)]

Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)
Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)
Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)
Items Standard Limit
Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)
Valve guide clearance
Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.09 (0.0035)
Intake 10.1 - 10.3 (0.398 - 0.406)
Projection length “L”
Exhaust 10.0 - 10.4 (0.394 - 0.409)
Valve Seat

Unit: mm (in)
A
EM
D
PBIC2745E
Items Standard Oversize (Service) [0.5 (0.020)]

E
Intake 36.500 - 36.516 (1.4370 - 1.4376) 37.000 - 37.016 (1.4567 - 1.4573)
Cylinder head seat recess diameter “D”
Exhaust 31.500 - 31.516 (1.2402 - 1.2408) 32.000 - 32.016 (1.2598 - 1.2605)
Intake 36.597 - 36.613 (1.4408 - 1.4415) 37.097 - 37.113 (1.4605 - 1.4611)
Valve seat outer diameter “d” F
Exhaust 31.600 - 31.616 (1.2441 - 1.2447) 32.100 - 32.116 (1.2638 - 1.2644)
Intake 0.081 - 0.113 (0.0032 - 0.0044)
Valve seat interference fit
Exhaust 0.084 - 0.116 (0.0033 - 0.0046) G
Intake 33.5 (1.319)
Diameter “d1”*1
Exhaust 28.0 (1.102)
H
Intake 35.1 - 35.3 (1.382 - 1.390)
Diameter “d2”*2
Exhaust 29.9 - 30.1 (1.177 - 1.185)
Intake 60° I
Angle “α1”
Exhaust 60°
Intake 88°45′ - 90°15′
Angle “α2” J
Exhaust 88°45′ - 90°15′
Intake 120°
Angle “α3”
Exhaust 120° K
Intake 1.05 - 1.35 (0.0413 - 0.0531)
Contacting width “W”*3
Exhaust 1.25 - 1.55 (0.0492 - 0.0610)
L
Intake 5.9 - 6.0 (0.232 - 0.236) 5.0 - 5.1 (0.197 - 0.201)
Height “h”
Exhaust 5.9 - 6.0 (0.232 - 0.236) 4.91 - 5.01 (0.1933 - 0.1972)
Depth “H” 6.0 (0.236) M
*1: Diameter made by intersection point of conic angles α1 and α2
*2: Diameter made by intersection point of conic angles α2 and α3
N
*3: Machining data
CAMSHAFT AND CAMSHAFT BEARING

Unit: mm (in) O
Camshaft journal oil clearance 0.045 - 0.086 (0.0018 - 0.0034) 0.15 (0.0059)
P
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 23.500 - 23.521 (0.9252 - 0.9260) —
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal outer diameter
No. 2, 3, 4, 5 23.435 - 23.455 (0.9226 - 0.9234) —
Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) —

Intake 45.015 - 45.205 (1.7722 - 1.7797)
Camshaft cam height “A” 0.2 (0.008)*1
Exhaust 43.975 - 44.165 (1.7313 - 1.7388)
Camshaft runout [TIR*2] Less than 0.02 (0.0008) —
Camshaft sprocket runout [TIR*2] — 0.15 (0.0059)
SEM671
*1: Cam wear limit

*2: Total indicator reading
CYLINDER BLOCK
Unit: mm (in)
PBIC0281E
Surface distortion Limit 0.1 (0.004)

Grade No. 2 89.010 - 89.020 (3.5043 - 3.5047)
Standard
Cylinder bore Inner diameter Grade No. 3 89.020 - 89.030 (3.5047 - 3.5051)
Wear limit 0.2 (0.008)
Out-of-round (Difference between “X” and “Y”) 0.015 (0.0006)
Limit
Taper (Difference between “A” and “C”) 0.01 (0.0004)

Grade No. A 58.944 - 58.945 (2.3206 - 2.3207)
Grade No. B 58.945 - 58.946 (2.3207 - 2.3207) A
Grade No. C 58.946 - 58.947 (2.3207 - 2.3207)
Grade No. D 58.947 - 58.948 (2.3207 - 2.3208)
Grade No. E 58.948 - 58.949 (2.3208 - 2.3208)
Grade No. F 58.949 - 58.950 (2.3208 - 2.3209) EM
Grade No. G 58.950 - 58.951 (2.3209 - 2.3209)
Grade No. H 58.951 - 58.952 (2.3209 - 2.3209)
Grade No. J 58.952 - 58.953 (2.3209 - 2.3210)
Grade No. K 58.953 - 58.954 (2.3210 - 2.3210)
C
Grade No. L 58.954 - 58.955 (2.3210 - 2.3211)
Grade No. M 58.955 - 58.956 (2.3211 - 2.3211)
Main bearing housing inner diameter grade
Grade No. N 58.956 - 58.957 (2.3211 - 2.3211) D
Grade No. P 58.957 - 58.958 (2.3211 - 2.3212)
Grade No. R 58.958 - 58.959 (2.3212 - 2.3212)
Grade No. S 58.959 - 58.960 (2.3212 - 2.3213)
Grade No. T 58.960 - 58.961 (2.3213 - 2.3213) E
Grade No. U 58.961 - 58.962 (2.3213 - 2.3213)
Grade No. V 58.962 - 58.963 (2.3213 - 2.3214)
Grade No. W 58.963 - 58.964 (2.3214 - 2.3214)
Grade No. X 58.964 - 58.965 (2.3214 - 2.3215) F
Grade No. Y 58.965 - 58.966 (2.3215 - 2.3215)
Grade No. 4 58.966 - 58.967 (2.3215 - 2.3215)
Grade No. 7 58.967 - 58.968 (2.3215 - 2.3216)
G
Difference in inner diameter between cylinders Standard Less than 0.03 (0.0012)
PISTON, PISTON RING AND PISTON PIN

H
Available Piston
Unit: mm (in)
L
PBIC0188E
Grade No. 2 88.990 - 89.000 (3.5035 - 3.5039)

Piston skirt diameter “A” Standard Grade No. 3 89.000 - 89.010 (3.5039 - 3.5043) M
Oversize (service) [0.2 (0.008)] 89.180 - 89.210 (3.5110 - 3.5122)
Piston height “H” dimension 42.98 (1.6921)
N
Grade No. 0 19.993 - 19.999 (0.7871 - 0.7874)
Piston pin hole diameter
Grade No. 1 19.999 - 20.005 (0.7874 - 0.7876)
Standard 0.010 - 0.030 (0.0004 - 0.0012) O
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
Piston Ring
Unit: mm (in) P
Top 0.045 - 0.080 (0.0018 - 0.0031) 0.11 (0.0043)
Side clearance 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.065 - 0.135 (0.0026 - 0.0053) —

Top 0.21 - 0.31 (0.0083 - 0.0122) 0.50 (0.0197)
End gap 2nd 0.37 - 0.57 (0.0146 - 0.0224) 0.63 (0.0248)
Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.91 (0.0358)
Piston Pin
Unit: mm (in)
Grade No. 0 19.989 - 19.995 (0.7870 - 0.7872)

Piston pin outer diameter
Grade No. 1 19.995 - 20.001 (0.7872 - 0.7874)
Piston to piston pin oil clearance Standard 0.002 - 0.006 (0.0001 - 0.0002)
Connecting rod bushing oil clearance Standard 0.005 - 0.017 (0.0002 - 0.0007)
CONNECTING ROD
Unit: mm (in)
Center distance 143.00 - 143.10 (5.630 - 5.634)

Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Grade No. 0 20.000 - 20.006 (0.7874 - 0.7876)
Connecting rod bushing inner diameter*
Grade No. 1 20.006 - 20.012 (0.7876 - 0.7879)
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Side clearance
Limit 0.5 (0.020)
Grade No. 0 48.000 - 48.001 (1.8898 - 1.8898)
Grade No. 1 48.001 - 48.002 (1.8898 - 1.8898)
Grade No. 2 48.002 - 48.003 (1.8898 - 1.8899)
Grade No. 3 48.003 - 48.004 (1.8899 - 1.8899)
Grade No. 4 48.004 - 48.005 (1.8899 - 1.8900)
Grade No. 5 48.005 - 48.006 (1.8900 - 1.8900)
Connecting rod big end diameter Grade No. 6 48.006 - 48.007 (1.8900 - 1.8900)
Grade No. 7 48.007 - 48.008 (1.8900 - 1.8901)
Grade No. 8 48.008 - 48.009 (1.8901 - 1.8901)
Grade No. 9 48.009 - 48.010 (1.8901 - 1.8902)
Grade No. A 48.010 - 48.011 (1.8902 - 1.8902)
Grade No. B 48.011 - 48.012 (1.8902 - 1.8902)
Grade No. C 48.012 - 48.013 (1.8902 - 1.8903)
*: After installing in connecting rod
CRANKSHAFT
Unit: mm (in)
SEM645 SBIA0535E
Center distance “r” 49.96 - 50.04 (1.9669 - 1.9701)

Out-of-round (Difference between “X” and “Y”) Limit 0.005 (0.0002)
Taper (Difference between “A” and “B”) Limit 0.005 (0.0002)
Runout [TIR*] Limit 0.05 (0.0020)

Standard 0.10 - 0.26 (0.0039 - 0.0102)
Crankshaft end play A
Limit 0.3 (0.012)
Grade No. A 44.974 - 44.973 (1.7706 - 1.7706)
Grade No. B 44.973 - 44.972 (1.7706 - 1.7705)
Grade No. C 44.972 - 44.971 (1.7705 - 1.7705) EM
Grade No. D 44.971 - 44.970 (1.7705 - 1.7705)
Grade No. E 44.970 - 44.969 (1.7705 - 1.7704)
Grade No. F 44.969 - 44.968 (1.7704 - 1.7704)
Grade No. G 44.968 - 44.967 (1.7704 - 1.7704)
C
Grade No. H 44.967 - 44.966 (1.7704 - 1.7703)
Grade No. J 44.966 - 44.965 (1.7703 - 1.7703)
Pin journal diameter grade. “Dp”
Grade No. K 44.965 - 44.964 (1.7703 - 1.7702) D
Grade No. L 44.964 - 44.963 (1.7702 - 1.7702)
Grade No. M 44.963 - 44.962 (1.7702 - 1.7702)
Grade No. N 44.962 - 44.961 (1.7702 - 1.7701)
Grade No. P 44.961 - 44.960 (1.7701 - 1.7701) E
Grade No. R 44.960 - 44.959 (1.7701 - 1.7700)
Grade No. S 44.959 - 44.958 (1.7700 - 1.7700)
Grade No. T 44.958 - 44.957 (1.7700 - 1.7700)
Grade No. U 44.957 - 44.956 (1.7700 - 1.7699) F
Grade No. A 54.979 - 54.978 (2.1645 - 2.1645)
Grade No. B 54.978 - 54.977 (2.1645 - 2.1644)
Grade No. C 54.977 - 54.976 (2.1644 - 2.1644) G
Grade No. D 54.976 - 54.975 (2.1644 - 2.1644)
Grade No. E 54.975 - 54.974 (2.1644 - 2.1643)
Grade No. F 54.974 - 54.973 (2.1643 - 2.1643)
Grade No. G 54.973 - 54.972 (2.1643 - 2.1642) H
Grade No. H 54.972 - 54.971 (2.1642 - 2.1642)
Grade No. J 54.971 - 54.970 (2.1642 - 2.1642)
Grade No. K 54.970 - 54.969 (2.1642 - 2.1641)
Grade No. L 54.969 - 54.968 (2.1641 - 2.1641) I
Grade No. M 54.968 - 54.967 (2.1641 - 2.1641)
Main journal diameter grade. “Dm”
Grade No. N 54.967 - 54.966 (2.1641 - 2.1640)
Grade No. P 54.966 - 54.965 (2.1640 - 2.1640)
Grade No. R 54.965 - 54.964 (2.1640 - 2.1639)
J
Grade No. S 54.964 - 54.963 (2.1639 - 2.1639)
Grade No. T 54.963 - 54.962 (2.1639 - 2.1639)
Grade No. U 54.962 - 54.961 (2.1639 - 2.1638) K
Grade No. V 54.961 - 54.960 (2.1638 - 2.1638)
Grade No. W 54.960 - 54.959 (2.1638 - 2.1637)
Grade No. X 54.959 - 54.958 (2.1637 - 2.1637)
Grade No. Y 54.958 - 54.957 (2.1637 - 2.1637) L
Grade No. 4 54.957 - 54.956 (2.1637 - 2.1636)
Grade No. 7 54.956 - 54.955 (2.1636 - 2.1636)
*: Total indicator reading
M
MAIN BEARING
Unit: mm (in)
N
SEM685D

0 1.973 - 1.976 (0.0777 - 0.0778) Black
1 1.976 - 1.979 (0.0778 - 0.0779) Brown
2 1.979 - 1.982 (0.0779 - 0.0780) Green
3 1.982 - 1.985 (0.0780 - 0.0781) Yellow Grade and color are the same
4 1.985 - 1.988 (0.0781 - 0.0783) Blue for upper and lower bearings.
5 1.988 - 1.991 (0.0783 - 0.0784) Pink

6 1.991 - 1.994 (0.0784 - 0.0785) Purple
7 1.994 - 1.997 (0.0785 - 0.0786) White
UPR 1.973 - 1.976 (0.0777 - 0.0778) Black
01
LWR 1.976 - 1.979 (0.0778 - 0.0779) Brown
UPR 1.976 - 1.979 (0.0778 - 0.0779) Brown
12
LWR 1.979 - 1.982 (0.0779 - 0.0780) Green
UPR 1.979 - 1.982 (0.0779 - 0.0780) Green
23
LWR 1.982 - 1.985 (0.0780 - 0.0781) Yellow
Grade and color are different
UPR 1.982 - 1.985 (0.0780 - 0.0781) Yellow for upper and lower bearings.
34
LWR 1.985 - 1.988 (0.0781 - 0.0783) Blue
UPR 1.985 - 1.988 (0.0781 - 0.0783) Blue
45
LWR 1.988 - 1.991 (0.0783 - 0.0784) Pink
UPR 1.988 - 1.991 (0.0783 - 0.0784) Pink
56
LWR 1.991 - 1.994 (0.0784 - 0.0785) Purple
UPR 1.991 - 1.994 (0.0784 - 0.0785) Purple
67
LWR 1.994 - 1.997 (0.0785 - 0.0786) White
Undersize
Unit: mm (in)
Items Thickness Main journal diameter

US 0.25 (0.0098) 2.106 - 2.114 (0.0829 - 0.0832) Grind so that bearing clearance is the specified value.
Bearing Oil Clearance

Unit: mm (in)
No. 1, 3 and 5 0.012 - 0.022 (0.0005 - 0.0009)

Standard
Main bearing oil clearance No. 2 and 4 0.018 - 0.028 (0.0007 - 0.0011)
Limit 0.1 (0.004)
CONNECTING ROD BEARING

Unit: mm (in)

0 1.493 - 1.496 (0.0588 - 0.0589) Black
1 1.496 - 1.499 (0.0589 - 0.0590) Brown
Grade and color are the same
2 1.499 - 1.502 (0.0590 - 0.0591) Green
for upper and lower bearings.
3 1.502 - 1.505 (0.0591 - 0.0593) Yellow
4 1.505 - 1.508 (0.0593 - 0.0594) Blue

UPR 1.493 - 1.496 (0.0588 - 0.0589) Black
01 A
LWR 1.496 - 1.499 (0.0589 - 0.0590) Brown
UPR 1.496 - 1.499 (0.0589 - 0.0590) Brown
12
LWR 1.499 - 1.502 (0.0590 - 0.0591) Green Grade and color are different EM
UPR 1.499 - 1.502 (0.0590 - 0.0591) Green for upper and lower bearings.
23
LWR 1.502 - 1.505 (0.0591 - 0.0593) Yellow
UPR 1.502 - 1.505 (0.0591 - 0.0593) Yellow C
34
LWR 1.505 - 1.508 (0.0593 - 0.0594) Blue
Undersize D
Unit: mm (in)
Items Thickness Crank pin journal diameter

US 0.25 (0.0098) 1.622 - 1.630 (0.0639 - 0.0642) Grind so that bearing clearance is the specified value.
E
Bearing Oil Clearance

Unit: mm (in)
F
Standard 0.035 - 0.045 (0.0014 - 0.0018)
Connecting rod bearing oil clearance
Limit 0.1 (0.004)
G

PRECAUTIONS
< SERVICE INFORMATION > [ZD30 WITHOUT COMMON RAIL]
SERVICE INFORMATION
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
WARNING:
an authorized NISSAN/INFINITI dealer.
ness connectors.
Precaution for Drain Coolant INFOID:0000000003397113
Drain coolant when engine is cooled.

• When instructed to use special service tools, use the specified tools. Always be careful to work safely, 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, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precaution for Inspection, Repair and Replacement INFOID:0000000003397116
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
• Use torque wrench to tighten bolts or nuts.

ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.
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.

PRECAUTIONS
Parts Requiring Angular Tightening INFOID:0000000003397118
A
• Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:
• Do not use a torque value for final tightening. EM
• The torque value for these parts are for a preliminary step.
Precaution for Liquid Gasket INFOID:0000000003397119 C
REMOVAL OF LIQUID GASKET SEALING

• After removing the mounting bolts and nuts, disconnect and D
remove the liquid gasket sealing using a seal cutter (SST).
CAUTION:
• Tap seal cutter (SST) to insert it, and then slide it by tapping on the E
side as shown in the figure.
• In areas where the seal cutter (SST) is difficult to use, use a plastic
hammer to lightly tap the areas where the liquid gasket is applied. F
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
PBIC0275E G

1. Using a scraper, remove the old liquid gasket adhering to the H
gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the gasket
application surface, mounting bolts, and bolt holes.
I
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
J
PBIC0003E K
3. Attach the liquid gasket to the tube presser (commercial service

tool). L
4. Apply the gasket without breaks to the specified location with the
specified dimensions. M
• If there is a groove for the liquid gasket application, apply the gas-
ket to the groove.
• As for the bolt holes, normally apply the gasket inside the holes.
N
Occasionally, it should be applied outside the holes. Check to read
the text of service manual.
• Within five minutes of gasket application, install the mating compo- EMA0622D
nent. O
• 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. P
CAUTION:
If there are specific instructions in the service manual, observe them.

PREPARATION
PREPARATION
Tool number
Description
Tool name
KV10111100 Removing steel oil pan and gear case. etc
Seal cutter
S-NT046
ED19600620 Checking compression pressure

Compression gauge adapter
S-NT820
KV10109300 a: 68 mm (2.68 in)

Pulley holder b: 8 mm (0.31 in) dia.
S-NT628
KV101151S0 Changing valve lifter shims

Lifter stopper set (For models produced after November 24,
1 KV10115110 2003)
Camshaft pliers
2 KV10115120
Lifter stopper
S-NT041
KV11106030 a: 6 mm (0.24 in) dia.

Positioning stopper pin b: 80 mm (3.15 in)
NT804
KV10112100 Tightening bolts for bearing cap, cylinder

Angle wrench head, etc.
S-NT014

PREPARATION
Tool number
Description
Tool name A
KV101092S0 Disassembling and assembling valve compo-
Valve spring compressor nents
1 KV10109210 EM
Compressor
2 KV10109220
Adapter
C
NT718
KV10107902 Removing valve oil seal

Valve oil seal puller D
S-NT011
F
Valve oil seal drift Use side A.
a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421) G
c: 10.3 (0.406) dia. f: 5 (0.20)
Unit: mm (in)
H
S-NT603
KV101056S0 Removing and installing crankshaft pulley

Ring gear stopper
1 KV10105630 a: 3 (0.12) e: 107 (4.21) I
Adapter b: 6.4 (0.252) f: 14 (0.55)
2 KV10105610 c: 2.8 (0.110) g: 20 (0.79)
Plate d: 6.6 (0.260) h: 14 (0.55) dia. J
Unit: mm (in)
NT617
KV11106100 K
Engine sub-attachment
ZZA1200D M
KV10106500
Engine attachment
When overhauling engine

N
O
ZZA0020D
ST0501S000
Engine stand assembly P
ZZA0022D

PREPARATION
Tool number
Description
Tool name
ST16610001 Removing pilot bearing
Pilot bearing puller
ZZA0046D

Piston ring compressor
S-NT044
Commercial Service Tool INFOID:0000000003397121

Tube presser Pressing the tube of liquid gasket
S-NT052
S-NT048
S-NT030

ENGINE ROOM COVER
ENGINE ROOM COVER
A
EM
PBIC4646E
G

H
REMOVAL
I
3. Partially remove floor carpet. J
5. Move parking brake lever and cable from engine compartment right side cover. Refer to PB-4, "Compo- K
nent".
CAUTION:
L
INSTALLATION
Install in the reverse order of removal following instructions below. M
: Vehicle front N
included] to specified torque in any given order. O
P
PBIC5379E
REMOVAL

ENGINE ROOM COVER
KBIA0742E
INSTALLATION
Following instructions below, install in the reverse order of removal.
2. Tighten other bolts to specified torque in any given order.
KBIA0742E

AIR CLEANER AND AIR DUCT (ZD30DD)
AIR CLEANER AND AIR DUCT (ZD30DD)
A
EM
J
PBIC4695E
1. Collar 2. Grommet 3. Resonator K

4. Clamp 5. Clamp 6. Air hose
7. Clamp 8. Air duct 9. Clamp
10. Air hose 11. Clamp 12. Air duct L
13. Grommet 14. Collar 15. Clamp
16. PCV hose 17. Air hose 18. Clamp
19. Grommet 20. Intake air temperature sensor 21. Washer M
22. Air cleaner case 23. Air cleaner element 24. Washer
25. Wing nut 26. Dust pan 27. Dust drain valve
28. Washer 29. Wing nut 30. Bolt N
31. Grille 32. Air duct (inlet) 33. Grommet
34. Air duct 35. Resonator 36. Grommet
37. Collar 38. Resonator 39. Clamp O
A. To throttle control actuator B. To rocker cover
• Refer to GI-8, "Component" for symbol marks in the figure. P

AIR CLEANER AND AIR DUCT (ZD30DDTI)
AIR CLEANER AND AIR DUCT (ZD30DDTI)
PBIC4696E
1. Air duct 2. Collar 3. Grommet

4. Clamp 5. PCV hose 6. Air hose
7. Clamp 8. Grommet 9. Collar
10. Clamp 11. Air hose 12. Clamp
13. Collar 14. Grommet 15. Intake air temperature sensor
16. Washer 17. Air cleaner case 18. Air cleaner element
19. Washer 20. Wing nut 21. Dust pan
22. Dust drain valve 23. Washer 24. Wing nut
25. Bolt 26. Grille 27. Air duct (inlet)
28. Collar 29. Grommet 30. Air duct
31. Resonator 32. Collar 33. Grommet
A. To rocker cover B. To air inlet pipe

CHARGE AIR COOLER [ZD30DDTI]
A
Layout INFOID:0000000003397127
EM
J
PBIC1855E
1. Turbocharger 2. Air inlet hose 3. Air inlet pipe K

4. Air inlet hose 5. Air inlet pipe 6. Air inlet hose
7. Bracket 8. Charge air pressure sensor 9. Charge air cooler
10. Bracket 11. Air hose (for charge air pressure sensor) 12. Air inlet hose L
13 Air inlet pipe 14. Air inlet hose 15. Air inlet pipe
16. Air inlet hose 17. Throttle body 18. Clamp (each air inlet hose both ends)
M

PBIC1856E
1. Charge air pressure sensor 2. Bracket 3. Air hose (for charge air pressure sensor)
4. Charge air cooler 5. Bracket

INTAKE MANIFOLD COLLECTOR AND INTAKE MANIFOLD
A
EM
PBIC1857E
N
1. Ground wire 2. Harness bracket 3. Water pipe
4. EGR volume control valve cover 5. Gasket 6. EGR tube
7. Gasket 8. Bracket 9. Gasket O
10. EGR volume control valve 11. Water hose 12. Harness bracket
13. Intake manifold collector cover 14. Intake manifold collector 15. Gasket
16. Intake manifold 17. Gasket 18. Harness bracket P
19. Intake manifold collector support 20. O-ring 21. Throttle control actuator
Intake air control valve control sole-
22. Fuel tube 23. Harness bracket 24.
noid valve bracket assembly
25. Oil level gauge guide and level gauge 26. O-ring

REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when the engine is hot.
INSTALLATION
EGR Volume Control Valve, EGR Cooler and Component Parts (ZD30DDTi)
PBIC4647E
1. Intake manifold 2. Intake manifold collector 3. Intake manifold collector support

4. EGR volume control valve 5. EGR tube 6. Bracket (*)
7. EGR cooler (*) 8. EGR cooler bracket (*) 9. EGR tube (*)
10. Exhaust manifold (*)
A. Engine rear view
NOTE:
“*” parts: Refer to EM-132.

TURBOCHARGER AND THREE WAY CATALYST (ZD30DDTI)
A
EM
L
PBIC5432E
1. Exhaust outlet cover 2. Turbocharger cover 3. Insulator M

4. Washer 5. Oil feed tube 6. Eye-bolt
7. Exhaust manifold 8. Washer 9. Gasket
10. Insulator (cylinder head left side) 11. Air inlet pipe 12. Turbocharger N
13. Gasket 14. Gasket 15. Oil return tube
16. Catalyst support 17. Catalyst 18. Catalyst cover
19. Washer 20. Converter cap 21. Exhaust outlet O
22. Gasket 23. Exhaust outlet support 24. Gasket
A. Catalyst side
• Refer to GI-8, "Component" for symbol marks in the figure. P

Waste gate valve
CAUTION:

Diaphragm in swing valve controller may be damaged if excessive pressure is applied. Check that air
gun pressure is within the standard by using pressure gauge to check before applying pressure to dia-
phragm.
Actuator rod operation pressure standard

: 107.3 - 112.7 kpa (805 - 845 mmHg)

EXHAUST MANIFOLD (ZD30DD)
EXHAUST MANIFOLD (ZD30DD)
A
EM
I
PBIC5415E
1. EGR tube 2. Gasket 3. EGR volume control valve J

4. Gasket 5. Exhaust manifold 6. Exhaust manifold cover
7. Gasket
A. Front mark K
: Engine front

L
REMOVAL M
WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
N

EXHAUST MANIFOLD (ZD30DDTI)
EXHAUST MANIFOLD (ZD30DDTI)
PBIC5416E
1. Water hose 2. Clamp 3. EGR cooler

4. Gasket 5. Clamp 6. Water hose
7. Bracket 8. Gasket 9. Exhaust manifold
10. Exhaust manifold cover 11. Gasket 12. EGR tube
13. EGR cooler bracket 14. Gasket
A. To heater pipe B. To EGR tube C. To water pipe
D. Front mark
: Engine front

REMOVAL
WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.

A
EM
I
PBIC5417E
1. Oil pan 2. Oil strainer 3. Gasket J

4. Drain plug 5. Washer 6. Insulator
A. Oil pan side
• Refer to GI-8, "Component" for symbol marks in the figure. K
L
REMOVAL
CAUTION:
To avoid the danger of being scalded, never drain engine oil when the engine is hot.
M

GLOW PLUG
GLOW PLUG
PBIC5418E
1. Glow plate 2. Glow harness 3. Glow nut

4. Glow plug oil seal 5. Glow plug
: Engine front
• Refer toGI-8, "Component" for symbol marks in the figure.

VACUUM PUMP
VACUUM PUMP
A
EM
I
PBIC5419E
1. Harness clamp 2. Vacuum pump 3. O-ring J

4. Vacuum pipe 5. Vacuum hose
A. To vehicle side vacuum tank
• Refer to GI-8, "Component" for symbol marks in the figure. K

INJECTION TUBE AND INJECTION NOZZLE
PBIC5420E
1. Spill hose 2. Eye-bolt 3. Copper washer

4. Spill tube 5. Washer 6. Nozzle support
7. Injection nozzle assembly 8. O-ring 9. Nozzle gasket
10. Nozzle oil seal 11. Clamp 12. Clamp
13. Clamp 14. Clamp 15. Injection tube
16. Spill connector 17. Clamp
To electronic control fuel injection
A. Upper side B. Paint C.
pump
: Engine front

ELECTRONIC CONTROL FUEL INJECTION PUMP
A
EM
J
PBIC5421E
1. Fuel injection pump rear bracket 2. Harness 3. Electronic control fuel injection pump K
4. Fuel connector (feed side) 5. Eye-bolt 6. Copper washer
7. Fuel connector (return side) 8. O-ring 9. Dowel pin
10. Spacer 11. Gasket 12. Fuel injection pump gear L
13. Fuel injection pump gear sprocket 14. Seal washer
: Engine front
M
• Refer to GI-8, "Component" symbol marks in the figure.
N
CAUTION:
• Apply new engine oil to parts marked in illustration before installation.
• Before removing or installing fuel injection pump sprocket, fixing internal mechanism of idler gear O
with bolt is absolutely performed.
• For the above, when removing or installing timing chain as an incidental work, never refer to the pro-
cedure in the section “TIMING CHAIN” which is predicated upon No. 1 cylinder compression top
dead center. (Possible to refer to the descriptions especially) P
• Before removing and installing fuel injection pump, be sure to remove sprocket. Never loosen or
remove installation bolt in the center of fuel injection pump. If loosened or removed, replace injec-
tion pump assembly.
• Idler gear inner mechanism fixing bolt is installed in bare engine. After timing chain and related parts
are installed, be sure to remove the fixing bolt.
REMOVAL

1. Drain engine coolant. Refer to CO-27.
2. Remove the following:
• Rocker cover: Refer to EM-142.
• Intake manifold collector: Refer to EM-127.
• Injection tube and spill tube: Refer to EM-136.
• Water outlet: Refer to EM-145.
• Radiator shroud: Refer to CO-28.
• Radiator: Refer to CO-28.
• Cooling fan: Refer to CO-29.
• Drive belt: Refer to EM section (DRIVE BELTS) in SM3E-1E25G3.
• Insulator
• Vacuum pump and vacuum pipe: Refer to EM-135.
3. Move the following:
• TDC sensor and harness: Refer to EM-150.
• Power steering oil pump: Refer to PS-13.
4. Disconnect harness connector from fuel injection pump.
• After pulling connector stopper all the way back, remove con-
nector.
NOTE:
When stopper is pulled all the way back, interlocked-connector
will come off.
As for installation, when connector is pushed all the way forward
until stopper locks, interlocked-connector is inserted.
5. Remove fuel injection pump rear bracket.
KBIA0772E
6. Remove chain cover.

• Remove the installation bolts A, B, and C shown in the figure.
CAUTION:
During chain cover removal, seal the opening to prevent
foreign objects from getting into the engine.
EMT0070D
7. Fix the internal mechanism of idler gear (scissors gear structure).

CAUTION:
• Always perform this work. If timing gear contacting idler gear (A) is removed without performing
this work, some difficulties will occur. Inner mechanism (scissors gear structure) of idler gear
(A) will open, resulting in idler gear (A) displacement.
• For bare engine, fixing is unnecessary because idler gear inner mechanism fixing bolt is
installed.
a. Remove the plug on the front side of gear case.
b. While turning crankshaft pulley clockwise, check the tightening
bolt hole of the idler gear internal mechanism through the plug
hole.
• Conduct the visual check using a mirror.
CAUTION:
When checking, note that there are 2 other holes (with no
thread) beside the tightening bolt hole on idler gear.
JEF262Z

c. Install the tightening bolt [Part No.: 81–20620–28, thread diame-
ter: M6, length: 20 mm (0.79 in), pitch: 1.0 mm (0.039 in)] to the A
idler gear tightening bolt hole, and tighten to the specified
torque:
EM
: 3.0 N·m (0.31 kg-m, 27 in-lb)
CAUTION:
• To protect idler gear (A) from damage, never use the sub- C
stitute part for the tightening bolt.
• Hereafter, never turn crankshaft to avoid hitting tightening
bolt head against gear case. JEF263Z
• Never remove the idler gear (A) tightening bolt before D

installations of timing chain and related parts are completed.
8. Make mating marks on camshaft sprocket, fuel injection pump
sprocket, and timing chain with paint. E
9. Make mating marks on fuel injection pump gear and idler gear
with paint.
F
JEF264Z
H
10. Remove chain tensioner and timing chain slack guide. Refer to EM-145.
11. Remove camshaft sprocket and timing chain at the same time. Refer to EM-145.
12. Remove fuel injection pump sprocket and gear as an assembly. I
• Fix fuel injection pump gear with the pulley holder (SST), and
loosen the installation bolt for removal.
• Try not to move the pump shaft when removing. J
NOTE:
Connect sprocket and gear with a dowel pin, and tighten them
together with the installation bolt.
K
JEF267Z
L
13. Make the mating marks on the fuel injection pump flange and
front plate with paint. M
14. Remove installation bolts first, and then fuel injection pump
toward the rear side of the engine.
CAUTION: N
Never disassemble or adjust fuel injection pump.
NOTE:
When fuel injection pump is stationary, it can still be retained by
the dowel without all bolts. O
JEF268Z
INSTALLATION P
NOTE:
The injection timing adjustment to correct the installation angle deviation is not necessary. Install the pump in
the proper position according to the dowel and installation bolts.
1. Install fuel injection pump from the rear side of the engine.

• Match the dowel of spacer to the dowel hole of the pump side
for installation.
• Replace seal washer of the installation bolt with a new one.
JEF269Z
2. Align the mating marks of the fuel injection pump flange and front plate, and then adjust the approximate
flange position.
• Each hole [6 mm (0.24 in) dia.] is used as a reference point for
the fuel injection pump flange, fuel injection pump gear, and
fuel injection pump sprocket.
NOTE:
Only during removal/installation at No. 1 cylinder compression
top dead center, can the hole [6 mm (0.24 in) dia.] of the pump
body be aligned.
JEF270Z
3. Install fuel injection pump sprocket and gear as an assembly.

• With positioning stopper pin [SST: KV11106030], align the 6
mm (0.24 in) diameter hole of fuel injection pump and gear
assembly with the 6 mm (0.24 in) diameter hole of fuel injec-
tion pump flange.
• Align the mating marks of idler gear and fuel injection pump
gear properly.
JEF271Z
4. Tighten the installation bolt of fuel injection pump sprocket.

• Fix fuel injection pump gear with the pulley holder (SST), and
tighten the installation bolt.
CAUTION:
Before tightening the installation bolt, check again that the
mating marks of idler gear and fuel injection pump gear are
aligned.
JEF267Z
5. Install camshaft sprocket and timing chain at the same time.

• Align the mating marks of fuel injection pump sprocket and
camshaft sprocket, and install timing chain. A
• Holding the hexagon head of camshaft with a wrench, tighten
the camshaft sprocket installation bolt.
CAUTION:
EM
Never tighten the installation bolt using a chain tension.
6. Install timing chain, related parts, and chain cover. Refer to EM-
145.
C
JEF264Z
D
7. Remove the tightening bolt of the idler gear internal mechanism.
CAUTION:
Bear engine is supplied with fixing bolt installed. Be sure to remove the bolt.
E
8. Apply the liquid gasket to the screw of the plug, and tighten the
plug.
F
: 8.9 N·m (0.1 kg-m, 79 in-lb)
H
JEF272Z
9. Install fuel injection pump rear bracket.

• Tighten all the installation bolts temporarily, and then tighten I
them firmly with both surfaces of fuel injection pump and cylin-
der block attached to the installation surface.
J
JEF273Z
L
10. Connect harness connector of fuel injection pump.
• Insert harness connector until stopper is completely locked.
NOTE: M
When connector is pushed fully to lock stopper, interlocked-
connector is inserted.
KBIA0772E
P
11. Install in the reverse order of removal.
12. Before starting engine, bleed air from fuel piping. Refer to FL-13, "Component".

ROCKER COVER
ROCKER COVER
PBIC5422E
1. Glow plug oil seal 2. Glow plate 3. Glow nut

4. Rocker cover bolt 5. Oil filler cap 6. Rocker cover gasket
7. PCV hose 8. Harness bracket
A. To air duct B. Front mark C. 4 areas

CAMSHAFT
CAMSHAFT
A
MODELS PRODUCED BEFORE NOVEMBER 23, 2003 EM
PBIC5426E
K
1. Baffle plate (rear) 2. Baffle plate (center) 3. Baffle plate (front)
4. Camshaft bracket 5. Camshaft gear (right side) 6. Camshaft sprocket
L
7. Washer 8. Camshaft gear (left side) 9. Thrust plate
10. Idler gear 11. Idler shaft 12. Cylinder head
13. Valve lifter 14. Camshaft (left side) 15. Camshaft (right side)
M
A. Refer to EM-174

MODELS PRODUCED AFTER NOVEMBER 24, 2003 N

CAMSHAFT
PBIC5427E
1. Baffle plate (rear) 2. Baffle plate (center) 3. Baffle plate (front)

4. Camshaft bracket 5. Camshaft gear (right side) 6. Camshaft sprocket
7. Washer 8. Camshaft gear (left side) 9. Thrust plate
13. Valve lifter 14. Adjusting shim 15. Camshaft (left side)
16. Camshaft (right side)
A. Refer to EM-174

TIMING CHAIN
TIMING CHAIN
A
EM
J
PBIC5428E
1. Chain tensioner 2. Timing chain slack guide 3. Camshaft gear (left side) K
4. Washer 5. Camshaft gear (right side) 6. Camshaft sprocket
7. Timing chain 8. Timing chain tension guide 9. Harness bracket
10. Water outlet 11. Gasket 12. Insulator L
13. Engine coolant temperature sensor 14. Seal gasket 15. Chain cover
• Refer to GI-8, "Component" for symbol marks in the figure. M

REMOVAL N
1. Remove the following parts:
• Spill tube: Refer to EM-136. O
• Radiator upper hose: Refer to CO-28.
• Water outlet
• Radiator shroud: Refer to CO-28.
P
• Vacuum pipe and vacuum pump: Refer to EM-135.
2. Move the following parts.
• TDC sensor and harness: Refer to EM-150.
• Power steering oil pump: Refer to PS-13.

TIMING CHAIN
• Remove the holding bolts A to C shown in the figure.
CAUTION:
While chain cover is removed, be careful not to allow
entry of dust or foreign objects.
EMT0070D
4. Set the No. 1 cylinder to the compression TDC.

a. Turn crankshaft pulley clockwise, and align the timing indicator
of gear case to the timing mark of crankshaft pulley.
When the timing mark (white paint) is aligned with the tim-
ing indicator, the mark for assembling signal plate (no
paint) (not used for servicing) will be located 90 degrees
clockwise from the timing mark.
SEM214H
CAUTION:
Never confuse timing mark with mark for assemble signal
plate.
SEM213H
b. Check that the camshaft sprocket mating mark is in the position

• If the mating mark is not in position, turn crankshaft pulley
360° and position it.
NOTE:
When removing at No. 1 cylinder compression TDC, each
sprocket and chain is fitted using the mating mark, therefore
there is no need to apply any mating marks beforehand.
PBIC0377E
5. Remove chain tensioner with the following procedure:

a. Open stopper tab, and press plunger in the chain tensioner body.
b. Engage stopper tab to groove on the end of plunger.

TIMING CHAIN
c. Lever hole is aligned with the tensioner body hole position in this
condition. Fix lever using stopper pin. A
NOTE:
Stopper pin is made from wires of approximately 0.5 mm (0.020
in) diameter or paperclips.
EM
d. Remove chain tensioner.
6. Remove timing chain slack guide.
C
KBIA2295E
D
7. Remove timing chain with camshaft sprocket.
• Loosen the camshaft sprocket holding bolt by fixing the hexag-
onal portion of the intake manifold side camshaft with a span- E
ner, etc.
CAUTION:
Never loosen the holding bolt by using the tension of the
chain. F
8. Remove timing chain tensioner guide.
G
EMT0075D
H
Timing Chain
Check timing chain for cracks and excessive wear at roller links. I
Replace chain if necessary.
SEM984C L
INSTALLATION
1. Install timing chain tensioner guide.
M
2. Install camshaft sprocket and timing chain together.

TIMING CHAIN
• Install by aligning the sprocket and timing chain mating marks.
• Tighten the camshaft sprocket holding bolt by fixing the hexag-
onal portion of camshaft.
CAUTION:
Never tighten in the holding bolt using the tension of the
chain.
3. Install timing chain slack guide.
CAUTION:
When the holding bolt is tightened to the specified torque,
there is a gap between the guide and bolt. Never over-
tighten.
PBIC0378E

• Pull out stopper pin and release plunger after installing chain
tensioner.
KBIA2295E
5. Install chain cover.

a. Before installing chain cover, apply liquid gasket to mating sur-
face as shown.
Use Genuine Liquid Gasket or equivalents.
FEM009
b. Install chain cover.

TIMING CHAIN
• The length of the holding bolt will vary depending on the part.
A
A: 20 mm (0.79 in)
B: 50 mm (1.97 in)
C: 60 mm (2.36 in) EM
EMT0070D
D
6. Install by following all removal procedures in the reverse.

TIMING GEAR
TIMING GEAR
PBIC5423E
1. Electronic control fuel injection pump 2. O-ring 3. Spacer

4. Gasket 5. Front plate 6. Seal washer
7. Fuel injection pump gear 8. Fuel injection pump sprocket 9. Balancer shaft (right)

TIMING GEAR
10. Crankshaft gear 11. Balancer shaft (left) 12. O-ring
13. Gear case 14. TDC sensor 15. Bracket A
16. Plug 17. Front oil seal 18. Crankshaft pulley
19. Drive belt auto tensioner 20. Bracket 21. O-ring
22. O-ring 23. O-ring 24. Gasket EM
25. Thrust plate 26. Idler gear (B) 27. Idler shaft
28. Thrust plate 29. Idler gear (A) 30. Idler shaft
31. Gasket 32. O-ring 33. Keys C
34. Oil jet
A. Upper side B. Engraved line
D
E
REMOVAL
1. Drain engine coolant. Refer to CO-27.
F
• Oil pan and oil strainer: Refer to EM-133.
• Spill tube: Refer to EM-136. G
• Radiator hose: Refer to CO-28.
• Radiator shroud and radiator: Refer to CO-28. H
• Alternator: Refer to SC-6. I
3. Move the following parts:
• TDC sensor harness
• Power steering oil pump: Refer to PS-13. J
• A/C compressor: Refer to MTC-68.
• A/C compressor bracket: Refer to MTC-68. K
• Drive belt, auto tensioner and idler pulley: Refer to EM section (DRIVE BELTS) in SM3E-1E25G3.
5. Following steps below, secure the inner mechanism (scissors gear structure) of idler gear (A).
CAUTION: L
Always carry out this work. If timing gear contacting idler gear (A) is removed without performing
this work, some difficulties will occur. The inner mechanism (scissors gear structure) of idler gear
(A) is opened, resulting in idler gear (A) replacement.
M
a. Remove plug in front of gear case.
P
JEF262Z

TIMING GEAR
b. Rotate crank pulley clockwise. At the same time, check the fix-
ing bolt hole for the inner mechanism of idler gear (A) from the
plug hole.
• Visually check it using a mirror.
CAUTION:
Be careful not to check a wrong hole. Idler gear (A) has 2
extra holes (without thread) in addition to fixing hole.
c. Install fixing bolt [part No.: 81–20620–28, bolt size: M6 (0.24 in),
bolt length: 20 mm (0.79 in)] into fixing bolt hole for idler gear
(A). Tighten it to specified torque below.
JEF263Z
: 3.0 N·m (0.31 kg-m, 27 in-lb)

CAUTION:
• Never use a substitute for fixing bolt. Idler gear (A) may be broken.
• From this point, never rotate crankshaft. Head of fixing bolt may interfere with gear case.
• Never remove fixing bolt for idler gear (A) until timing chain and related parts have been installed.
6. Paint mating marks onto camshaft sprocket, fuel injection pump
sprocket, and timing chain.
• Paint mating marks onto easy-to-see places with oil-resistant-
method.
7. Paint mating marks onto fuel injection pump gear and idler gear.
• Paint mating marks onto easy-to-see places with oil-resistant-
method.
8. Remove chain tensioner and timing chain slack guide. Refer to
EM-145.
JEF264Z
9. Remove timing chain together with camshaft sprocket. Refer to

EM-145.
10. Remove TDC sensor.
CAUTION:
• Handle it carefully without giving any impact.
• Never place it where iron chips can adhere.
• Keep it clear of objects affected by magnetic fields.
11. Remove water pump. Refer to CO-30.
EMT0075D
12. Remove crankshaft pulley.

• Secure crankshaft by inserting hammer handle into gap
around counter weight. Loosen mounting bolts to remove
crankshaft pulley.
CAUTION:
• Be careful not to damage crankshaft.
• Be careful to keep inside of engine clear of foreign materi-
als.
KBIA0779E

TIMING GEAR
• Handle crank pulley carefully to avoid damaging or mag-
netizing protrusion for signal detection. A
EM
KBIA0913E
D
13. Remove gear case.
• There are 3 pry grooves (shown by arrows in figure) on gear
case. Using grooves and a flat-bladed screwdriver or seal cut-
E
ter [SST: KV10111100], remove gear case.
CAUTION:
Be careful not to damage mounting surface.
14. Remove front oil seal from gear case. F
• Using a flat-bladed screwdriver, remove it.
CAUTION:
Be careful not to damage gear case. G
EMT0105D
H
15. Remove each timing gear.
• Before removal, check backlash between each two gears. Refer to "INSPECTION AFTER REMOVAL".
CAUTION:
I
• Never loosen the inner mechanism fixing bolt of idler gear (A). (If the inner mechanism is
opened, idler gear cannot be reused.)
• After removing idler gears (A) and (B), never face rear side downward. Idler main shaft will
drop. J
• Use a pulley holder (SST). While securing fuel injection timing
gear with pulley holder, loosen mounting bolts.
K
M
JEF267Z
• Pull balancer shaft straight out to avoid damaging bushing inside of cylinder block. N
16. Remove electronic control fuel injection pump. Refer to EM-137.
17. Remove front plate.
O
Backlash of Each Gear
Method using a fuse wire P
• Tighten the holding bolts of each gear to the specification.

TIMING GEAR
• Place a fuse wire in the biting area of the teeth between the gears
to be checked, rotate the crankshaft in the operating direction so
that the wire is taken inwards.
• Measure the thickness of the crushed area in the wire with a
micrometer.
PBIC2003E
Method using dial indicator

• Place the dial indicator on the tooth surface area of the gear to be checked.
• With the other gear in a set position, measure the dial indicator (A)
value while moving the gear left and right.
Standard : 0.07 - 0.11 mm (0.0028 - 0.0043 in)

Limit : 0.20 mm (0.0079 in)
• If it exceeds the limit, replace gear and measure again.
• If it exceeds the limit again, check for the installation condition of
the gear driving parts, wear of shaft and gear, and oil clearance.
JPBIA1264ZZ
Idler Gear End Play

• Tighten the holding bolts to the specification.
• Measure the clearance between thrust plate and idler gear using a feeler gauge.
Unit: mm (in)
Standard Limit
Idler gear (A)
0.06 - 0.12 (0.0024 - 0.0047) 0.15 (0.0059)
Idler gear (B)
• If it exceeds the limit, replace the idler gear, shaft, and thrust plate.
Idler Gear Oil Clearance
• Measure the inner diameter (d1) of the idler gear shaft.
Standard:
Idler gear (A)
43.000 - 43.020 mm (1.6929 - 1.6937 in) dia.
Idler gear (B)
28.600 - 28.620 mm (1.1260 - 1.1268 in) dia.
• Measure the outer diameter (d2) of the idler shaft.
EMT0112D
Standard:
Idler gear (A)
42.959 - 42.975 mm (1.6913 - 1.6919 in) dia.
Idler gear (B)
28.567 - 28.580 mm (1.1247 - 1.1252 in) dia.
• Calculate the oil clearance.
Clearance = d1 − d2

TIMING GEAR
Unit: mm (in)
Standard Limit A
Idler gear (A) 0.025 - 0.061 (0.0010 - 0.0024)
0.2 (0.008)
Idler gear (B) 0.020 - 0.053 (0.0008 - 0.0021)
EM
• If it exceeds the limit, refer to each standard specification and replace idler gear and/or shaft.
Balancer Shaft End Play
• Measure the clearance between the plate and gear using a feeler C
gauge.
Standard : 0.07 - 0.22 mm (0.0028 - 0.0087 in) D

• If it exceeds the specification, replace the balancer shaft assembly.
NOTE:
As the gears are press-fitted, there are no service setting for indi- E
vidual parts.
FEM038 F
Balancer Shaft Oil Clearance
Outer diameter of balancer shaft journal
Measure the outer diameter of the balancer shaft journal with a G
micrometer.
Standard: H
Front side
50.875 - 50.895 mm (2.0029 - 2.0037 in) dia.
I
Rear side
50.675 - 50.695 mm (1.9951 - 1.9959 in) dia.
PBIC2005E
J
Inner diameter of balancer shaft bearing

Measure the inner diameter of the balancer shaft bearing using a K
bore gauge.
Standard: L
Front side
50.940 - 51.010 mm (2.0055 - 2.0083 in) dia.
Rear side M
50.740 - 50.810 mm (1.9976 - 2.0004 in) dia.
Oil clearance calculations PBIC2006E N
(Oil clearance) = (Bearing inner diameter) − (Journal outer diameter)
Standard : 0.045 - 0.135 mm (0.0018 - 0.0053 in)

O
Limit : 0.180 mm (0.0071 in)
• If it exceeds the limit, refer to each standard specification and replace balancer shaft and/or cylinder block.
INSTALLATION P

TIMING GEAR
1. Install front plate.
a. Install O-ring and gasket to cylinder block.
b. Install front plate.
• Lightly tap with a hammer if dowel pin cannot be inserted eas-
ily.
CAUTION:
Check that O-ring does not pop out.
c. Apply liquid gasket with a spreader between the cylinder block
plate under the cylinder block (oil pan side) and the front plate
(shown by the arrows in the figure).
Use Genuine Liquid Gasket or equivalent. PBIC2007E
2. Install electronic control fuel injection pump. Refer to EM-137,

"Removal and Installation".
• After installing the fuel pump to front plate, align the 6 mm
(0.24 in) dia. hole of the pump flange and the 6 mm (0.24 in)
dia. hole position of the pump body.
3. Install each timing gear.
• Align the match marks of the timing gears by referring to the
figure below.
PBIC2008E
PBIC2009E
4. Install front oil seal to gear case.

• Apply engine oil to the fitting side.
• Evenly insert front oil seal using a drift [outer dia.: approx. 64
mm (2.52 in)] completely.
CAUTION:
Check oil seal does not spill off the end side of gear case.
PBIC2010E
5. Install gear case.

TIMING GEAR
a. Before installing gear case, apply liquid gasket to mating surface
as shown. A
b. Install O-rings to gear case.
c. Install gasket to gear case. EM
d. Install gear case.
• Tap the area around dowel pin with a plastic hammer if it can-
not be inserted easily. C
CAUTION:
Never pop out O-rings.
KBIA0803E
D
e. Install the holding bolt referring to the figure.
Bolt length: E
A: 30 mm (1.18 in)
B: 50 mm (1.97 in)
C: 80 mm (3.15 in) F
f. Install the holding bolts from the rear side of front plate.
G
KBIA0804J
6. Install crankshaft pulley. H

• Insert by aligning the 2 flat face of oil pump with the 2 flat face of the shaft on the rear side of the crank-
shaft pulley.
CAUTION:
I
Never damage the oil seal lip when inserting.
7. Install water pump. Refer to CO-30.
• Install it before installing TDC sensor.
J
8. Install TDC sensor.
• Align the bracket knock pin with the hole on gear case side and tighten the holding bolt.
• Confirm that the clearance between the end of sensor and the signal detection protrusion of the crank-
shaft pulley is within the specification. K
Standard: 0.5 - 1.5 mm (0.020 - 0.059 in)

• Arrange TDC sensor harness to the position shown in the fig- L
ure.
CAUTION:
Confirm that the harness has no deflection around crank- M
shaft pulley when installing the clamp.
PBIC0380E
O

P

TIMING GEAR
• Align the mating marks of fuel injection pump sprocket and
camshaft sprocket, and install timing chain.
• Holding the hexagon head of camshaft with wrench, tighten
the camshaft sprocket installation bolt.
CAUTION:
10. Install timing chain, related parts, and chain cover. Refer to EM-
145.
JEF264Z
11. Remove the internal mechanism setting bolt of idler gear (A). Bear engine is supplied with fixing bolt
installed. Be sure to remove the bolt.
12. Apply liquid gasket to the plug thread.
13. Install remaining parts in the reverse order of removal.
PBIC2011E

CYLINDER HEAD
CYLINDER HEAD
A
Component (Removal and Installation) INFOID:0000000003397150
EM
I
PBIC4643E
1. Glow plug 2. Cylinder head assembly 3. Cylinder head bolt J

4. Thermal transmitter 5. O-ring 6. Gasket
7. Thrust plate 8. Idler gear 9. Idler shaft
10. Dowel 11. Cylinder head gasket 12. Dowel K
13. Oil return hose 14. Oil return tube 15. O-ring
16. Rear engine slinger
A. Refer to EM-174 B. Install to gear case C. Markings L
D. To cylinder block
: Engine front
M

CYLINDER HEAD
Component (Disassembly and Assembly) INFOID:0000000003397151
MODELS PRODUCED BEFORE NOVEMBER 23, 2003
PBIC1888E
MODELS PRODUCED AFTER NOVEMBER 24, 2003
FEM081A
Inspection After Assembly and Disassembly INFOID:0000000003397152
VALVE GUIDE AND VALVE SEAT REPLACEMENT

CYLINDER HEAD
WARNING:
Use a protector to prevent a burn after heating the cylinder head with an oil bath, etc. A
EM

ENGINE ASSEMBLY
ENGINE ASSEMBLY
PBIC4709E
1. Rear engine mounting bracket 2. Rear engine mounting insulator 3. Engine mounting bracket (RH)
4. Engine mounting insulator (RH) 5. Engine mounting bracket (LH) 6. Engine mounting insulator (RH)
7. Rear engine mounting bolt
WARNING:
• Situate the vehicle on a flat and solid surface.
CATALOG.
CAUTION:
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at rear axle jacking point with transmission jack or similar tool before starting
work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-34, "Garage Jack and
Safety Stand" or GI-35, "2-Pole Lift".

CYLINDER BLOCK
CYLINDER BLOCK
A
EM
PBIC4640E
1. Rear oil seal and retainer assembly 2. Oil pressure switch 3. Washer
4. Oil jet relief valve 5. Cylinder block 6. Top ring
7. Second ring 8. Oil ring 9. Oil jet

CYLINDER BLOCK
10. Piston pin 11. Snap ring 12. Piston
13. Main bearing (upper) 14. Thrust bearing 15. Connecting rod
16. Crankshaft key 17. Connecting rod bearing 18. Connecting rod cap
19. Connecting rod nut 20. Lower cylinder block sub bolt 21. Lower cylinder block main bolt
22. Lower cylinder block sub bolt 23. Lower cylinder block 24. Main bearing (lower)
25. Crankshaft 26. Rear plate 27. Pilot bush
28. Flywheel 29. Drain plug
A. Oil seal lip B. Refer to EM-174 C. Cylinder block side

Inspection After Disassembly (ZD30DD) INFOID:0000000003397156
PISTON RING END GAP

If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, re-
bore cylinder and use oversize piston and piston rings. Refer to "PISTON TO CYLINDER BORE CLEAR-
ANCE".
• Oversize piston is provide. When using oversize piston, hone cylinder so that the clearance between piston
and cylinder satisfies. the standard.
CAUTION:
• If oversize piston is used, use it for all cylinders with oversize piston rings.
• Use the same grade of oversize for piston and piston rings.
Oversize (O/S) : 0.25 mm (0.0098 in)

: 0.50 mm (0.0197 in)
• Install top ring and second ring with the stamped surface facing upward.
• Identify top ring and second ring by thickness.
Top ring : 2.0 mm (0.079 in)

Second ring : 1.2 mm (0.047 in)

A
GENERAL SPECIFICATIONS EM

Displacement cm3 (cu in) 2,953 (180.19) C
Bore and stroke mm (in) 96 x 102 (3.78 x 4.02)
D
Compression 2
Oil 1 E
Number of main bearings 5
F
Standard 2,942 (29.42, 30.0, 427)
Compression pressure
Minimum 2,452 (24.52, 25.0, 356)
kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 294 (2.94, 3.0, 43) G
Valve timing I
PBIC0517E
Unit: degree K
a b c d e
232 232 6 46 50
L
Unit: mm (in)
Items Limit M
Intake manifold collector 0.2 (0.008)
Surface distortion Intake manifold 0.2 (0.008)
N
Exhaust manifold 0.2 (0.008)
DRIVE BELTS
O
Tension of drive belts Auto adjustment by auto tensioner
TURBO CHARGER
P
Turbo Charger
Unit: mm (in)
Items Standard
Rotor shaft end play 0.002 – 0.006 (0.0001 – 0.0002)
Waste gate Valve

Unit: kPa (mmHg)
Items Standard
Actuator rod operation pressure 107.3 – 112.7 (805 – 843)

Injection Nozzle
Unit: kPa (bar, kg/cm2, psi)

ZD30DD 20,399 – 22,458 (204 – 225, 208 – 229, 2,958 – 3,256) 17,751 (178, 181, 2,574)
Opening pressure
ZD30DDTi 19,500 – 20,500 (195 – 205, 199 – 209, 2,828 – 2,973) 16,200 (162, 165, 2,349)
Spill Tube
Unit: kPa (mbar, mmHg, inHg)
Items Standard
Airtight degree −53 to −67 (−530 to −670, −398 to −503, −15.65 to −19.79)
TIMING GEAR
Idler Gear (A), Idler Gear (B)
Unit: mm (in)
Backlash of Method1 Using a dial indicator 0.07 – 0.11 (0.0028 – 0.0043) 0.20 (0.0079)
each gear Method2 Using a fuse wire Measure the thickness of the crushed area in the wire with a micrometer.
Idler gear end Idler gear (A)

0.06 – 0.12 (0.0024 – 0.0047) 0.15 (0.0059)
play Idler gear (B)
Idler gear oil Idler gear (A) 0.025 – 0.061 (0.0010 – 0.0024)
0.2 (0.008)
clearance Idler gear (B) 0.020 – 0.053 (0.0008 – 0.0021)
Balancer Shaft
Unit: mm (in)

Front side 50.875 – 50.895 (2.0029 – 2.0037)
Rear side 50.675 – 50.695 (1.9951 – 1.9959)
Balancer shaft —
Front side 50.940 – 51.010 (2.0055 – 2.0083)
oil clearance Inner diameter of balancer shaft bearing
Rear side 50.740 – 50.810 (1.9976 – 2.0004)
Oil clearance calculations 0.045 – 0.135 (0.0018 – 0.0053) 0.180 (0.0071)
Balancer shaft end play 0.07 – 0.22 (0.0028 – 0.0087) —
CYLINDER HEAD

Unit: mm (in)
Items Standard Limit A
Head surface distortion Less than 0.03 (0.0012) 0.2 (0.008)
EM
SEM368G
E
Idler gear end play 0.070 - 0.14 (0.0028 - 0.0055) 0.2 (0.008)
Idler gear oil clearance 0.023 - 0.053 (0.0009 - 0.0021) 0.1 (0.004)
F
Available Cylinder Head Gasket
Unit: mm (in)
Grade Piston crown depression Gasket thickness* No. of notches

G
1 More than 0.078 (0.0031) 0.65 (0.0256) 1
2 Less than 0.078 (0.0031) 0.70 (0.0276) 2 H
*: Thickness of gasket tightened with head bolts
PBIC0409E
J
VALVE
Valve
Unit: mm (in) K
PBIC0413E
Intake O
Valve length “a” 113.5 (4.47)
Exhaust
Intake
“b” 3.8 - 4.2 (0.150 - 0.165) P
Exhaust
Intake
Valve margin “c” 1.5 (0.059)
Exhaust
Intake 6.962 - 6.977 (0.2741 - 0.2747)
Exhaust 6.945 - 6.960 (0.2734 - 0.2740)

Intake 31.9 - 32.1 (1.256 - 1.264)
Exhaust 29.9 - 30.1 (1.177 - 1.185)
Intake
Exhaust
Valve Clearance
Unit: mm (in)
Items Cold*
Intake & Exhaust 0.30 - 0.40 (0.012 - 0.016)
Valve Spring
Free length mm (in) 55.43 (2.1823)

Installation load N (kg, lb) at height mm (in) 180 - 206 (18.4 - 21.0, 40.5 - 46.3) at 40.8 (1.606)
Square mm (in) 2.4 (0.094)
Available Valve Lifters (Models Produced Before November 23, 2004)

Unit: mm (in)
Stamp Thickness
535 5.35 (0.2106)
540 5.40 (0.2126)
545 5.45 (0.2146)
550 5.50 (0.2165)
555 5.55 (0.2185)
560 5.60 (0.2205)
565 5.65 (0.2224)
570 5.70 (0.2244)
575 5.75 (0.2264)
580 5.80 (0.2283)
585 5.85 (0.2303)
590 5.90 (0.2323)
595 5.95 (0.2343)
600 6.00 (0.2362)
605 6.05 (0.2382)
KBIA2292E
Available Shims (Models Produced After November 24,2003)

Unit: mm (in)
Stamp Thickness A
2.35 2.35 (0.0925)
2.40 2.40 (0.0945)
EM
2.45 2.45 (0.0965)
2.50 2.50 (0.0984)
2.55 2.55 (0.1004) C
2.60 2.60 (0.1024)
2.65 2.65 (0.1043)
D
2.70 2.70 (0.1063)
2.75 2.75 (0.1083)
2.80 2.80 (0.1102) E
2.85 2.85 (0.1122)
2.90 2.90 (0.1142)
2.95 2.95 (0.1161)
F
3.00 3.00 (0.1181)
3.05 3.05 (0.1201)
G
JEM184G
Valve Lifter K
Unit: mm (in)
Items Standard
L
Lifter guide inner diameter 34.495 - 34.515 (1.3581 - 1.3589)
Clearance between lifter and lifter guide 0.030 - 0.065 (0.0012 - 0.0026) M
Valve Guide
Unit: mm (in)
N
PBIC0420E
Items Standard

Outer diameter 11.023 - 11.034 (0.4340 - 0.4344)
Valve guide
Cylinder head valve guide hole diameter 10.996 - 10.975 (0.4329 - 0.4321)
Intake 0.023 - 0.053 (0.0009 - 0.0021)
Stem to guide clearance
Exhaust 0.040 - 0.070 (0.0016 - 0.0028)
Intake 0.10 (0.0039)
Valve deflection limit
Exhaust 0.10 (0.0039)
Projection length 12.8 - 13.2 (0.504 - 0.520)

Unit: mm (in)

Camshaft journal clearance 0.045 - 0.090 (0.0018 - 0.0035) 0.09 (0.0035)
Inner diameter of camshaft bearing 30.000 - 30.021 (1.1811 - 1.1819) —
Outer diameter of camshaft journal 29.931 - 29.955 (1.1784 - 1.1793) —
Camshaft runout [TIR*] — 0.04 (0.0016)
Camshaft end play 0.065 - 0.169 (0.0026 - 0.0067) 0.2 (0.008)
PBIC1911E
Dimension A for camshaft No. 1 journal 19.455 – 19.507 (0.7659 – 0.7680) —

Dimension B for cylinder head No. 1 journal bearing 19.348 – 19.390 (0.7617 – 0.7634) —
SEM671
INT
ZD30DD 40.98 - 41.02 (1.6134 - 1.6150)
EXH
Cam height “A”
INT 40.468 - 40.508 (1.5392 - 1.5948)
ZD30DDTi
EXH 40.83 - 40.87 (1.6075 - 1.6091)
Wear limit of cam height 0.15 (0.0059)
CYLINDER BLOCK

Unit: mm (in)
A
EM
SEM370G
D
Surface flatness Limit 0.1 (0.004)

E
Grade No. 1 96.000 - 96.010 (3.7795 - 3.7799)
Standard Grade No. 2 96.010 - 96.020 (3.7799 - 3.7803)
Cylinder bore Inner diameter
Grade No. 3 96.020 - 96.030 (3.7803 - 3.7807) F
Wear limit 0.20 (0.0079)
Out-of-round (X − Y) Less than 0.02 (0.0008)
Taper (A − C) Less than 0.02 (0.0008)
G
Main bearing housing 74.981 - 75.000 (2.9520 - 2.9528)
Crankshaft journal bearing inner diameter (With bearing) 70.955 - 70.990 (2.7935 - 2.7949) H
Difference in inner diameter
Limit Less than 0.05 (0.0020)
between cylinders
PISTON, PISTON RING AND PISTON PIN I
Available Piston
Unit: mm (in)
J
SEM369G
Grade No. 1 95.950 - 95.960 (3.7776 - 3.7779) N

Standard
Grade No. 2 95.960 - 95.970 (3.7779 - 3.7783)
Piston skirt diameter “A”
0.25 (0.0098)* Grade No. 5* 96.210 - 96.220 (3.7878 - 3.7882)*
Oversize (service)*
0.50 (0.0197)* Grade No. 6* 96.460 - 96.470 (3.7976 - 3.7980)* O
“a” dimension 10 (0.39)
Piston pin bore diameter 32.997 - 33.005 (1.2991 - 1.2994)
P
Piston clearance to cylinder block 0.040 - 0.060 (0.0016 - 0.0024)
*: For ZD30DD engine models
Piston Ring

Unit: mm (in)

Top 0.05 - 0.07 (0.0020 - 0.0028) 0.5 (0.020)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059)
Top 0.25 - 0.45 (0.0098 - 0.0177) 1.5 (0.059)
End gap 2nd 0.50 - 0.65 (0.0197 - 0.0256) 1.5 (0.059)
Oil (rail ring) 0.25 - 0.45 (0.0098 - 0.0177) 1.5 (0.059)
Piston Pin
Unit: mm (in)
Piston pin outer diameter 32.993 - 33.000 (1.2989 - 1.2992)

Interference fit of piston pin to piston −0.003 to 0.012 (−0.0001 to 0.0005)
Standard 0.025 - 0.045 (0.0010 - 0.0018)
Piston pin to connecting rod bushing clearance
Limit 0.045 (0.0018)
*: Values measured at ambient temperature of 20°C (68°F)
CONNECTING ROD
Unit: mm (in)
Center distance 154.5 (6.083)

Bend [per 100 (3.94)] Limit 0.05 (0.0020)
Connecting rod small end inner diameter 35.087 - 36.000 (1.3814 - 1.4173)
Piston pin bushing inner diameter* 33.025 - 33.038 (1.3002 - 1.3007)
Connecting rod big end inner diameter* 59.987 - 60.000 (2.3617 - 2.3622)
Standard 0.10 - 0.22 (0.0039 - 0.0087)
Side clearance
Limit 0.22 (0.0087)
CRANKSHAFT
Unit: mm (in)
Main journal dia. “Dm” 70.907 - 70.920 (2.7916 - 2.7921)

Pin journal dia. “Dp” Grade No. 0 56.913 - 56.926 (2.2407 - 2.2412)
Taper: (Difference between “A”
Standard Less than 0.01 (0.0004)
and “B”)
Out–of–round: (Difference be-
tween “X” and “Y”)

Standard 0.055 - 0.140 (0.0022 - 0.0055)
Side clearance A
Limit 0.250 (0.0098)
EM
SBIA0535E
SEM645
E
MAIN BEARING
Undersize F
Unit: mm (in)
J
FEM127
Size Thickness Main journal diameter “Dm”

Standard 2.005 - 2.013 (0.0789 - 0.0793) K
US 025 2.130 - 2.138 (0.0839 - 0.0842)
Grind so that bearing clearance is the spec-
US 050 2.255 - 2.263 (0.0888 - 0.0891)
ified value.
US 075 2.380 - 2.388 (0.0937 - 0.0940) L
US 100 2.505 - 2.513 (0.0986 - 0.0989)
Main Bearing Oil Clearance M

Unit: mm (in)
Items Standard
Main bearing oil clearance 0.035 - 0.083 (0.0014 - 0.0033) N
THRUST BEARING
Unit: mm (in)
O
Grade symbol Thickness of thrust bearing
A 2.275 - 2.325 (0.0896 – 0.0915)
B 2.300 - 2.350 (0.0906 – 0.0925) P
C 2.325 - 2.375 (0.0915 – 0.0935)
OS 020 2.475 - 2.525 (0.0974 – 0.0994)
• OS 020 has part No. of 12280 2W215 and OS 0.20 marked on bearing surface.
Undersize

Unit: mm (in)
Grade number Thickness Width

Standard 1.505 - 1.513 (0.0593 - 0.0596)
US 025 1.630 - 1.638 (0.0642 - 0.0645)
US 050 1.755 - 1.763 (0.0691 - 0.0694) 25.9 - 26.1 (1.020 - 1.028)
US 075 1.880 - 1.888 (0.0740 - 0.0743)
US 100 2.005 - 2.013 (0.0789 - 0.0793)
Connecting Rod Bearing Oil Clearance

Unit: mm (in)
Items Standard
Connecting rod bearing oil clearance 0.035 - 0.077 (0.0014 - 0.0030)
FLYWHEEL
Unit: mm (in)
Items Limit
Flywheel runout [TIR]* 0.10 (0.0039)
Tightening Torque INFOID:0000000003397158
*1: Parts to be tightened in particular orders.

1): Order of tightening when tightening two or more times separately.
Unit: N·m (kg-m, ft-lb)
Unit: N·m (kg-m, in-lb)*2
Engine room rear cover 5.1 (0.52, 45)*2
*1 Oil pan 1) 26.5 (2.7, 20)
2) 26.5 (2.7, 20)
*1 Rocker cover 1) 10.8 (1.1, 8)
2) 10.8 (1.1, 8)
*1 Camshaft bracket 1) 12.3 (1.3, 9)
2) 22.0 (2.2, 16)
*1 Cylinder head 1) 101 (10.0, 74)
2) 0 (0, 0)
3) 41.7 (4.3, 31)
4) 90° (angle tightening)
5) 90° (angle tightening)
*1 Lower cylinder block Main bolt 1) 19.6 (2.0, 14)
Sub bolt 2) 9.8 (1.0, 87)*2
Main bolt 3) 98.1 (10.0, 72)
Sub bolt 4) 19.6 (2.0, 14)
Main bolt 5) 172 (18.0, 127)
Sub bolt 6) 42.7 (4.4, 31)

MODIFICATION NOTICE
< SERVICE INFORMATION > [ZD30 WITH COMMON RAIL]
SERVICE INFORMATION A
MODIFICATION NOTICE
Major Modification Item INFOID:0000000003625195
EM
ZD30DDTi with common rail engine has been added.
C

PRECAUTIONS
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
WARNING:
an authorized NISSAN/INFINITI dealer.
ness connectors.
Precaution for Drain Engine Coolant INFOID:0000000003451634
• Drain engine coolant when engine is cooled.

• Use the specified tools when instructed to use Special Service Tools. Always be careful to work safely, and
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 reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. Do exactly as specified if the order of loosening is specified.
Precaution for Inspection, Repair and Replacement INFOID:0000000003451637
Thoroughly inspect parts before repairing or replacing. Inspect new replacement parts in the same way, and
• Use torque wrench to tighten bolts or nuts to specification.

ones in center, then ones on inside and outside diagonally in this order. Do exactly as specified if the order of
tightening is specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and blow-dry each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
Oil sliding surfaces well before assembly.
• Release air within route when refilling after draining engine coolant.
• Start engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gas for leak-
age after repairing.
Parts Requiring Angular Tightening INFOID:0000000003451639
• Use an angle wrench [SST: KV10112100] for the final tightening of the following engine parts:

PRECAUTIONS
• Do not use a torque value for final tightening. A
• The torque values for these parts are for a preliminary step.
Precaution for Liquid Gasket INFOID:0000000003451640 EM
REMOVAL OF LIQUID GASKET SEALING

• Separate the mating surface using a seal cutter (SST) and remove C
the old liquid gasket sealing after removing the mounting bolts and
nuts.
CAUTION: D
• Use a plastic hammer to lightly tap the areas where the liquid gas-
ket is applied in areas where the seal cutter (SST) is difficult to
use. E
CAUTION:
Be careful not to damage the mating surfaces if for some
unavoidable reason a tool such as a flat-bladed screwdriver is F
PBIC0275E
used.
1. Remove the old liquid gasket adhering to the liquid gasket appli- G
cation surface and the mating surface using a scraper.
• Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts, and bolt H
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove I
adhering moisture, grease and foreign materials.
PBIC0003E
J
3. Attach the liquid gasket tube to the tube presser (commercial

service tool). K
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions. L
• Apply the liquid gasket to the groove if there is a groove for the
liquid gasket application.
M
EMA0622D
N
• As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the holes.
Check to read the text of this manual. O
• Install the mating component within five minutes of liquid gas-
ket application.
• Wipe the liquid gasket off immediately If it protrudes.
• Do not retighten after the installation. P
• Wait 30 minutes or more after installation before refilling the
engine with engine oil and engine coolant.
CAUTION:
Observe any specific instructions in this manual.
SEM159F

PREPARATION
PREPARATION
Tool number
Description
Tool name
KV10111100 Removing oil pan and gear case, etc.
Seal cutter
S-NT046
ED19600620 Checking compression pressure

Compression gauge adapter
S-NT820
KV10109300 a: 68 mm (2.68 in)

Pulley holder b: 8 mm (0.31 in) dia.
S-NT628
KV101151S0 Changing valve lifter shims

Lifter stopper set
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
S-NT041
KV10112100 Tightening bolts for lower cylinder block, cylin-

Angle wrench der head, etc.
S-NT014
KV101092S0 Disassembling and assembling valve compo-

Valve spring compressor nents
1 KV10109210
Compressor
3 KV10109220
Adapter (M8)
NT718

PREPARATION
Tool number
Description
Tool name A
KV10107902 Removing valve oil seal
Valve oil seal puller
1 KV10116100 EM
Valve oil seal puller adapter
C
S-NT605

Valve oil seal drift Use side A. D
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
E
e: 10.7 (0.421)
f: 5 (0.20)
S-NT603 Unit: mm (in)
F
ST16610001 Removing pilot bearing
Pilot bearing puller
H
ZZA0046D

Piston ring compressor I
S-NT044
KV101056S0 Preventing crankshaft from rotating K

Ring gear stopper a: 3 (0.12)
1. KV10105630 b: 6.4 (0.252)
Adapter c: 2.8 (0.110)
L
2. KV10105610 d: 6.6 (0.260)
e: 107 (4.21)
f: 14 (0.55)
g: 20 (0.79) M
NT617
h: 14 (0.55) dia.
Unit: mm (in)
Commercial Service Tool INFOID:0000000003451642 N

PREPARATION
Tube presser Pressing the tube of liquid gasket
S-NT052
S-NT048
S-NT030
Engine stand When overhauling engine
KBIA2232E

A
NVH Troubleshooting - Engine Noise INFOID:0000000003451643
EM
P
JPBIA1967GB
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000003451644
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 Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Top of en- Ticking or Tappet
C A — A B — Valve clearance EM-228
gine clicking noise
Rocker
cover Camshaft
Camshaft oil clearance EM-223
Cylinder Rattle C A — A B C bearing
Camshaft runout EM-223
head noise
Piston to piston pin

Slap or Piston pin clearance EM-270
— A — B B —
knock noise Connecting rod bushing EM-270
clearance
Piston-to-bore clear-
Crank- ance
EM-270
shaft pul- Piston ring side clear-
Slap or Piston EM-270
ley A — — B B A ance
rap slap noise EM-270
Cylinder Piston ring end gap
EM-270
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod clearance (Small end) EM-270
Knock A B C B B B
bearing Connecting rod bearing EM-270
noise clearance (Big end)
Main bearing oil clear-
Main bear- EM-270
Knock A B — A B C ance
ing noise EM-270
Crankshaft runout
Front of Timing
Timing chain cracks
engine chain and
Tapping or and wear EM-232
Timing A A — B B B chain ten-
ticking Timing chain tensioner EM-232
chain cov- sioner
operation
er noise
Other
Squeak- drive belt
ing or fizz- A B — B — C (Sticking Drive belt deflection
ing or slip-
ping) EM-185
Front of
Other
engine Pulley bearing opera-
Creaking A B A B A B drive belt
tion
(Slipping)
Water
Squall
A B — B A B pump Water pump operation CO-54
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

ENGINE COVERS
ENGINE COVERS
A
EM
PBIC4646E
G

H
REMOVAL
I
2. Remove front RH seat. Refer to SE-2, "Component Parts Drawing".
3. Partially remove floor carpet. J
5. Move parking brake lever and cable from engine compartment right side cover. Refer to PB-4, "Compo- K
nent".
CAUTION:
L
INSTALLATION
Install in the reverse order of removal following instructions below. M
: Vehicle front N
included] to specified torque in any given order. O
P
PBIC5379E
REMOVAL

ENGINE COVERS
KBIA0742E
INSTALLATION
Following instructions below, install in the reverse order of removal.
2. Tighten other bolts to specified torque in any given order.
KBIA0742E

DRIVE BELTS
DRIVE BELTS
A
Checking Drive Belt INFOID:0000000003451647
WARNING: EM
Be sure to perform after engine has stopped.
• Drive belt is automatically adjusted by auto tensioner, so tension check for drive belt is unnecessary.
• Check drive belt for wear, damage or cracks, replace if necessary.
C
• Check drive belt grooves for deposit of foreign materials such as sand mud. Clean or replace if necessary.
Tension Adjustment INFOID:0000000003451648
D
Belt tensioning is not necessary, as it is automatically adjusted by the auto belt tensioner.
E
WATER PUMP, ALTERNATOR AND AIR CONDITIONER COMPRESSOR BELT
NOTE:
If following sentences, water pump-alternator-air conditioner compressor belt is called “belt”, and drive belt F
auto tensioner is “auto tensioner”.
Removal
1. Remove undercover. G
3. Retract and secure (or hold) auto tensioner (4) following steps
bellow: H
1 : Alternator
2 : Belt I
3 : Water pump pulley
5 : Crankshaft pulley
: A/C compressor (with A/C models) J
6
: Idler pulley (without A/C models)
N
JPBIA0962ZZ
a. Ensure to hold 19 mm (0.75 in) hexagon portion (A) on auto ten- O

sioner with a ring-end wrench or socket wrench.
NOTE:
• Tools with handle of 500 mm (19.69 in) or more is recom-
mended. P
• Never loosen bolts or nuts during work.
JPBIA1282ZZ

DRIVE BELTS
b. Carefully rotate hexagon in direction shown by arrow (to loosen).
CAUTION:
• Because tensioner has large reaction force, ensure to
hold it securely with a tool.
• If a sudden force is applied, hexagon may be damaged.
Carefully rotate it in accordance with retraction of damper
unit.
4. Release belt starting from alternator pulley to remove.
CAUTION:
• When removing or installing, step away from each pulley,
hold side of belt. This is to prepare for the case if retaining JPBIA1283ZZ
tool slips off.
• Handle removed belt carefully, avoiding oil and coolant contamination. Never twist or bend it
with excessive force.
Installation
Following same procedure as removal, while holding auto tensioner in belt loosening direction, and install belt.
CAUTION:
• Never put hands within area where they may be caught by belt, preparing for the case if retaining
tool slips off.
• After belt installation, check that belt grooves and pulley ridges are securely engaged.
Drive Belt Auto Tensioner INFOID:0000000003451649
REMOVAL
1. Remove drive belt. Refer to EM-185, "Tension Adjustment".
2. Remove damper unit (2) and auto tensioner (1).
JPBIA1570GB

• Check that pulley has no looseness and rotates smoothly.
• Check damper unit for oil leak.
INSTALLATION

A
EM
L
JPBIA1369GB
1. Air duct (inlet) 2. Grille 3. Air duct M

4. Resonator 5. Grommet 6. Collar
7. Air cleaner case 8. Air cleaner element 9. Washer
10. Wing nut 11. Dust pan 12. Washer N
13. Wing nut 14. Dust drain valve 15. Clamp
16. Air hose 17. Clamp 18. PCV hose
19. Clamp 20. Air duct 21. Grommet O
22. Collar 23. Vacuum hose 24. Clamp
25. Air hose 26. Clamp 27. Mass air flow meter
28. Spacer 29. Collar 30. Grommet P
Turbocharger boost control solenoid
31. 32. Vacuum hose 33. Vacuum hose
valve
34. Bracket
A. To air inlet pipe B. To rocker cover C. To vacuum pump
D. To VNTC control actuator

REMOVAL
4. Remove engine room rear cover. Refer to EM-183, "Removal and Installation of Engine Room Rear
Cover".
6. If air duct [(7) of step 9] shall be removed, remove the following:
• Oil level gauge: Refer to EM-262, "Disassembly and Assembly".
• A/T fluid level gauge (A/T models): Refer to AT-129, "Removal and Installation".
• A/T fluid charging pipe mount bolts (A/T models): Refer to AT-129, "Removal and Installation".
7. Disconnect harness connector from mass air flow meter.
8. For correct installation, make matching marks on each connection.
9. Remove from engine side after separating the system with the
following procedure.
1 : Air duct (inlet)

2 : Air duct
: Vehicle front
a. Remove PCV hose (5).

b. Remove air hose (6).
c. Loosen clamp from air hose (8) thoroughly.
d. Disconnected vacuum hose between air duct and turbocharger
boost control solenoid valve.
e. Remove air hose.
f. Remove mass air flow meter (9) and spacer (10).
CAUTION:
• Handle with care, avoiding any shocks.
• Never disassemble mass air flow meter.
• Never touch sensor part.
g. Remove air duct (7) front of vehicle.
h. If following components shall be removed, remove fuel filter
bracket assembly. Refer to FL-19, "Component".
JPBIA1455ZZ
i. Remove resonator (4).
j. Remove turbocharger boost control solenoid valve mounting bolts, and then move it aside.
k. Remove air cleaner case (3).
10. If components inside RH body shall be removed, follow steps below.

a. Remove components up to air cleaner case, referring to step 9.
b. Remove air inlet grille from outside of vehicle.
c. Remove kicking plate on RH side, and lift up panel under RH side seat belt anchor. Refer to SB-2,
"Removal and Installation of Seat Belt for Separate Seat".

d. Lift up air duct (J) from vehicle opening, and separate it from air
duct (K). A
e. Pull and remove air duct.
f. Remove air duct from mounting hole of air duct.
EM
KBIA0902E
D
INSTALLATION
Install in the reverse order of removal, paying attention to points below.
• Install dust drain valve so that its opening is along circumference. E
KBIA0819E
H
Changing Air Cleaner Filter INFOID:0000000003451748
I
REMOVAL
1. Remove brake pipe protector under vehicle, behind front RH wheel.
2. Remove 3 clips, and the cover at the bottom of air cleaner case. J
NOTE:
• Mark “*” in the figure shows part of lift arm.
• For replacement of air cleaner element, it is not necessary to K
lift up vehicle.
3. Remove wing nut, dust pan, and then air cleaner element.
L
KBIA0749E M
INSTALLATION
N

CHARGE AIR COOLER
CHARGE AIR COOLER
Layout INFOID:0000000003451774
JPBIA1571GB
1. Air inlet hose 2. Turbocharger 3. Clamp (each air inlet hose both ends)
4. Throttle body 5. Air inlet hose 6. Air inlet pipe
7. Air inlet hose 8. Air inlet pipe 9. Air inlet hose
Air hose (for charge air pressure
10. 11. Bracket 12. Charge air cooler
sensor)
13 Charge air pressure sensor 14. Bracket 15. Air inlet hose
16. Air inlet pipe 17. Air inlet hose 18. Air inlet pipe

CHARGE AIR COOLER
EM
JPBIA1572GB
I
1. Charge air pressure sensor 2. Bracket 3. Charge air cooler
4. Bracket 5. Air hose (for charge air pressure sensor) 6. Clamp
A. To air inlet pipe J
Removal and Installation INFOID:0000000003451654 K
REMOVAL
1. Remove charge air cooler with following procedure. L
a. Remove under cover.
b. Remove bracket from charge air cooler (front side).
M
c. Loosen charged air cooler side connecting clamp from air inlet hose (charged air cooler inlet side and out-
left side).
d. Remove bracket from charge air cooler (rear side).
N
e. Remove charge air cooler mounting bolt (upper-left side).
f. Remove charge air cooler.
CAUTION:
Never damage or scratch charge air cooler when removing. O
2. Remove charge air pressure sensor.
a. Remove charge air cooler while referring to step 1.
P
b. Disconnect charge air pressure sensor harness connector.
c. Remove air hose.
d. Remove charge air pressure sensor with bracket.
3. Put a mating mark onto air inlet hose (vehicle side) and air inlet pipe for reference at installation.
Charge air cooler visually check.

CHARGE AIR COOLER
• Visually check that there is no incident and damage on the charge air cooler core and air tank (upper side
and lower side).
• If there is an unusual condition, replace the charge air cooler.
INSTALLATION
Install in the reverse order of removal following instructions below.
CHECKING CHARGE AIR COOLER
Check charge air cooler for mud or clogging. If necessary, clean charge air cooler as follows.
CAUTION:
• Be careful not to bend or damage the charge air cooler fins.
• When charge air cooler is cleaned without removal, remove all surrounding parts such as cooling
fan shroud and horns. Then tape the harness and connectors to prevent water from entering.
1. Apply water by hose to the back side of the charge air cooler core vertically download.
• Apply water again to all charge air cooler core surfaces once per minute.
• Stop washing if any stains no longer flow out from the charge air cooler.
2. Blow air into the back side of charge air cooler core vertically download.
• Use compressed air lower than 490 kPa (5 kg/cm2, 71 psi) and keep distance more than 30 cm (11.81
in).
• Blow air again into all the charge air cooler core surfaces once per minute until no water sprays out.

INTAKE MANIFOLD
INTAKE MANIFOLD
A
Components INFOID:0000000003451792
EM
I
JPBIA1456GB
1. Gasket 2. Intake manifold 3. EGR passage J

4. Gasket 5. Gasket 6. Electric throttle control actuator

K
REMOVAL L
1. Remove under cover.
2. Open engine compartment left side cover and secure it. Refer to EM-183, "Component".
3. Remove front RH seat. Refer to SE-2, "Component Parts Drawing". M
4. Remove engine room right side cover. Refer to EM-183, "Removal and Installation of Engine Room Right
Side Cover".
5. Remove engine room rear cover. Refer to EM-183, "Removal and Installation of Engine Room Rear N
Cover".
7. Remove air inlet hose from electric throttle control actuator. Refer to EM-190, "Layout". O
8. Remove EGR cooler and EGR volume control valve. Refer to EM-196, "Component".
9. Disconnected harness connector at electric throttle control actuator.
P
10. Remove electric throttle control actuator from intake manifold.
• Diagonally loosen mounting bolts.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator.
• Never disassemble or adjust it.
11. Remove fuel feed tube clamp. Refer to EM-213, "Component".
12. Move intake manifold upper side clamp and harness aside.

INTAKE MANIFOLD
13. Disconnect vacuum hose from swirl control valve.
14. Remove intake manifold.
• Loosen and remove bolts and nuts in the reverse order shown
in the figure.
MBIB9063E

Surface Distortion
Inspect surface distortion of intake manifold using straightedge (1)
and feeler gauge (2).
Limit : 0.2 mm (0.008 in)

• If it exceeds the limit, replace intake manifold.
MBIB9058E
INSTALLATION
Intake Manifold
MBIB9063E
Electric Throttle Control Actuator

Tighten mounting bolts equally and diagonally in several steps and in numerical order.

INTAKE MANIFOLD
Components INFOID:0000000003451791
EM
JPBIA1467GB
G
1. Thrust stopper 2. Valve screw 3. Swirl control valve
4. Intake manifold 5. Lip seal 6. Swirl control valve shaft assembly
7. Washer 8. Snap ring 9. Swirl control valve actuator
H
I
DISASSEMBLY
1. Remove thrust stopper.
J
2. Remove swirl control valve actuator mounting bolts.
3. Remove snap ring from the swirl control valve shaft assembly.
4. Remove all valve screws. K
5. Remove all valves.
6. Remove swirl control valve shaft assembly from intake manifold.
L
ASSEMBLY
Reassemble in reverse order of disassembly, paying attention to the following points:
CAUTION:
• Take precaution to not bend the shaft. M
• Replace stopper thrust, valve screws, lip seal and snap ring by new parts.
• Before inserting the lip seal, spread oil on the seal outer, and press fit into the intake manifold body.
• Install valve with arrow in opposite direction of the swirl control N
valve.
• After installation of valve screws, wait at least 2 hours.
• After installation of all parts, check for smooth operation.
O
MBIB9059E

EGR SYSTEM
EGR SYSTEM
JPBIA1578GB
1. Clamp 2. Water hose 3. Water pipe

4. EGR tube 5. Gasket 6. Clamp
7. Water hose 8. EGR cooler 9. Connection tube
10. Clamp 11. Fuel hose 12. Clamp
13. Water hose 14. Fuel hose 15. Water hose
16. Gasket 17. EGR volume control valve 18. Electric throttle control actuator
19. Gasket 20. Gasket 21. EGR cooler support
22. Water hose 23. Water hose
A. To heater pipe B. To exhaust manifold C. To fuel filter
D. To cylinder block E. To fuel return tube
REMOVAL
Side Cover".
Cover".
5. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-39, "Changing Engine Coolant".

EGR SYSTEM
CAUTION:
• Perform this step when engine is cold. A
• Never spill engine coolant on drive belt.
6. Remove water hoses.
7. Remove exhaust outlet cover (upper). Refer to EM-198, "Component". EM
8. Remove EGR tube.
9. Remove EGR cooler.
10. Remove EGR volume control valve. C
CAUTION:
• Handle carefully to avoid any shock to EGR volume control valve.
• Never adhere the engine coolant to harness connector. D
• Never disassemble or adjust EGR volume control valve.
INSTALLATION
E
JPBIA1037ZZ J
1. Tighten EGR volume control valve mounting bolts (1) to the specified torque at intake manifold.
2. Temporarily tighten all mountings bolts.
3. Tighten EGR tube mounting bolts (2) (exhaust manifold side) to the specified torque. K
4. Tighten EGR cooler mounting bolts (3) (EGR volume control valve side) to the specified torque.
5. Tighten EGR cooler upper side mounting bolts (4) to the specified torque.
L
6. Tighten EGR cooler bracket mounting bolts (5) to the specified torque.
7. Tighten EGR cooler bracket mounting bolt (6) to the specified torque.
8. Tighten EGR tube mounting bolts (7) (EGR cooler side) to the specified torque. M

JPBIA1460GB
1. Exhaust manifold 2. Gasket 3. Air inlet pipe

4. Turbocharger 5. Gasket 6. Gasket
7. Oil feed/return tube 8. Gasket 9. Washer
10. Exhaust outlet support 11. Exhaust outlet 12. Converter cap
13. Washer 14. Catalyst cover 15. Catalyst
16. Gasket 17. Catalyst cover support 18. Catalyst support
19. Gasket 20. Exhaust outlet cover (lower) 21. Exhaust outlet cover (upper)

REMOVAL
Cover".

4. Remove catalyst cover.
5. Remove exhaust front tube. Refer to EX-7, "Component". A
6. Remove heat shield plate from cylinder head LH surface. Refer to CO-56, "Component".
7. Remove alternator, and then move it to the floor. (Do not disconnect piping.) Refer to SC-11, "Removal
and Installation (ZD30DD, ZD30DDTi)". EM
8. Remove PCV hose, air hose (between air duct and air inlet pipe). Refer to EM-187, "Component".
9. Remove EGR tube (between exhaust manifold and EGR cooler). Refer to EM-196, "Component".
C
10. Remove exhaust outlet covers (upper and lower).
11. Remove exhaust outlet support.
12. Remove catalyst support. D
13. Remove oil feed/return tube for turbocharger.
14. Remove exhaust outlet and catalyst assemblies and put to vehicle under body.
• Apply penetrating lubricant to bolts and nuts before operation. Loosen bolts and nuts when lubricant has E
penetrated enough.
CAUTION:
Avoid impacts to three-way catalyst.
F
15. Separate exhaust outlet and catalyst.
16. Remove turbocharger outlet side air inlet hose. Refer to EM-190, "Layout".
17. Remove exhaust manifold side nuts, and then remove turbocharger toward upper front of the vehicle hold- G
ing air inlet pipe.
• Apply penetrating lubricant to nuts before operation. Loosen nuts when lubricant has penetrated
enough.
CAUTION: H
• Be careful not to contact with the vehicle.
• Be careful not to bend piping.
• Never hold swing valve controller and actuator rod. I
• Check the following route if compressor wheel, turbine wheel, and/or rotor shaft were broken.
Remove all fragments and other foreign materials in order to avoid secondary contamination.
Intake side: Between turbocharger and intercooler
Exhaust side: Between turbocharger and catalyst J
18. Separate turbocharger and air inlet pipe.
CAUTION:
Never disassemble or adjust turbocharger assembly. K
L

MBIB9061E
1. Variable nozzle turbocharger 2. Turbine wheel 3. Compressor wheel

(VNTC) control actuator
Check for negative air pressure
A. B. Check for exhaust gas leaks C. Check for charge air pressure leaks
leaks
D. Check for oil leaks
• Refer to the figure for component names and visually check points.
NOTE:
The following figures show the image of the inspection procedure. (Existing parts are not the same shape as
the parts in the figure.)
Oil tubes
• Clean inside of oil feed tube and oil return tube, and check tubes for clogging.
• Replace oil feed tube or oil return tube if clogging still exists after cleaning.
Turbocharger
• Perform the following inspection, and then clean it if there are any deposits.
• Replace turbocharger if it is not functioning properly or outside the standard.
• Clean before checking.
• Clean oil feed/return port.
MBIB9073E

• Dry it using an air gun after cleaning.
• Dry compressor wheel, turbine wheel, compressor housing, and A
turbine housing using an air gun.
EM
MBIB9074E
D
Rotor shaft oil clearance
• Check that the rotor shaft (1) rotates smoothly without any resis-
tance when it is rotated by fingertips.
• Shake rotor shaft vertically and horizontally and check for loose- E
ness.
Standard : 0.056 - 0.127 mm (0.0022 - 0.0050 in) F

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

• Place a dial indicator at the rotor shaft end in the axial direction to
measure the end play.
Standard : 0.030 - 0.111 mm (0.0012 - 0.0044 in) I
• Replace turbocharger if out of standard.

J
K
MBIB9060E
Turbine wheel
• Check for engine oil stains on turbine wheel. L
• Check for carbon deposits.
• Check if turbine wheel (2) vane is bent or broken.
• Check for interference with turbine housing (1).
M
MBIB9066E O
Compressor wheel

• Check for engine oil stains inside inlet port.
• Check for interference with compressor housing (2).
• Check if compressor wheel (1) is bent or broken.
MBIB9065E
VNTC control actuator

• Disconnect vacuum hose on VNTC control solenoid valve side,
and connect the handy vacuum pump (B) to the VNTC control
actuator (A).
C : Dial indicator
• Check that control actuator rod (D) is operated strokes smoothly in
compliance with the following pressure.
• First, apply the negative air pressure of about -66.7 kPa (-667
mbar, -500 mmHg, -19.69 inHg).
• Then, measure the values while reducing the negative air pressure
to 0. JPBIA1604ZZ
Standard (Pressure/rod stroke amount)

: -53.3 to -47.9 kPa (-533 to -479 mbar, -400 to -359 mmHg, -15.74 to -14.14 in-
Hg)/0.2 mm (0.008 in)
-37.2 to -27.8 kPa (-372 to -278 mbar, -279 to -209 mmHg, -10.99 to -8.21 inHg)/
5.0 mm (0.197 in)
CAUTION:
Diaphragm in VNTC control actuator may be damaged if excessive negative air pressure is applied.
Check that vacuum pump pressure is within the standard by using pressure gauge to check before
applying pressure to VNTC control actuator.
Trouble diagnosis of turbocharger
Check items before trouble diagnosis
1. Check that the engine oil level is between L (Low level) and H (High level) of the oil level gauge. (When
the engine oil amount is more then H (High level), the engine oil flows into the inlet duct through the blow-
by gas passage, and the turbocharger is misjudged failure.) Refer to LU-21, "Inspection".
2. Ask the customer if he/she always runs the vehicle in idle engine speed to cool the engine oil down after
driving.
• Replace the turbocharger assembly when any malfunction is found after unit inspections specified in the
table below.
• If no malfunction is found after the unit inspections, judge that the turbocharger body has no non-stan-
dard conditions. Check the other parts again.

Symptoms likely to occur when the results shown on A

the left exist.
Inspection Location Result Poor pow-

Oil leakage Smoke Noise
er EM
Poor ac-
celeration
Wet with oil. C A C C
C
Carbon deposits observed. C A B B
Turbine wheel
“Rubs against” housing. C B A B
Vane is bent or broken. A A D
Inside of intake port is badly stained
B B
with oil.
Compressor wheel
“Rubs against” housing. C B A B
E
Vane is bent or broken. A A
Heavy feel or catching when turned by
C C B F
hand.
Check both turbine and compres-
sor rotor shaft end play. Cannot be turned by hand. A
Excessively loose bearing. C C B C G
Rotor shaft, oil return port (Check Carbon or sludge deposits in oil drain
C A C C
inside using penlight.) port.
• Does not operate smoothly when H
negative air pressure is gradually
VNTC control actuator operation
applied. B A
(using a handy vacuum pump)
• Stroke amount is not compliance
with the negative air pressure. I
A: Highly possible. B: Possible. C: May exist.

J
INSTALLATION
Three-way Catalyst K
Install converter cap and wire mesh washer in the direction as shown in the Component Parts Location.
INSPECTION AFTER INSTALLATION L
Start engine, and raise engine speed to check that there are exhaust gas and no oil leakage.

EXHAUST MANIFOLD
EXHAUST MANIFOLD
JPBIA1461GB
1. Gasket 2. Exhaust manifold cover 3. Exhaust manifold

: Engine front

REMOVAL
1. Remove turbocharger. Refer to EM-198, "Removal and Installation".
2. Remove EGR tube. Refer to EM-196, "Removal and Installation".
3. Remove exhaust manifold cover.
4. Loosen mounting nuts in reverse order shown in the figure, and
remove exhaust manifold.
: Engine front
JPBIA1581ZZ

Surface Distortion

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

• If it exceeds the limit, replace exhaust manifold. EM
PBIC2210E
D
INSTALLATION
Exhaust Manifold E
1. Tighten mounting nuts in order shown in the figure.
: Engine front F
: 41.7 N·m (4.3 kg-m, 31 ft-lb)

G
2. Tighten mounting nuts in order shown in the figure again.
H
JPBIA1581ZZ

Start engine, and raise engine speed to check no exhaust gas leakage. I

JPBIA1370GB
1. Baffle plate 2. Baffle plate 3. Oil level sensor

4. Oil strainer 5. Gasket 6. Oil pan (lower)
7. Drain plug 8. Washer 9. Rear plate cover
10. Oil pan (upper)
A. Oil pan side

REMOVAL
WARNING:
To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
4. Following steps below, remove oil pan (lower).

a. Loosen and remove oil pan (lower) mounting bolts in reverse
order as shown in the figure. A
A : Lower side view

: Engine front EM
b. Using a seal cutter [SST KV10111100], separate liquid gasket,
and remove oil pan (lower).
CAUTION: C
• Never insert a screwdriver, this will damage the mating JPBIA1480ZZ
surfaces. D
5. Following steps below, remove oil pan (upper).
a. Remove cross member under oil pan. Refer to FSU-6, "Component".
b. Remove transmission assembly to access to oil pan (upper) rear E
mountings bolts (A). Refer to MT-9, "Removal and Installation"
(M/T models) or AT-129, "Removal and Installation" (A/T mod-
els). F
c. Drain engine coolant (for vehicles with rear heater). Refer to
CO-39, "Changing Engine Coolant".
G
JPBIA1265ZZ
H
d. Loosen and remove oil pan (upper) mounting bolts in the

reverse order shown in the figure. I
KBIA0762E
L
e. Using a seal cutter [SST KV10111100], separate liquid gasket, and remove oil pan (upper).
CAUTION:
• Never insert a screwdriver, this will damage the mating surfaces. M
6. Remove oil strainer.
INSPECTION AFTER REMOVAL N
Check oil strainer and clean it if any object attached.
INSTALLATION
Install Oil Pan (upper) O

1. Apply liquid gasket thoroughly as in installation.
• Use Genuine Liquid Gasket or equivalent.
MBIB9108E
2. Tighten mounting bolts in numerical order as shown in the fig-

ure.
3. Retighten mounting bolts in ascending order as shown in the fig-
ure.
KBIA0762E
Install Oil Pan (lower)

1. Apply liquid gasket thoroughly as in installation.
a : 4.5 mm (0.18 in)

: Engine front
• Use Genuine Liquid Gasket or equivalent.
JPBIA1481ZZ
2. Tighten mounting bolts in numerical order as shown in the fig-

ure.
A : Lower side
: Engine front
3. Retighten mounting bolts in ascending order as shown in the fig-

ure.
JPBIA1480ZZ
Install Drain Plug Washer

Install it direction shown in “Components Parts Illustration”. Refer to EM-206, "Component".
1. Check engine oil level. Refer to LU-21, "Inspection".
2. Warm up engine and check the oil amount and no leakage of oil. Refer to LU-21, "Inspection".
3. Stop the engine and wait for 10 minutes.
4. Check engine oil level again. Refer to LU-21, "Inspection".

GLOW PLUG
GLOW PLUG
A
EM
G
JPBIA1507GB
1. Glow harness 2. Glow plate 3. Glow plug oil seal

4. Glow plug
H
: Engine front
• Refer toGI-8, "Component" for symbol marks in the figure. I

J
REMOVAL
2. Remove front RH seat. Refer to SE-2, "Component Parts Drawing" K
Side Cover".
4. Remove engine room rear cover. Refer to EM-183, "Removal and Installation of Engine Room Rear L
Cover".
5. Remove air duct. Refer to EM-187, "Component".
6. Disconnect harness connector from glow plate. Move it from above rocker cover. M
7. Remove glow nut to remove glow plate.
• For No. 4 cylinder, open access hole removing grommet on
vehicle-side floor arch first. Then loosen glow nut through N
access hole.
8. Remove glow plug oil seal.
9. Remove glow plug. O
• For No. 4 cylinder, remove and install it out of/through grom-
met hole on vehicle-side floor arch.
CAUTION:
• When removing or installing, never use impact-applying P
tools such as an air impact wrench.
• Handle it carefully without giving any impact, even after KBIA0765E
removal. [As a guide, if it drops from height of 10 cm (3.94

in) or higher, always replace it.]
INSTALLATION
1. Install glow plug.

GLOW PLUG
2. Install glow plug oil seal.

VACUUM PUMP
VACUUM PUMP
A
EM
J
JPBIA1580GB
1. Gasket 2. Eye bolt 3. Oil pipe K

4. Gasket 5. Eye bolt 6. O-ring
7. Valve 8. Gasket 9. Vacuum pump connector
10. Gasket 11. Vacuum pump 12. Gasket L
13. Eye bolt
To turbocharger boost control sole-
A. To fuel pump mounting bracket B. To cylinder block C.
noid valve M
Removal and Installation INFOID:0000000003451664 N
REMOVAL
CAUTION: O
Never disassemble vacuum pump.
2. Remove cooling fan. Refer to CO-53, "Component". P
3. Remove vacuum hose vacuum pump side.
4. Remove oil pipe.
5. Remove vacuum pump.
• Remove mounting bolts, and pull off vacuum pump straight toward front of engine.
• If it is difficult to be pulled off due to stuck spline, tap it with a plastic hammer to remove.
CAUTION:
Never disassemble vacuum pump.

VACUUM PUMP
INSTALLATION
Following instructions bellow, install in the reverse order of removal.
• When connected, vacuum hose shall be inserted securely by at least 15 mm (0.59 in).
Following the steps below, check vacuum generated by vacuum pump.
1. Disconnect vacuum hose, and connect a vacuum gauge via 3-
way connector. Or, remove plug on vacuum pipe, and connect a
vacuum gauge. (Figure shows later case.)
NOTE:
• Connect a vacuum gauge to any point where vacuum gener-
ated by vacuum pump can be measured. (Figure shows an
example.)
KBIA0767E
2. Start engine, and measure vacuum generated at idle speed.
Standard : -93.3 to -101 kPa (-933 to -1,010 mbar, -700 to -758 mmHg, -27.56 to -29.83 inHg)
• If outside of standard, check for air suction in vacuum route, and measure again.
• If still outside of standard, replace vacuum pump.

A
EM
L
JPBIA1968GB
1. Spill tube 2. Connector 3. Spill hose M

4. Injection tube (No. 1) 5. Injection tube (No. 2) 6. Injection tube (No. 3)
7. Injection tube (No. 4) 8. Common rail assembly 9. Gasket
10. Connector 11. Clamp 12. Spill hose N
13. Fuel feed tube (upper) 14. Clamp 15. Fuel feed hose
16. Fuel feed tube (lower) 17. Fuel feed hose 18. Fuel return hose
19. Clamp 20. Fuel return hose 21. Fuel return tube (lower) O
22. Fuel feed tube (lower) 23. Nozzle gasket 24. O-ring
25. Fuel injector 26. Nozzle support 27. Washer
28. Injection cover P
A. To fuel filter B. To fuel pump
: Nozzle support side

CAUTION:

• Check that no foreign materials attach and enter into the paths when disassembling fuel piping.
• Except eye bolt and eye connector, never remove any part such fuel pressure sensor, plugs, etc.
from the common rail assembly.
• Injector tube and fuel supply tube are not reusable. Replace by new ones if removed.
• Handle common rail carefully and avoid impacts.
REMOVAL
Side Cover".
4. Disconnect injector harness connectors (A) from injector.
5. Pull up to release injector cover (1) from injector.
6. Remove each injection tube.
• Loosen injection tubes at fuel injector side retaining inlet con-
nector of fuel injector with a spanner to prevent it from loosing.
7. Remove all spill tube connector with the following procedure:
a. Disconnect spill tube on common rail assembly side.
JPBIA1256ZZ
b. Push (B) and pull (A) fuel injector fixing clip (2) to release the
spill tube (1) connector from the injector.
CAUTION:
• Never remove the clip
• Replace the clip if it has been removed.
• Remove spill tube.
• Pull spill tube holding connector position.
JPBIA1579ZZ
8. Remove fuel feed tube from fuel supply pump and common rail assembly.
CAUTION:
• Hold the fuel pump side connector with a spanner securely.
• Prepare container and cloth beforehand as fuel will leak out.
9. Disconnected harness connector from common rail assembly.
10. Move harness for intake manifold upper side.
11. Remove common rail assembly mountings bolts, and remove
common rail assembly from the cylinder head.
CAUTION:
Never disassemble common rail assembly.
MBIB9106E
12. Remove rocker cover. Refer to EM-220.

13. Following steps below when remove fuel injector (No. 4).
a. Remove exhaust front tube. Refer to EX-7, "Component".
b. Support the bottom surface of engine using a transmission jack, and remove rear engine mounting
bracket through bolt. Refer to EM-257, "Component".

c. Lower the jack for the engine and the transmission assembly to the height.
CAUTION: A
• Check that no part interferes with the vehicle side.
14. Remove all spill tube connector with the following procedure: EM
a. Remove nozzle support mounting bolts.
b. Remove fuel injector.
CAUTION: C
• Handle fuel injector carefully and avoid impacts.
• Identify installation position of fuel injector. Arrange removed parts to prevent mixing them up.
• Never disassemble fuel injector.
D
c. Remove nozzle gasket from cylinder head mounting hole if it is not at top of fuel injector.
CAUTION:
Be careful not to damage cylinder head.
E
INSTALLATION
CAUTION:
While tightening injector tubes or fuel supply tube, prevent partner part to move by meaning of a span-
ner, so as not to stress or loose the part. F
NOTE:
In this section, information about non-reusable parts is shown in the text considering these parts' characteris-
tics. (In other sections, information about non-reusable parts is shown in Component Parts Location.) G
1. Installation fuel injector with the following procedure:
a. Record “IMA DATA (ALPHA NUM CODE)” on the top surface
when replacing fuel injector. H
• Refer to "INSPECTION AFTER INSTALLATION" for use of
“IMA DATA (ALPHA NUM CODE)”.
I
KBIA2268E
K
b. Assemble O-ring and nozzle gasket to fuel injector.
• Apply grease around the O-ring.
• Install fuel injector in its original position. L
CAUTION:
Replace O-ring and nozzle gasket.
c. Insert fuel injector to cylinder head.
• Install fuel injector support while inserting. M
• Set one side of fuel injector support to the top of cylinder head bolt.
d. Tighten nozzle support bolt.
• Install washer so that the curved surface side faces downward (fuel injector support side). N
2. Install rear engine mounting bracket through bolt. Refer to EM-257, "Component".
3. Install exhaust front tube bracket. Refer to EX-7, "Component".
O
4. Install rocker cover. Refer to EM-220, "Component".

5. Install common rail assembly to cylinder head and tighten
mountings bolts to the specified torque.
MBIB9106E
6. Finger tightens fuel injector connections (A), common rail con-

nections (B) and fuel supply pump connection (C).
7. Finger tightens fuel feed tubes clamp mounting bolt (D).
JPBIA1258ZZ
8. Tighten connections (A) and (B) to the specified torque.
: 30.5 N·m (3.1 kg-m, 22 ft-lb)
JPBIA1259ZZ
9. Tighten connections (A) to the specified torque.
: 30.5 N·m (3.1 kg-m, 22 ft-lb)
10. Tighten fuel feed tubes clamp mounting bolt (B).
: 22.0 N·m (2.2 kg-m, 16 ft-lb)
JPBIA1260ZZ
11. Apply diesel fuel around O-ring spill tube connector.

12. Open fuel injector head clip with clip (2) pushed (B).
A
A : Engine upper side
CAUTION:
• Never remove the clip. EM
• Replace the clip if it is removed.
13. Insert spill tube (1) to fuel injector.
14. Release the clip to original position and fix it. C
CAUTION:
Replace O-ring of spill tube connector.
JPBIA1579ZZ
15. Pull up spill tube connector by hand, and check that it does not D
disconnect.
16. Connect fuel hose to common rail assembly.
INSPECTION AFTER INSTALLATION E
Start engine, increase the engine speed, and check that there is no fuel leakage.

FUEL SUPPLY PUMP
FUEL SUPPLY PUMP
JPBIA1280GB
1. Front plate 2. Gasket 3. Fuel supply pump mounting bracket

4. Fuel supply pump 5. O-ring 6. Oldham coupling
7. Washer 8. Gear case
• Refer to GI-8, "Component" symbol marks in the figure.

REMOVAL
Side Cover".
4. Drain engine coolant. Refer to CO-39, "Changing Engine Coolant".
• Air inlet pipe: Refer to EM-191, "Component".
• EGR cooler and EGR volume control valve: Refer to EM-196, "Component".
• Intake manifold: Refer to EM-193, "Components".
6. Move power steering oil pump aside. Refer to PS-13, "On-Vehicle Inspection and Service".
7. Disconnected harness connector from fuel supply pump.
8. Remove fuel feed tube and fuel feed hose. Refer to EM-213, "Component".
9. Remove fuel supply pump mounting bolts, and then move it engine rear side.
CAUTION:

FUEL SUPPLY PUMP
Never disassemble or adjust fuel supply pump.
10. Remove fuel supply pump gear. Refer to EM-236, "Component". A
11. Remove oil pipe from fuel supply pump mounting bracket. Refer to EM-211, "Component".
12. Remove fuel supply pump mounting bracket.
EM
INSTALLATION
CAUTION:
C
Never reuse fuel feed tube between common rail assembly and fuel supply pump. Replace it with a
new one.
Fuel Supply Pump
D
NOTE:
The injection timing adjustment to correct the installation angle deviation is not necessary. Install the fuel sup-
ply pump in the proper position according to the oldham coupling.
E
1. Note the following, and install fuel supply pump on engine rear side.
a. Replace fuel supply pump o-ring by a new one.
b. Direct the oldham coupling (1) to a vertical direction. Install it so
that both sides of width (A) become equal. F
B : Fuel supply pump shaft position

G
c. Turn crankshaft with a manual tool to align the direction of the
mounting groove (C) of fuel supply pump mounting bracket with
the direction of oldham coupling.
NOTE: H
Use mirrors and confirm a position when hard to see.
d. Install fuel supply pump into the mounting groove of the fuel
pump mounting bracket, being careful not to move the oldham I
coupling.
L
JPBIA1287ZZ
2. Install in the reverse order of removal. M

3. Before starting engine, bleed air from fuel piping. Refer to FL-20, "Air Bleeding".
Start engine, and increase engine speed to check for fuel leakage. N

ROCKER COVER
ROCKER COVER
JPBIA1051GB
1. Glow plug oil seal 2. Hose clamp 3. Oil filler cap

4. Rocker cover 5. Rocker cover gasket 6. Hose clamp
7. PCV hose 8. Clamp
A. Refer to EM-209 B. Front mark C. Refer to EM-220
D. To air duct

REMOVAL
Cover".
5. Remove air duct. Refer to EM-187, "Component".
6. Remove PCV hose from rocker cover.
7. Disconnected harness connector from fuel injector. Refer to EM-213, "Component".
8. Remove injection tubes. Refer to EM-213, "Component".
9. Remove glow plate. Refer to EM-209, "Component".

ROCKER COVER
10. Remove glow plug oil seal (1) from rocker cover.
A
A : Tighten
• While holding cutout on top of oil seal with pliers, rotate it
counterclockwise (B) to remove. EM
JPBIA1286ZZ
D
11. Remove rocker cover.
a. Loosen and remove mounting bolts in reverse order shown in
the figure. E
: Engine front
b. Raise rocker cover in direction of glow plug inclination to avoid F

contacting glow plug.
c. Changing angle of rocker cover frequently, take it out from
between body and cylinder head. G
CAUTION:
Be careful not to damage injector oil seal position of rocker JPBIA1052ZZ
cover. H
INSTALLATION
1. Apply liquid gasket to points shown in the figure following the
steps below. I
1 : Front cover
2 : Gear case J
3 : Cylinder head
A : Liquid gasket application point
B : 10 mm (0.39 in) (from gear case matching surface) K
C : Gear case width
D : 4 mm (0.16 in) (liquid gasket application width)
JPBIA1053ZZ
: Engine front L

a. Fill gap between mating faces with sealant using a spatula. M
b. Apply additional sealant into a heap.
2. Install rocker cover gasket into mounting groove on rocker cover.
• Immobilize a rocker cover gasket by hand lightly not to be dropping at the installation. N
CAUTION:
If some traces of fluid gasket that was used in past service work are found, remove them com-
pletely before work.
• Install it with tab of front mark "FR" coming front of engine and upward. O
3. Install rocker cover.
CAUTION:
• Be careful to keep rocker cover gasket securely, avoiding dropping it. P
• Never touch liquid gasket applied to cylinder head.
4. Tighten rocker cover mounting bolts following the steps below.

ROCKER COVER
a. Temporarily tighten rocker cover mounting bolts in numerical
order shown in the figure.
: Engine front
JPBIA1052ZZ
b. Install glow plug oil seal.

c. Tighten mounting bolts to the specified torque in numerical order
: Engine front
JPBIA1052ZZ

CAMSHAFT
CAMSHAFT
A
EM
J
JPBIA1054GB
1. Camshaft bracket 2. Camshaft gear (INT) 3. Camshaft sprocket K

4. Washer 5. Camshaft gear (EXH) 6. Thrust plate
10. Valve lifter 11. Adjusting shim 12. Camshaft (EXH) L
13. Camshaft (INT)
A. Refer to EM-223
M
N
REMOVAL
1. Remove rocker cover. Refer to EM-220, "Component".
2. Set the No. 1 cylinder at TDC, and then remove the chain case, timing chain and other parts in connec- O
tion. Refer to EM-232, "Removal and Installation".
3. Remove camshaft gear and camshaft sprocket.
P

CAMSHAFT
• Loosen the camshaft gear mounting bolt by fixing the hexago-
nal portion of the camshaft.
NOTE:
The idler gear cannot be removed at this point as gear case is
in the way. (Cylinder head can be removed as a single unit.)
FEM011
4. Remove camshaft.
• Place matching marks on the right and left sides with paint.
• Loosen and remove the mounting bolt in the reverse order
5. Remove adjusting shim and valve lifter.
• Remove by taking notice of the installation position, and place
outside engine in order to prevent confusion.
PBIC0364E

Visual Check of Camshaft
• Check the camshaft for one-sided wear or scratches.
• Replace the camshaft if there are non-standard conditions.
Camshaft Runout
• Prepare V-block on a flat surface and secure camshaft journals No. 1 and No. 5.
• Set the dial indicator (A) vertically on journal No. 3.
• Rotate camshaft in one direction by hand, then read needle move-
ment on dial indicator. (Total indicator reading)
Limit : 0.04 mm (0.0016 in)

• Replace camshaft if outside the limit.
PBIC3177J
Height of Cam Nose

• Measure by using a micrometer.
Standard:
Intake
40.468 - 40.508 mm (1.5932 - 1.5948 in)
Exhaust
40.83 - 40.87 mm (1.6075 - 1.6091 in)
Wear limit : 0.15 mm (0.0059 in)

SEM549A
• Replace camshaft if outside the wear limit.

Camshaft Oil Clearance

CAMSHAFT
CAMSHAFT JOURNAL OUTER DIAMETER
• Measure by using a micrometer. A
Standard: 29.931 - 29.955 mm (1.1784 - 1.1793 in) dia.

EM
FEM015 D
CAMSHAFT BRACKET INNER DIAMETER

• Install camshaft bracket and tighten bolts to the specified torque. Refer to EM-223, "Removal and Installa-
tion". E
• Measure inner diameter of camshaft bracket using an inside
micrometer.
F
Standard 30.000 - 30.021 mm (1.1811 - 1.1819 in) dia.
H
FEM016
CAMSHAFT OIL CLEARANCE CALCULATIONS I

• (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal outer diameter)
Standard 0.045 - 0.090 mm (0.0018 - 0.0035 in) dia. J

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

Limit : 0.2 mm (0.008 in)
PBIC2446E O

CAMSHAFT
• Replace the following parts if outside the limit.
- A dimension of camshaft No. 2 journal
Standard : 19.455 - 19.507 mm (0.7659 - 0.7680 in)

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

• Refer to the standards above, and then replace camshaft and/or
cylinder head.
KBIA2318E
Visual Inspection of Valve Lifter and Adjusting Shim

Check if surface of valve lifter and adjusting shim has any wear or cracks.
• If anything is found, replace valve lifter and adjusting shim.
• When replacing adjusting shim, refer to EM-228, "Valve Clear-
ance".
SEM160D
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER

• Measure the outer diameter of the valve lifter with a micrometer.
Standard : 34.450 - 34.465 mm (1.3563 - 1.3569 in) dia.
KBIA2286E
VALVE LIFTER BORE DIAMETER

• Measure the bore diameter of the cylinder head valve lifter with an
inside micrometer.
PBIC0367E
VALVE LIFTER CLEARANCE CALCULATIONS

• (Clearance) = (Valve lifter bore diameter) – (Valve lifter outer diameter)
Standard : 0.030 - 0.065 mm (0.0012 - 0.0026 in)

• If it exceeds the standard value, refer to the outer diameter and bore diameter standard values and replace
valve lifter and/or cylinder head.

CAMSHAFT
INSTALLATION
1. Install adjusting shim and valve lifter. A
• Check that these are installed in the same position as before the removal process.
2. Install camshaft.
• Follow the matching marks that were placed on parts in the removal process. EM
- Compare the direction of camshaft nose (No.1), with camshaft
key (A) points straight up.
C
1 : Camshaft (INT)
2 : Camshaft (EXH)
E
JPBIA1292ZZ
• Face the key in the direction shown in the figure. F
FEM020 I
3. Install camshaft bracket.

• Remove foreign material completely from camshaft bracket back side and from cylinder head installa-
J
tion face.
• Refer to the camshaft bracket upper side journal No. and
install.
• Looking from the exhaust manifold side (left side of engine), K
install in the direction that the journal number can be read cor-
rectly.
L
M
PBIC0368E
4. Tighten the installation bolts in numerical order in the figure. N

a. Tighten to 12.3 N·m (1.3 kg-m, 9 ft-lb).
• Check that the thrust portion of the camshaft is fitted properly
in the head installation side. O
b. Tighten to 21.6 N·m (2.2 kg-m, 16 ft-lb).
PBIC0364E
5. Install camshaft gear.

CAMSHAFT
• Align the matching marks (B), and install idler gear (2) and
each camshaft gear to the position shown in the figure.
1 : Camshaft gear (INT)

3 : Camshaft gear (EXH)
A : Knock pin
• Tighten the camshaft gear installation bolt by fixing the hexag-
JPBIA1015ZZ
6. Install timing chain, all other related parts, and chain cover. Refer to EM-232, "Component".
Valve Clearance INFOID:0000000003451670
INSPECTION
• When camshaft or parts in connection with valves are removed or replaced, and a fault has occurred (poor
starting, idling, or other malfunctions) due to the maladjustment of the valve clearance, Inspect as follows.
• Inspect and adjust when the engine is cool (at normal temperature).
• Components on the figure are as follow
I : Intake valve
E : Exhaust valve
: Engine front
MBIB9085E

• Under cover
2. Set the No. 1 cylinder at TDC on compression stroke.
a. Rotate crankshaft pulley (1) clockwise, and align the TDC mark
of crankshaft pulley (2) with the timing indicator (3) of gear case.
MBIB9113E

CAMSHAFT
b. Confirm that the cam nose of the No. 1 cylinder (2, 3) and the
knock pin (1) of the camshaft sprocket are in the position shown A
in the figure.
• Rotate the crankshaft pulley again if it is not in the position
EM
MBIB9114E
D
3. Measure valve clearance as follows:
• Measure the valve clearance using a fine feeler gauge when
the engine is cool (at normal temperature).
E
Valve clearance:
When engine e is cold [Approximately 20°C
F
(68°F)]
Intake and exhaust
0.30 - 0.40 mm (0.012 - 0.016 in) G
• The injection order is 1-3-4-2.
KBIA2290E
H
a. While referring to the figure, measure the valve clearance in the
“×” of the table below.
I
: Engine front
Measuring point No. 1 (A) No. 2 (B) No. 3 (C) No. 4 (D) J
When the No. INT × ×
1 cylinder is in
the TDC EXH × ×
K
b. Set the No. 4 cylinder at TDC on its compression stroke by rotat- JPBIA1251ZZ
ing the crankshaft clockwise once.

L
c. While referring to the figure, measure the valve clearance in the
“×” of the table below.
M
: Engine front
Measuring point No. 1 (A) No. 2 (B) No. 3 (C) No. 4 (D) N
When the No. INT × ×
1 cylinder is in
the TDC EXH × ×
O
4. For measurements that are outside the specified range, perform JPBIA1252ZZ
adjustment below.
ADJUSTMENTS P
NOTE:
Adjust the valve clearance while engine is cold.
• Remove the adjusting shim for parts which are outside the specified valve clearance.
1. Thoroughly wipe off the engine oil on the upper side of the cylinder head (for the air gun used in step 7).

CAMSHAFT
2. Rotate the crankshaft to face the cam nose for adjusting shims
that are to be removed upward.
3. Move the round hole of the adjusting shim to the front with an
extra-fine screwdriver or like that.
CAUTION:
Perform (the above procedure) while camshaft never con-
tact with adjusting shim.
PBIC0373E
4. Grip the camshaft with camshaft pliers (SST), then using the
camshaft as a support point, push the adjusting shim downward
to compress the valve spring.
CAUTION:
Never damage the camshaft, cylinder head, and the outer
circumference of the valve lifter.
5. With the valve spring in a compressed state, remove the cam-
shaft pliers (SST) by securely setting the outer circumference of
the valve lifter with the end of the lifter stopper (SST).
• Hold the lifter stopper by hand until the shim is removed.
CAUTION: FEM029A
Never retrieve the camshaft pliers forcefully, as the cam-
shaft will be damaged.
6. Remove the adjusting shim from the valve lifter by blowing air
through the round hole of the shim with an air gun.
CAUTION:
• When blowing, use goggles to protect your eye.
• To prevent any remaining oil from being blown around,
thoroughly wipe the area clean.
MBIB9117E
7. Remove the adjusting shim (1) by using a magnetic hand.
MBIB9118E

CAMSHAFT
8. Measure the thickness of the adjusting shim using a micrometer.
• Measure near the center of the shim (the part that touches the A
camshaft).
9. Select the new adjusting shim from the following methods.
EM
Calculation method of the adjusting shim thickness:
t = t1 + (C1 – C2)
t = Thickness of replacement adjusting shim C
t1 = Thickness of removed adjusting shim
C1 = Measured valve clearance SEM145D
D
C2 = Specified valve clearance
When engine is cold [approximately 20°C (68°F)]
0.35 mm (0.014 in) E
• New adjusting shims have the thickness stamped on the rear
side.
Unit: mm (in) F
Stamp Shim thickness
2.35 2.35 (0.0925)
2.40 2.40 (0.0945) G
· ·
· ·
· ·
3.05 3.05 (0.1201) H
• The thickness of the adjusting shim ranges from 2.35 to 3.05 JEM184G
mm (0.0925 to 0.1201 in), where in the space of 0.05 mm

(0.0020 in). There are 15 types of shims available. I
10. Fit the selected adjusting shim to the valve lifter.
CAUTION:
Place the stamped side of the adjusting shim to the valve lifter. J
11. Compress the valve spring using the camshaft pliers and
remove the lifter stopper (SST).
K
M
FEM029A
12. Rotate the crankshaft 2 to 3 times by hand. N

13. Confirm that the valve clearance is within the specification. Refer to EM-228, "Valve Clearance".
14. Install remaining parts in reverse order of removal.
O

TIMING CHAIN
TIMING CHAIN
JPBIA1056GB
1. Chain tensioner 2. Timing chain slack guide 3. Camshaft gear (EXH)

4. Washer 5. Camshaft gear (INT) 6. Camshaft sprocket
7. Timing chain 8. Timing chain tension guide 9. Insulator
10. Harness bracket 11. Camshaft position sensor 12. O-ring
13. Chain cover 14. Sub harness 15. Engine coolant temperature sensor
16. Seal gasket 17. Gasket 18. Water outlet

REMOVAL
• Radiator upper hose: Refer to CO-42, "Component".
• Water outlet
• Cooling fan: Refer to CO-53, "Component".

TIMING CHAIN
• Vacuum pipe and vacuum pump: Refer to EM-211. A
2. Move the power steering oil pump aside. Refer to PS-13, "On-Vehicle Inspection and Service".
• Remove the holding bolts (A, B, C) shown in the figure. EM
CAUTION:
While chain cover is removed, be careful not to allow
entry of dust or foreign objects.
C
JPBIA1284ZZ E
4. Set the No. 1 cylinder to the compression TDC.

a. Turn crankshaft pulley (1) clockwise, and align the timing indica- F
tor (B) of gear case to the TDC mark of crankshaft pulley (A).
JPBIA1055ZZ I
b. Check that the camshaft sprocket mating mark is in the position

• If the mating mark is not in position, turn crankshaft pulley 360 J
degrees and position it.
NOTE:
When removing at No. 1 cylinder compression TDC, each K
sprocket and chain is fitted using the mating mark, therefore
there is no need to apply any mating marks beforehand.
L
PBIC0377E
5. Remove chain tensioner with the following procedure: M

a. Open stopper tab, and press plunger in the chain tensioner body.
b. Engage stopper tab to groove on the end of plunger.
N
c. Lever hole is aligned with the tensioner body hole position in this
condition. Fix lever using stopper pin.
NOTE:
Stopper pin is made from wires of approximately 0.5 mm (0.020 O
in) diameter or paperclips.
d. Remove chain tensioner.
6. Remove timing chain slack guide. P
KBIA2295E
7. Remove timing chain with camshaft sprocket.

TIMING CHAIN
• Loosen the camshaft sprocket holding bolt by fixing the hexag-
onal portion of the intake manifold side camshaft with a span-
ner, etc.
CAUTION:
Never loosen the holding bolt by using the tension of the
chain.
8. Remove timing chain tensioner guide.
EMT0075D

Timing Chain
Check timing chain for cracks and excessive wear at roller links.
Replace chain if necessary.
SEM984C
INSTALLATION
1. Install timing chain tensioner guide (5).
2 : Chain tensioner
4 : Fuel supply pump sprocket
A : Alignment mark (Dark blue link)
B : Alignment mark identification
C : Alignment mark (Yellow link)
D : Alignment mark
2. Install camshaft sprocket (1) and timing chain together.
• Install by aligning the sprocket and timing chain mating marks.
• Tighten the camshaft sprocket holding bolt by fixing the hexag-
CAUTION:
Never tighten in the holding bolt using the tension of the
chain.
3. Install timing chain slack guide (3).
CAUTION:
When the holding bolt is tightened to the specified torque,
there is a gap between the guide and bolt. Never over-
tighten.
JPBIA1016ZZ

TIMING CHAIN
• Pull out stopper pin and release plunger after installing chain
tensioner. A
EM
KBIA2295E
D
5. Install chain cover.
a. Before installing chain cover, apply liquid gasket to mating sur-
face as shown. E
Use Genuine Liquid Gasket or equivalents.
FEM009
H
b. Install chain cover.
• The length of the holding bolt will vary depending on the part.
A: 20 mm (0.79 in) I
B: 60 mm (2.36 in)
C: 70 mm (2.76 in) J
JPBIA1284ZZ
6. Install by following all removal procedures in the reverse. L

TIMING GEAR
TIMING GEAR
JPBIA1464GB
1. Fuel supply pump mounting bracket 2. Gasket 3. O-ring

4. Oil jet 5. Keys 6. O-ring
7. Gasket 8. Front plate 9. Fuel supply pump gear

TIMING GEAR
10. Fuel supply pump sprocket 11. Washer 12. Balancer shaft (right)
13. Crank gear 14. Balancer shaft (left) 15. Thrust plate A
16. Idler gear (B) 17. Idler shaft 18. Idler shaft
19. Idler gear (A) 20. Thrust plate 21. O-ring
22. O-ring 23. Gasket 24. O-ring EM
25. Gear case 26. Dowel pin 27. TDC sensor
28. Front oil seal 29. Crankshaft pulley 30. Protector
31. Dowel pin 32. O-ring C
A. Engraved line B. Refer to EM-218
: Upper side
D
E
REMOVAL
1. Drain engine coolant. Refer to CO-39, "Changing Engine Coolant". F
• Oil pans (upper and lower) and oil strainer: Refer to EM-206.
• Spill tube: Refer to EM-213. G
• Radiator hoses (upper and lower): Refer to CO-42, "Component".
• Radiator shroud and radiator: Refer to CO-42, "Component". H
I
• Alternator: Refer to SC-11, "Removal and Installation (ZD30DD, ZD30DDTi)".
3. Move the following parts:
• TDC sensor harness
• Power steering oil pump: Refer to PS-13, "Disassembly and Assembly". J
• A/C compressor: Refer to MTC-68, "Component".
• A/C compressor bracket: Refer to MTC-68, "Component". K
• Auto-tensioner and idler pulley: Refer to EM-186, "Drive Belt Auto Tensioner".
5. Paint mating marks onto camshaft sprocket, fuel supply pump sprocket, and timing chain.
• Paint mating marks onto easy-to-see places with oil-resistant method. L
6. Paint mating marks onto fuel supply pump gear and idler gear.
• Paint mating marks onto easy-to-see places with oil-resistant method.
7. Remove chain tensioner and timing chain slack guide. Refer to EM-232. M
8. Remove timing chain together with camshaft sprocket. Refer to

EM-232.
N
9. Remove TDC sensor.
CAUTION:
• Handle it carefully without giving any impact.
• Never place it where iron chips can adhere. O
• Keep it clear of objects affected by magnetic fields.
10. Remove water pump. Refer to CO-54, "Component".
P
EMT0075D
11. Remove crankshaft pulley.

TIMING GEAR
• Secure crankshaft by inserting hammer handle into gap
around counter weight. Loosen mounting bolts to remove
crankshaft pulley.
CAUTION:
• Be careful not to damage crankshaft.
• Be careful to keep inside of engine clear of foreign materi-
als.
KBIA0779E
• Handle crank pulley carefully to avoid damaging or mag-

netizing protrusion for signal detection.
KBIA0913E
12. Remove gear case.

• There are 3 pry grooves (shown by arrows in figure) on gear
case. Using grooves and a flat-bladed screwdriver or seal cut-
ter [SST: KV10111100], remove gear case.
CAUTION:
Be careful not to damage mounting surface.
13. Remove front oil seal from gear case.
• Using a flat-bladed screwdriver, remove it.
CAUTION:
Be careful not to damage gear case.
EMT0105D
14. Remove each timing gear.

• Before removal, check backlash between each two gears. Refer to "INSPECTION AFTER REMOVAL".
CAUTION:
• Never loosen the inner mechanism fixing bolt of idler gear (A). (If the inner mechanism is
opened, idler gear cannot be reused.)
• After removing idler gears (A) and (B), never face rear side downward. Idler main shaft will
drop.
• Pull balancer shaft straight out to avoid damaging bushing inside of cylinder block.
15. Remove electronic control fuel injection pump. Refer to EM-218.
16. Remove front plate.
Backlash of Each Gear
Method using a fuse wire

TIMING GEAR
• Place a fuse wire (A) in the biting area of the teeth between the
gears to be checked, rotate the crankshaft in the operating direc- A
tion so that the wire is taken inwards.
1 : Fuel supply pump gear

EM
2 : Idler gear (A)
B : Measure position
• Measure the thickness of the crushed area in the wire with a C
micrometer.
JPBIA1263ZZ
D
Method using dial indicator
• Place the dial indicator on the tooth surface area of the gear to be checked. E
• With the other gear in a set position, measure the dial indicator (A)
value while moving the gear left and right.
F
Standard : 0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit : 0.20 mm (0.0079 in)
• If it exceeds the limit, replace gear and measure again. G
• If it exceeds the limit again, check for the installation condition of
the gear driving parts, wear of shaft and gear, and oil clearance.
H
JPBIA1264ZZ
Idler Gear End Play

• Tighten the holding bolts to the specification. I
• Measure the clearance between thrust plate and idler gear using a feeler gauge.
Unit: mm (in)
Standard Limit J
Idler gear (A)
0.06 - 0.12 (0.0024 - 0.0047) 0.15 (0.0059)
Idler gear (B)
K
• If it exceeds the limit, replace the idler gear, shaft, and thrust plate.
• Measure the inner diameter (d1) of the idler gear shaft. L
Standard:
Idler gear (A) M
43.000 - 43.020 mm (1.6929 - 1.6937 in) dia.
Idler gear (B)
N
28.600 - 28.620 mm (1.1260 - 1.1268 in) dia.
• Measure the outer diameter (d2) of the idler shaft.
EMT0112D O
Standard:
Idler gear (A)
42.959 - 42.975 mm (1.6913 - 1.6919 in) dia. P
Idler gear (B)
28.567 - 28.580 mm (1.1247 - 1.1252 in) dia.
• Calculate the oil clearance.
Clearance = d1 − d2

TIMING GEAR
Unit: mm (in)
Standard Limit
Idler gear (A) 0.025 - 0.061 (0.0010 - 0.0024)
0.2 (0.008)
Idler gear (B) 0.020 - 0.053 (0.0008 - 0.0021)
• If it exceeds the limit, refer to each standard specification and replace idler gear and/or shaft.
Balancer Shaft End Play
• Measure the clearance between the plate and gear using a feeler
gauge.
Standard : 0.07 - 0.22 mm (0.0028 - 0.0087 in)

• If it exceeds the specification, replace the balancer shaft assembly.
NOTE:
As the gears are press-fitted, there are no service setting for indi-
vidual parts.
FEM038
Balancer Shaft Oil Clearance

Measure the outer diameter of the balancer shaft journal with a
micrometer.
Standard:
Front side
50.875 - 50.895 mm (2.0029 - 2.0037 in) dia.
Rear side
50.675 - 50.695 mm (1.9951 - 1.9959 in) dia.
PBIC2005E
Inner diameter of balancer shaft bearing

Measure the inner diameter of the balancer shaft bearing using a
bore gauge.
Standard:
Front side
50.955 - 50.980 mm (2.0061 - 2.0071 in) dia.
Rear side
50.755 - 50.780 mm (1.9982 - 1.9992 in) dia.
Oil clearance calculations PBIC2006E
(Oil clearance) = (Bearing inner diameter) − (Journal outer diameter)
Standard : 0.045 - 0.135 mm (0.0018 - 0.0053 in)

Limit : 0.180 mm (0.0071 in)
• If it exceeds the limit, refer to each standard specification and replace balancer shaft and/or cylinder block.
INSTALLATION
1. Install front plate.
a. Install O-ring and gasket to cylinder block.
b. Install front plate.
• Lightly tap with a hammer if dowel pin cannot be inserted easily.
CAUTION:
Check that O-ring does not pop out.

TIMING GEAR
c. Apply liquid gasket with a spreader between the cylinder block
plate under the cylinder block (oil pan side) and the front plate A
(shown by the arrows in the figure).
EM
PBIC2007E
D
2. Install each timing gear.
• Align the match marks of the timing gears by referring to the figure below.
E
L
JPBIA1482ZZ
1. Fuel supply pump gear 2. Balancer shaft gear (right) 3. Crankshaft gear
M
4. Crankshaft key 5. Balancer shaft gear (left) 6. Idler gear (B)
7. Idler gear (A)
3. Install front oil seal to gear case. N

• Evenly insert front oil seal using a drift [outer dia.: approx. 64
mm (2.52 in)] completely. O
CAUTION:
Check oil seal does not spill off the end side of gear case.
P
PBIC2010E

TIMING GEAR
4. Install gear case.
a. Before installing gear case, apply liquid gasket to mating surface
as shown.
b. Install O-rings (3) to gear case.
c. Install seal ring (2) to gear case.
d. Install gasket (1) to gear case.
e. Install gear case.
• Tap the area around dowel pin with a plastic hammer if it can-
not be inserted easily.
CAUTION: JPBIA1573ZZ
Never pop out O-rings.
f. Install the holding bolt referring to the figure.
Bolt length:
A : 25 mm (0.98 in)
B : 30 mm (1.18 in)
C : 60 mm (2.36 in)
D : 90 mm (3.54 in)
g. Install the holding bolts from the rear side of front plate.
JPBIA1574ZZ
5. Install crankshaft pulley.

• Insert by aligning the 2 flat face of oil pump with the 2 flat face of the shaft on the rear side of the crank-
shaft pulley.
CAUTION:
Never damage the oil seal lip when inserting.
6. Install water pump. Refer to CO-54, "Component".
• Install it before installing TDC sensor.
7. Install TDC sensor.
• Align the bracket knock pin with the hole on gear case side and tighten the holding bolt.
• Confirm that the clearance between the end of TDC sensor (1)
and the signal detection protrusion of the crankshaft pulley (2)
is within the specification.
Standard (a): 0.5 - 1.5 mm (0.020 - 0.059 in)

CAUTION:
Confirm that the harness has no deflection around crank-
shaft pulley when installing the clamp.
JPBIA1285ZZ

• Align the mating marks of fuel supply pump sprocket and camshaft sprocket, and install timing chain.
• Holding the hexagon head of camshaft with wrench, tighten the camshaft sprocket installation bolt.
CAUTION:
9. Install timing chain, related parts, and chain cover. Refer to EM-232.

OIL SEAL
OIL SEAL
A
Removal and Installation of Valve Oil Seal INFOID:0000000003470090
REMOVAL EM
1. Remove camshafts, adjusting shim and valve lifter. Refer to EM-223, "Component".
2. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder. C
3. Remove valve collet, valve spring retainer and valve spring with
valve spring compressor (SST).
CAUTION: D
F
SEM354G
4. Remove valve oil seal with the valve oil seal puller (SST). G
CAUTION:
H
SEM356G J
INSTALLATION
1. Install valve oil seal with valve oil seal drift (SST) K
• Apply new engine oil to valve oil seal joint surface and seal lip.
• Press in valve oil seal to the position in the figure.
L
PBIC0412E
N
Removal and Installation of Front Oil Seal INFOID:0000000003470091
REMOVAL O
• Radiator shroud: Refer to CO-42, "Component". P
• Crankshaft pulley: Refer to EM-236, "Component".

OIL SEAL
2. Remove front oil seal with a suitable tool.
CAUTION:
Be careful not to damage front cover and crankshaft.
SEM358G
INSTALLATION
1. Install front oil seal to gear case.
• Install new oil seal in the direction shown.
SEM715A
• Every insert front oil seal using a drift [outer dia.: approx.
64mm (2.52 in)] completely.
CAUTION:
Check oil seal dose not spill off the end side of gear case.
PBIC2010E
Removal and Installation of Rear Oil Seal INFOID:0000000003470092
REMOVAL
1. Remove transaxle assembly. Refer to MT-28, "Removal and Installation" (M/T models) or AT-129,
"Removal and Installation" (A/T models).
2. Remove clutch cover and clutch disk. (M/T models) Refer to CL-11, "Removal and Installation".
3. Remove flywheel (M/T models) or drive plate (A/T models). Refer to EM-261, "Component".
4. Remove rear oil seal with the following procedure:
a. Remove rear oil seal retainer assembly mount bolts and under side bolts.
b. Use a seal cutter [SST: KV10111100] to cut away liquid gasket and remove rear oil seal retainer.
CAUTION:
Be careful not to damage surface.
NOTE:
Oil seal alone is not available as service parts.
INSTALLATION
1. Remove old liquid gasket on mating surface of cylinder block and oil pan using scraper.

OIL SEAL
2. Apply liquid gasket to rear oil seal and retainer assembly using
tube presser (commercial service tool) as shown in figure. A
3. Install rear oil seal retainer assembly to cylinder block and oil
pan. EM
• Apply engine oil to the oil seal lip.
Rear oil seal retainer C

: 22.1 N·m (2.3 kg-m, 16 ft-lb)
Oil pan mounting bolts PBIC1976E
D
: 16.7 N·m (1.7 kg-m, 12 ft-lb)

E

CYLINDER HEAD
CYLINDER HEAD
On-Vehicle Service INFOID:0000000003451673
COMPRESSION PRESSURE INSPECTION

2. Using CONSULT-III, check no error codes are indicated for self-diagnosis items. Refer to EC-348, "DTC
No. Index".
• Do not disconnect CONSULT-III until the end of this operation; it will be used to check engine rpm and
for error detection at the end of this operation.
3. Disconnect the negative battery cable.
4. Disconnect the harnesses from all fuel injectors. Refer to EM-213, "Component".
5. Remove glow plugs from all the cylinders. Refer to EM-209.
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into the
engine.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs.
6. Install compression gauge adapter [SST: ED19600620] (B) to

installation holes of glow plugs and connect compression gauge
(A) for diesel engine.
: 17.2 N·m (1.8 kg-m, 13 ft-lb)

7. Connect negative battery cable.
8. Set the ignition switch to “START” and crank. When gauge
pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
• Always use a fully charged battery to obtain specified engine JPBIA1254ZZ
speed.
Unit: kPa (bar, kg/cm, psi)/rpm
Standard Minimum Difference limit between cylinders

2,844 (28.4, 29, 412)/200 2,452 (24.5, 25, 356)/200 294 (2.9, 3.0, 43)/200
• When engine rpm is outside of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
• If engine rpm exceeds the limit, check valve clearance and combustion chamber components (valves,
valve seats, cylinder head gaskets, piston rings, pistons, cylinder bores, cylinder block upper and lower
surfaces) and measure again.
• If compression pressure is low in some cylinders, apply small amount of engine oil from glow plug instal-
lation hole. Then check pressure again.
- If compression pressure becomes normal after applying oil, piston ring may be worn or damaged. Check
piston ring for malfunction. If any, replace piston ring.
- If compression pressure is still low after applying oil, valve may be malfunctioning. Check valve for mal-
function. If contact malfunction is found, replace valve or valve seat.
• If compression pressure in adjacent two cylinders is low after applying oil, pressure may be leaking from
gasket. In this case, replace cylinder head gasket.
9. Complete this operation as follows:
a. Turn ignition switch to “OFF”.
b. Disconnect negative battery cable.
c. Install glow plug and install all the parts removed in step 4.
CAUTION:
Replace glow plug oil seals with new one. Refer to EM-209.
d. Connect negative battery cable.
e. Using CONSULT-III check no error code is indicated for items of self-diagnosis. Refer to EC-367, "Trouble
Diagnosis Introduction".

CYLINDER HEAD
Component (Removal and Installation) INFOID:0000000003451767
EM
JPBIA1307GB
I
1. Engine slinger (rear) 2. Cylinder head assembly 3. Glow plug
4. Cylinder head bolt 5. Gasket 6. Thrust plate
7. Idler gear 8. Idler shaft 9. Dowel J
10. Cylinder head gasket 11. Engine slinger (front) 12. Gasket
13. Heater pipe
A. Refer to EM-247 B. Markings C. To heater core K
: Engine front
• Refer to GI-8, "Component" for symbol marks in the figure. L

REMOVAL M
N
• Injection tube, spill tube and fuel injector: Refer to EM-213, "Component".
• Intake manifold: Refer to EM-193, "Components". O
• Turbocharger and catalyst: Refer to EM-198, "Component".
• Exhaust manifold: Refer to EM-204, "Component".
• Timing chain: Refer to EM-232, "Component".
P
• Camshaft: Refer to EM-223, "Component".

CYLINDER HEAD
3. Remove mounting bolts of the gear case and water pump as
shown by arrows in the figure.
EMT0125D
4. Remove cylinder head assembly.

• Loosen and remove mounting bolts in the reverse order shown
in the figure.
• Lift up the cylinder head assembly to avoid interference with
dowel pins located between the block and head, and remove
cylinder head assembly.
CAUTION:
Remove glow plug in advance to avoid damage as the tip
of the glow plug projects from the bottom of the cylinder
head. Or, place wood blocks beneath both ends of the cyl-
inder head to keep the cylinder bottom from any contact.
PBIC0408E
• For glow plug removal, the following shall be noted.
CAUTION:
• To avoid breakage, never remove glow plugs unless necessary.
• Perform continuity test with glow plug installed.
• Never use air impact wrench.
• Keep glow plug from any impact. [Replace if dropped from a height 10 cm (3.94 in) or higher.]
5. Remove idler gear from cylinder head.
CAUTION:
While removing idler gear, keep the rear of idler gear facing up to prevent idler shaft from falling.
Cylinder Head Bolt Deformation
• Using micrometer, measure the outer diameters d1 and d2 of bolt
thread as shown in the figure.
• If the necking point can be identified, set it as measuring point d2.
• Calculate the difference between d1 and d2.
Limit : 0.15 mm (0.0059 in)

• If out of limit, replace cylinder head bolt.
FEM056
Cylinder Head Distortion

Using straightedge and feeler gauge, check the bottom of the cylin-
der head for distortion.
Limit : 0.2 mm (0.008 in)

Replace cylinder head if it exceeds the limit.
FEM066

CYLINDER HEAD
Idler Gear End Play
• Tighten mounting bolts to the specified torque. Refer to EM-247, "Removal and Installation". A
• Measure the clearance between thrust plate and idler gear using feeler gauge.
Standard : 0.07 - 0.14 mm (0.0028 - 0.0055 in) EM

Limit : 0.2 mm (0.0079 in)
• Replace idler gear, idler shaft, and/or thrust plate if the measured value exceeds the limit value.
C
• Measure the inner diameter (d1) of idler gear shaft hole.
Standard : 26.000 - 26.020 mm (1.0236 - 1.0244 in) D
• Measure the outer diameter (d2) of idler shaft (Camshaft).

E
Standard : 25.967 - 25.980 mm (1.0223 - 1.0228 in)
• Calculate gear oil clearance.
(Clearance) = (d1) – (d2)
F
Standard : 0.023 - 0.053 mm (0.0009 - 0.0021 in) EMT0128D
• Replace idler gear (Camshaft) or idler shaft, or both if outside the limit. G
INSTALLATION
1. Install cylinder head gasket.
H
: Engine front
• Cylinder head gasket to be installed is selected by its thick-

I
ness through the following procedure.
- When replacing gasket only
• Install gasket with the same thickness as the one removed.
• Gasket thickness is identified by the number of notches J
located on center rear side.
Unit: mm (in)
JPBIA1288ZZ
Grade (A) Gasket thickness* No. of notches (B) K
1 0.65 (0.0256) 1
2 0.70 (0.0276) 2
L
3 0.75 (0.0295) 3
*: Thickness of gasket tightened with head bolts

• The number of notches can be checked at the position shown M
in the figure before cylinder head is removed. (It is necessary
to remove exhaust manifold.)
N
PBIC0410E P
- When repairing/replacing the following.

• When the top of cylinder block or crankshaft pin/journal is repaired.
• When cylinder block, piston, connecting rod, or crankshaft is replaced.
2. Install idler gear and idler shaft.
• Check that the counter marks with camshaft gear, “AA” and “BB”, are located on the front side of the
engine. Refer to EM-247, "Component (Removal and Installation)".

CYLINDER HEAD
CAUTION:
Since idler gear cannot be installed or removed with cylinder head assembly mounted on the
engine because of interference with gear case, check that there are no reverse installations or
un installed parts.
3. Install cylinder head assembly.
a. Attach gasket onto the rear of gear case.
b. Align cylinder head assembly with dowel pin of cylinder block
and install.
CAUTION:
Never damage gasket located at the front.
PBIC2227E
4. Position cylinder head assembly close to the rear of gear case.

a. Install cylinder head bolts to the front and rear of cylinder head respectively, and tighten to the specified
torque.
: 44.1 N·m (4.5 kg-m, 33 ft-lb)

b. Loosen cylinder head bolts completely.
c. Install gear case mounting bolts to 2 positions shown by arrows
in the figure, and tighten to the specified torque.
: 9.8 N·m (1.0 kg-m, 87 in-lb)
EMT0211D
5. Tighten cylinder head bolts in numerical order shown in the fig-

ure.
CAUTION:
For procedure “c”, loosen bolts in the reverse order as indi-
cated in the figure.
a. Apply engine oil to installation bolt threads and washers.
b. Tighten all cylinder head bolts.
: 100.6 N·m (10 kg-m, 74 ft-lb)

c. Completely loosen all cylinder head bolts. PBIC0408E
: 0 N·m (0 kg-m, 0 ft-lb)

d. Tighten all cylinder head bolts.
: 44.1 N·m (4.5 kg-m, 33 ft-lb)

e. Tighten all cylinder head bolts at the angle of 90 degrees clockwise (angle tightening).
f. Once again, tighten all cylinder head bolts at the angle of 90 degrees clockwise (angle tightening).
CAUTION:

CYLINDER HEAD
Perform the following procedure to check turning angle of
angle tightening, and never judge by visual check. A
• Make counter marks on the bolt heads of cylinder head and
cylinder head surface with paint, and check the turning angle.
• Check the turning angle using angle indicator of angle wrench
EM
(SST).
PBIC2228E
D
6. Loosen gear case mounting bolts which were tightened in “c” of procedure 4, and retighten them to the
specified torque.
7. Install water pump installation bolt (removed at step 3). E
8. Install glow plug.
• Using reamer, remove the carbon adhering to the installation hole of glow plug, and install glow plug.
9. Install remaining parts in the reverse order of removal. F
Component (Disassembly and Assembly) INFOID:0000000003451768
FEM081A
N
O
DISASSEMBLY
1. Remove adjusting shims and valve lifters.
• Check the installation positions, and keep them to avoid being confused. P
2. Remove valve collets.

CYLINDER HEAD
• Using valve spring compressor (SST), compress valve spring.
3. Remove valve spring retainers and valve springs.
PBIC1750E
4. Remove valves as pressing valve stems toward cylinder head lower surface.
• Before removing the valve, check the valve guide clearance. Refer to “Valve Guide Clearance”.
• Check installation positions, and keep them to avoid being
confused.
I : Intake valve
E : Exhaust valve
: Engine front
MBIB9085E
5. Remove valve oil seals using valve oil seal puller (SST).
6. Remove valve spring seats.
7. Perform valve seat contact check before removing valve spring
seats. Refer to "Valve Seat Contact".
8. Perform valve guide clearance check before removing valve
guides. Refer to "Valve Guide Clearance".
PBIC1795E
ASSEMBLY
1. Install valve guides. Refer to "Valve Guide Replacement".
2. Install valve seats. Refer to "Valve Seat Replacement".
3. Using valve oil seal drift (SST), install valve oil seal referring to
the dimension shown in the figure.
• The figure shows the dimension before valve spring seats are
installed.
4. Install valve spring seats.
5. Install valves.
• Install the valves with bigger openings to intake valve side.
PBIC0412E
6. Install valve springs.

• When installing valve spring, check that a narrow pitch side faces the cylinder head.

CYLINDER HEAD
- Intake
A
A : Narrow pitch
B : Wide pitch
EM
MBIB9128E
D
- Exhaust
Paint mark : Orange E
SEM085D
H
7. Install valve spring retainers.
8. Using valve spring compressor (SST), compress valve springs.
Then install valve collets using magnetic hand. I
• After installing valve collets, tap the stem end using a plastic
hammer, and check the installation status.
9. Install adjusting shims and valve lifters to the same positions as J
before.
PBIC1750E
L
INSPECTION AFTER DISASSEMBLY
Valve Dimension
Measure the dimensions of each part using micrometer. M
Standard:
Intake valve Exhaust valve N
a: 113.5 mm (4.47 in) 113.5 mm (4.47 in)
b: 3.8 - 4.2 mm (0.150 - 3.8 - 4.2 mm (0.150 -
0.165 in) 0.165 in) O
c: 1.5 mm (0.059 in) 1.5 mm (0.059 in)
d: 6.962 - 6.977 mm (0.2741 6.945 - 6.960 mm (0.2734
- 0.2747 in) - 0.2740 in)
PBIC0413E P
D: 31.9 - 32.1 mm (1.256 - 29.9 - 30.1 mm (1.177 -
1.264 in) 1.185 in)
α: 45°00 - 45°30′ 45°00 - 45°30′
• Replace valve if out of standard.
Valve Guide Clearance

CYLINDER HEAD
• Calculate the clearance by measuring valve stem outer diameter
and valve guide inner diameter.
Standard:
Intake : 0.023 - 0.053 mm (0.0009 - 0.0021 in)
Exhaust : 0.040 - 0.070 mm (0.0016 - 0.0028 in)
Limit:
Intake : 0.1 mm (0.004 in)
Exhaust : 0.1 mm (0.004 in)
SEM938C
• Replace valve guide and/or valve if the measured value exceeds

the limit. Refer to "Valve Guide Replacement".
Valve Guide Replacement
There is no setup for oversized valve guide.
1. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.
SEM008A
2. Using valve guide drift (commercial service tool), tap valve

guides out from the combustion chamber side.
CAUTION:
Use protective, etc. to prevent burns because the cylinder
head is hot.
PBIC2229E
3. Heat cylinder head to 110 to 130°C (230 to 266°F) in oil bath.

4. Using valve guide drift (commercial service tool), press fit valve
guides from camshaft side, referring to the dimension shown in
the figure.
CAUTION:
Use protective, etc. to prevent burns because the cylinder
head is hot.
PBIC0420E

CYLINDER HEAD
5. Using valve guide reamer (commercial service tool), perform
reaming to the press-fitted valve guides. A
Reaming specifications:
Intake and exhaust EM
7.000 - 7.015 mm (0.2756 - 0.2762 in)
PBIC2230E
D
Valve Seat Contact
• After confirming that the dimensions of valve guides and valves are
within specifications, perform this procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve E
seat to check the condition of the valve contact on the surface.
• Check if the contact area band is continuous all around the circum-
ference. F
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace
valve seat.
G
EMA0487D
Valve Seat Replacement H

1. Cut valve seat to make it thin, and pull it out.
2. Heat cylinder head to approximately 110 to 130°C (230 to 266°F) in oil bath.
3. After cooling valve seats sufficiently with dry ice, press fit it to cylinder head. I
CAUTION:
• Never touch the cooled valve seats directly by bare hand.
• Cylinder head contains heat. Wear protective equipment to avoid getting burned when working. J
4. Using compound, perform valve fitting.
5. Check again to check that contacting status is satisfactory. For details, refer to “Valve Seat Contact”.
Valve Spring Squareness K
Position a straightedge to valve spring, turn the spring, and measure
the maximum clearance value between top surface of spring and the
straightedge. L
Limit
Intake : 1.90 mm (0.0748 in) M
Exhaust : 1.95 mm (0.0768 in)
• If it exceeds the limits, replace valve spring.
N
PBIC0080E
Valve Spring Dimensions and Valve Spring Pressure Load

O
Using valve spring tester, check the following.
SEM113

CYLINDER HEAD
Standard:
Free length: 55.51 mm (2.1854 in) 55.81 mm (2.1972 in)
Installation height: 40.8 mm (1.606 in) 40.8 mm (1.606 in)
Installation load: 180 - 206 N (18.4 - 21.0 kg, 40 - 46 lb) 216.2 - 243.8 N (22.1 - 24.9 kg, 49 - 55 lb)
Height during valve open: 32.31 mm (1.2720 in) 31.95 mm (1.2579 in)
Load with valve open: 336 - 372 (34.3 - 37.9 kg, 76 - 84 lb) 382 - 430.8 (39.0 - 43.9 kg, 86 - 97 lb)
paint mark: — (No mark) Orange
• If the installation load or load with valve open is out of the standard, replace valve spring.

ENGINE ASSEMBLY
ENGINE ASSEMBLY
A
EM
I
JPBIA1849GB
1. Rear engine mounting bracket 2. Rear engine mounting insulator 3. Engine mounting bracket (RH) J
4. Engine mounting insulator (RH) 5. Engine mounting bracket (LH) 6. Engine mounting insulator (LH)

K
WARNING: L
• Situate vehicle on a flat and solid surface.
CATALOG. M
CAUTION:
• Never start working until exhaust system and engine coolant are cool enough. N
• For work items that are not covered by the engine main body section, refer to the applicable sec-
tions.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid- O
able reasons, support at the rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking points, refer to GI-34, "Garage Jack and Safety Stand". P
REMOVAL
Outline
Remove engine and transmission assembly with suspension member downwards. Then separate engine from
transmission.
Preparation
1. Remove floor cover behind RH and LH seats.

ENGINE ASSEMBLY
4. Remove engine compartment right side cover. Refer to EM-183, "Component".
5. Open fuel filler cap, and release internal pressure of fuel tank.
6. Disconnect battery negative terminal.
• Under cover
• Front wheels (RH and LH).
• Drive belts. Refer to EM-185, "Removal and Installation".
• Reservoir tank, radiator shroud, and radiator. Refer to CO-42, "Component".
9. Disconnect glow plug harness and alternator harness at engine side. Temporarily fix it on engine upper
side.
Engine room LH
10. Remove A/C compressor, high-pressure pipe and low-pressure pipe. Refer to MTC-68, "Component".
11. Disconnect heater hose from heater pipe, and plug hose to prevent engine coolant leakage. Refer to CO-
56, "Component".
12. Disconnect all hoses (ex. vacuum hose) connected to vehicle at engine side.
Engine room RH
13. Disconnect fuel feed and return hoses above air duct in engine room, and move them aside.
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leak.
14. Remove PCV hose and air hose (between engine RH-side and vehicle). Refer to EM-187, "Component".
15. Remove power steering oil pump from engine. Temporarily fix it on vehicle with rope in a manner in which
excessive load is applied to piping. Refer to PS-13, "Disassembly and Assembly".
16. Disconnect engine harness at ECM side. Temporarily fix it on engine upper side.
Engine room RR
17. Disconnect S and B terminals from starter motor, and move harness to vehicle. Refer to SC-27, "Removal
and Installation (ZD30, ZD30DDTi with Common Rail)".
18. Disconnect harness connector from EGR volume control valve, and move harness onto vehicle.
19. Disconnect engine ground attached to upper front end of transmission, at vehicle side.
Vehicle underbody
20. Remove exhaust front tube, and bracket on transmission side. Refer to EX-7, "Component".
21. Remove rear propeller shaft. Refer to PR-2, "Removal and Installation".
22. Disconnect all the harnesses connector from transmission, and temporarily fasten them on vehicle.
23. Remove clutch operating cylinder from transmission, and temporarily fix it aside. (M/T models) Refer to
CL-9, "Removal and Installation".
24. Remove shift control wires from transmission, and temporarily fix them aside. Refer to MT-7, "Removal
and Installation of Control Device and Cable" (M/T models) or AT-116, "Removal and Installation" (A/T
models).
25. Disconnect engine coolant piping for rear heater between vehicle and engine and transmission assembly
(vehicle with rear heater).
26. Remove brake caliper from steering knuckle. Temporarily secure brake hose on body with rope to avoid
putting a load on it. Refer to BR-17, "Component".
27. Remove stabilizer from vehicle. Refer to FSU-6, "Component".
28. Remove suspension lower arm on suspension member side and damper lower end side, to free it
together with steering knuckle. Refer to FSU-6, "Component".
Removal
29. Securely support bottom surface of engine and transmission with two transmission jacks.
CAUTION:
• Make lifting height minimal where work under vehicle can be performed. Reserve gap for lifting
up (height where engine upper part protrudes above vehicle bottom).

ENGINE ASSEMBLY
• Take fixing measures as necessary so that jack does not slip from supporting surface. (The fig-
ure shows fixing with a rope as an example.) A
30. Pull out rear engine mounting through-bolt from upper surface of transmission.
31. Remove suspension member mounting bolts. Refer to FSU-6, "Component".
32. Carefully lift up vehicle, and remove engine and transmission assembly from vehicle. EM
NOTE:
The figure shows an example with the vehicle front and rear
supported by a 2-pole lift and using two transmission jacks. C
(Vehicle rear is not shown in the figure.)
CAUTION:
• Check that no part interferes with vehicle.
• Check that every part is connected. D
• Check that vehicle does not fall off by shifting of center of
gravity of vehicle, or counter-action. (Refer to “CAUTION
EM-257, "Removal and Installation"” in the beginning.) E
[Disassemble work]
• On level ground, separate engine and transmission in the following KBIA0893E
procedure. F
CAUTION:
During operation, securely support engine by placing pieces of wood under engine oil pan, transmis-
sion oil pan, and suspension member, and suspend engine slings from a hoist.
G
33. Install engine slingers (front and rear) into front left of cylinder
head and rear right of cylinder head.
1 : Engine slinger (rear) H

2 : Engine slinger (front)
I
Slinger bolts : 22.0 N·m (2.2 kg-m, 16 ft-lb)
34. Remove engine and transmission assembly from suspension
member. J
CAUTION:
Securely support engine by placing pieces of wood under
bottom surface.
K
35. Remove starter motor. Refer to SC-27, "Removal and Installa-
tion (ZD30, ZD30DDTi with Common Rail)".
36. Separate engine and transmission. Refer to MT-28, "Removal
and Installation" (M/T models) AT-129, "Removal and Installa- L
tion" (A/T models).
MBIB9100E
INSTALLATION N
• Where positioning pin is used, be sure to securely insert it into the hole of mating part.
• Do not allow oil to adhere to mount insulators. Be careful not to damage mount insulators. O
• Be sure that each mount insulator is not twisted, and has uneven thickness at right and left when it is
installed.
INSPECTION AFTER INSTALLATION P

The following are procedures for checking fluids leak, lubricates leak exhaust gases leak.
• Before starting engine, check the levels of engine coolant, engine oil, working fluid, and of air conditioner
refrigerant. If less than required quantity, fill to the specified level.
• Before starting engine, bleed air from fuel piping.

ENGINE ASSEMBLY
• Warm up engine thoroughly to check there is no leakage of engine coolant, engine oil, working fluid, fuel and
exhaust gas.
• Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
• After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to
Inspection:
Working fluid Level Leakage Level
Fuel Leakage Leakage –
Exhaust gas – Leakage –

CYLINDER BLOCK
CYLINDER BLOCK
A
EM
JPBIA1468GB
1. Oil level gauge 2. Oil level gauge guide 3. O-ring

4. Lower cylinder block 5. Lower cylinder block sub bolt 6. Lower cylinder block main bolt
7. Lower cylinder block sub bolt 8. Snap ring 9. Connecting rod

CYLINDER BLOCK
10. Connecting rod bearing 11. Connecting rod cap 12. Piston
13. Oil ring 14. Second ring 15. Top ring
16. Piston pin 17. Thrust bearing 18. Main bearing (upper)
19. Crankshaft 20. Crankshaft key 21. Main bearing (lower)
22. Pilot converter 23. Pilot bush 24. Flywheel
25. Drive plate 26. Reinforcement plate 27. Rear plate
28. Oil jet 29. Drain plug 30. Rear oil seal and retainer assembly
31. Oil pressure switch 32. Washer 33. Oil jet relief valve
34. Cylinder block
A. Oil seal lip B. Refer to EM-262 C. M/T models

DISASSEMBLY
1. Remove engine assembly from the vehicle, then separate engine and transmission. Refer to MT-28,
"Removal and Installation" (M/T models) orAT-129, "Removal and Installation" (A/T models).
2. Remove clutch cover and disk. (M/T models) Refer to CL-11, "Removal and Installation".
3. If they need to be replaced, replace pilot bushing. (M/T models)
• Using pilot bushing puller (SST), remove the bushing from rear
edge of crankshaft.
PBIC2231E
4. Install engine to engine stand (commercial service tool) as follows.

a. Remove flywheel (M/T models) or drive plate (A/T models).
b. Secure ring gear with ring gear stopper (SST), and then loosen
and remove installation bolt.
NOTE:
Figure is shown as an example of flywheel.
PBIC0516E
c. Remove pilot converter. (A/T models)

d. Remove rear plate.

CYLINDER BLOCK
e. Hoist engine and install it to the engine stand (commercial ser-
vice tool). A
EM
PBIC0085E
D
5. Drain engine oil and engine coolant from inside engine. Refer to LU-22, "Changing Engine Oil" and CO-
39, "Changing Engine Coolant".
6. Remove the following parts and related parts: E
• Intake manifold: Refer to EM-193, "Components".
• Turbocharger and catalyst: Refer to EM-198, "Component".
• Exhaust manifold: Refer to EM-204, "Component".
• Rocker cover: Refer to EM-220, "Component". F
• Injection tube and fuel injector: Refer to EM-213, "Component".
• Oil pan (upper and lower) and oil strainer: Refer to EM-206, "Component".
• Water pump: Refer to CO-54, "Component". G
• Thermostat and water piping: Refer to CO-56, "Component".
• Vacuum pomp and vacuum pipe: Refer to EM-211, "Component".
• Timing chain: Refer to EM-232, "Component".
• Timing gear: Refer to EM-236, "Component". H
• Fuel supply pump: Refer to EM-218, "Component".
• Camshaft: Refer to EM-223, "Component".
• Cylinder head: Refer to EM-247, "Component (Removal and Installation)". I
• Oil cooler: Refer to LU-26, "Component".
• Accessory, accessory bracket and mount bracket.
7. Remove rear oil seal and retainer assembly. J
• Insert slotted screwdriver into lower cylinder block and rear oil seal retainer to remove them.
NOTE:
Oil seal alone is not available as a service part.
K
8. Remove piston and connecting rod assembly.
• Before removing piston and connecting rod assembly check connecting rod side clearance. Refer to
EM-270, "Inspection After Disassembly". L
a. Move crankshaft pin to be removed to approximately BDC.
b. Remove connecting rod caps.
c. Press the piston and connecting rod assembly out to cylinder M
head side using the grip of a hammer.
EMT0160D
P
CAUTION:

CYLINDER BLOCK
• When removing the piston and connecting rod assembly,
prevent the big end of the connecting rod from interfering
with the oil jet.
• Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod
big end.
PBIC2232E
9. Remove connecting rod bearings from connecting rod and cap.

• Keep them by cylinder to avoid confusion.
10. Remove piston rings from piston using piston ring expander
(commercial service tool).
CAUTION:
• When removing, prevent pistons from being damaged.
• Never expand piston rings excessively. This may damage
the piston rings.
PBIC0087E
11. Remove piston from connecting rod.

a. Remove snap rings using long nose pliers.
PBIC0388E
b. Using industrial dryer, heat piston up to 60 to 70°C (140 to

158°F).
PBIC0089E

CYLINDER BLOCK
c. Using rod with outer diameter of 30 mm (1.18 in), press piston
pin out. A
EM
EMM0072D
D
12. Remove lower cylinder block.
NOTE:
• Because two mounting bolts support in the process, support the lower part of cylinder block.
E
• Lower cylinder block is the lower part of cylinder block, which works as main bearing cap (beam) and oil
pan mounting face.
a. Remove mounting bolts to engine stand if they are tightened on lower cylinder block.
F
b. Loosen and remove mounting bolts in the reverse order shown
in the figure.
I
PBIC2233E
c. Insert flat-bladed screwdriver into 5 locations shown by arrows

in the figure. Lift lower cylinder block evenly, and remove liquid J
gasket.
CAUTION:
Prevent mating faces from being damaged. K
13. Remove crankshaft.
14. Remove main bearings and thrust bearings from cylinder block
and lower cylinder block. L
CAUTION:
Check mounting positions. Keep them to avoid confusion.
15. Remove oil jets. PBIC2234E
M
16. Remove oil jet relief valve.
ASSEMBLY
1. Blow air sufficiently to inside of coolant passage, oil passage, crankcase, and cylinder bore to remove for- N
eign materials.
2. Install oil jet relief valve.
3. Install oil jets. O

CYLINDER BLOCK
• Align knock pin on back of oil jet with pin on block when install-
ing oil jet.
PBIC0389E
4. Install main bearings and thrust bearings.

a. Remove contamination, dust and oil from bearing mounting positions on cylinder block and lower cylinder
block.
b. Install thrust bearings on both sides of No. 4 housing on cylinder
block.
• Install thrust bearings with oil groove facing to crankshaft arm
(outside).
PBIC2235E
c. Being careful with the direction, install main bearings.

• Install main bearings with the oil holes and grooves onto the
cylinder block side, and those without oil holes and grooves
onto the lower cylinder block side.
• Apply engine oil to bearing surfaces (inside) while installing
bearings. Do not apply engine oil to back surfaces, but clean
them completely.
• Align stopper notches on bearings to install them.
• Check that the oil holes on the cylinder block body are mated
with the oil hole positions on the bearings.
PBIC2236E
5. Install crankshaft to cylinder block.

• While rotating crankshaft by hand, check for smooth rotation.
6. Install lower cylinder block.
• Apply a continuous bead of liquid gasket to lower cylinder
block as shown in the figure.
• Using slots on engine sub-attachment, install lower cylinder
block to cylinder block, avoiding interference of dowel pins.
FEM128

CYLINDER BLOCK
7. Tighten lower cylinder mounting bolts to the torque shown below
in 3 consecutive steps in numerical order shown in the figure. A
Items Main bolt (No. 1 - 10) Sub bolt (No. 11 - 20)

1st 19.6 N·m (2.0 kg-m, 14 ft-lb) 9.8 N·m (1.0 kg-m, 7 in-lb) EM
2nd 98.0 N·m (10 kg-m, 72 ft-lb) 19.6 N·m (2.0 kg-m, 14 ft-lb)
3rd 172 N·m (18 kg-m, 127 ft-lb) 42.7 N·m (4.4 kg-m, 31 ft-lb)
C
• Sub-bolt No. 17 has shorter length than that of other sub-bolts.
PBIC2233E
D
8. After tightening bolts to the specified torque, check crankshaft for smooth rotation.
9. Check crankshaft side clearance. Refer to EM-270, "Inspection After Disassembly".
10. Install piston to connecting rod. E
a. Using long nose pliers, install snap ring to grooves on piston rear side.
• Fit snap ring correctly into grooves.
b. Install piston to connecting rod. F
• Using industrial dryer, heat piston up to approximately 60 to 70°C (140 to 158°F) until piston pin can be
pressed down by touching with a finger touch. Then insert piston pin into piston and connecting rod from
front side of piston toward rear. G
• Assemble piston and connecting rod with front mark of piston
crown and cylinder No. stamped on connecting rod being posi-
tioned as shown in the figure.
H
c. Install snap ring to front side of pistons.
• Refer to above a) for precaution on snap ring installation.
• After installation, check connecting rod for smooth movement.
I
J
PBIC1754E
11. Use piston ring expander (commercial service too) to install piston rings.
CAUTION: K
When installing, prevent piston from being damaged.
• Install top ring and second ring with stamped “R” surfaces fac- L
ing upward.
Identification thickness: M
Top ring : 2.5 mm (0.098 in)
N
PBIC2237E
O
12. Install connecting rod bearings to connecting rod and cap.

• While installing connecting rod bearings, apply engine oil to bearing surfaces (inside). Do not apply oil to
rear surfaces, but clean them completely. P

CYLINDER BLOCK
• Align stoppers on connecting rod bearings with connecting rod
stopper notches to install connecting rod bearings.
PBIC1788E
13. Install piston and connecting rod assembly to crankshaft.

• Move crankshaft pin to be installed to BDC.
• Align cylinder position with cylinder No. on connecting rod to install piston and connecting rod assembly.
• Using piston ring compressor [SST: EM03470000], install pis-
ton and connecting rod assembly with front mark on piston
crown facing toward the front side of engine.
CAUTION:
When installing piston and connecting rod assembly, pre-
vent the big end of connecting rod from interfering with
oil jet.
PBIC2238E
14. Install connecting rod caps and mounting nuts.

• Align cylinder No. stamped on connecting rod with that on cap
to install connecting rod cap.
• After tightening nuts, check crankshaft for smooth rotation.
• Check connecting rod side clearance. Refer to EM-270,
"Inspection After Disassembly".
PBIC1754E
15. Install rear oil seal and retainer assembly. Refer to EM-244,
"Removal and Installation of Rear Oil Seal".
• Apply a continuous bead of liquid gasket to rear oil seal and
retainer assembly as shown in the figure.
PBIC1976E

CYLINDER BLOCK
16. Press-fit pilot bearing into crank shaft. (M/T models)
• Using drift with outer diameter of 20 mm (0.79 in), press fit A
pilot bushing by the length shown in the figure.
EM
PBIC0390E
G
KBIA0820E
17. Install rear plate.

18. Install removed parts to engine in the reverse order of disassembly. H
19. Remove engine from engine stand.
20. Install flywheel (M/T models) or drive plate (A/T models).
• Install pilot converter (1), drive plate (2) and reinforcement I
plate (3) in direction shown in the figure. (A/T models)
A : Engine rear side stamp J

B : Chamfered
: Engine front
K
JPBIA1850ZZ
L
• Using the same method as disassembly, secure crankshaft and tighten mounting bolts.
• Tighten mounting bolts for flywheel (M/T models) or drive plate M
(A/T models) in numerical order shown in the figure.
PBIC2240E P
How to Select Piston INFOID:0000000003451680
DESCRIPTION

CYLINDER BLOCK
Connecting points Connecting parts Selection items Selection methods

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

1. Measure cylinder block bore inner diameter.
2. Referring to “Cylinder block bore inner diameter” in “Selective
combination chart”, select appropriate piston according to cylin-
der bore grade.
PBIC2242E
Selective combination chart

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

A: Preferable combination
1 2
B: Allowable combination
-: NG combination 95.930 - 95.940 95.940 - 95.950
(3.7768 - 3.7772) (3.7772 - 3.7776)
96.000 - 96.010
1 A -
(3.7795 - 3.7799)
Cylinder bore grade 96.010 - 96.020
2 B A
(Cylinder block bore inner diameter) (3.7799 - 3.7803)
96.020 - 96.030
3 B A
(3.7803 - 3.7807)
• The piston is available together with piston pin as an assembly.

• Piston grade 3 (95.950 - 95.960) is applicable at factory only.
CRANKSHAFT SIDE CLEARANCE

CYLINDER BLOCK
• Measure the crankshaft travel amount using dial indicator by mov-
ing the crankshaft forward or backward. A
• Or, measure the crankshaft travel amount using feeler gauge with
the lower cylinder block removed.
EM
Standard : 0.055 - 0.140 mm (0.0022 - 0.0055 in)
Limit : 0.25 mm (0.0098 in)
• Select appropriate thrust bearings if measured value exceeds the C
limit.
Unit: mm (in)
PBIC2377E
Grade symbol Thickness of thrust bearing D

A 2.295 - 2.325 (0.0904 - 0.0915)
B 2.320 - 2.350 (0.0913 - 0.0925)
E
C 2.345 - 2.375 (0.0923 - 0.0935)
OS 020 2.495 - 2.525 (0.0982 - 0.0994)
• OS 020 has part No. of 12280 2W215 and OS 0.20 marked on bearing surface. F
CONNECTING ROD SIDE CLEARANCE

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

H
Limit : 0.22 mm (0.0087 in)
• Replace connecting rod and measure again if measured value
exceeds the limit.
I
Replace crankshaft if measured value still exceeds the limit.
FEM096
J
PISTON TO PISTON PIN CLEARANCE
Piston Pin Hole Inner Diameter
• Measure piston pin hole inner diameter using inside micrometer. K
Standard:
32.997 - 33.005 mm (1.2991 - 1.2994 in) dia. L
N
PBIC0116E

• Measure piston pin outer diameter using micrometer. O
Standard:
32.993 - 33.000 mm (1.2989 - 1.2992 in) dia. P
PBIC0117E

CYLINDER BLOCK
Calculation of Piston to Piston Pin Clearance
• (Piston pin clearance) = (Piston pin hole inner diameter) − (Piston pin outer diameter)
Standard : −0.003 (Tightening clearance) to 0.012 mm (−0.0001 to 0.0005 in)

• Replace piston and piston pin assembly if clearance is exceeds the specification.
PISTON RING SIDE CLEARANCE
• Measure the clearance between piston ring and piston ring groove
using feeler gauge.
Unit: mm (in)

Top ring 0.05 - 0.07 (0.0020 - 0.0028)
0.1 (0.004)
Second ring 0.04 - 0.08 (0.0016 - 0.0031)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059)
SEM024AA
• Align top ring and external surface of piston. Measure lower side
clearance of top ring with top ring pressed onto upper side of ring
groove.
• Replace piston ring if side clearance exceeds the limit.
• Check clearance again. Replace piston if side clearance still
exceeds the limit.
FEM100
PISTON RING END GAP

• Check that cylinder bore diameter is within the specifications.
Refer to "PISTON TO CYLINDER BORE CLEARANCE".
• Lubricate with new engine oil to piston and piston ring, and then
insert piton ring until middle of cylinder head with piston.
• Measure piston ring end gap with feeler gauge.
Standard:
Top ring : 0.25 - 0.45 mm (0.0098 - 0.0177 in)
Second ring : 0.50 - 0.65 mm (0.0197 - 0.0256 in)
Oil ring : 0.25 - 0.45 mm (0.0098 - 0.0177 in) FEM101
Limit:
Top ring : 1.5 mm (0.059 in)
Oil ring : 1.5 mm (0.059 in)
• Replace piston ring if measured value exceeds the limit. Re-bore cylinder and use oversized piston and pis-
ton rings if measured value still exceeds the limit.
CONNECTING ROD BEND AND TORSION

CYLINDER BLOCK
• Use connecting rod aligner to check bend and torsion.
A
Bend limit:
0.05 mm (0.0020 in)/100 mm (3.94 in)
Torsion limit: EM
0.05 mm (0.0020 in)/100 mm (3.94 in)
• Replace connecting rod assembly if measured value exceeds the C
limit.
SEM038F
G
SEM003F
CONNECTING ROD BEARING HOUSING DIAMETER (BIG END) H

• Install connecting rod cap without connecting rod bearings and
tighten connecting rod nuts to the specified torque. Refer to EM-
262, "Disassembly and Assembly". Measure connecting rod big
end inner diameter using inside micrometer. I
Standard:
59.987 - 60.000 mm (2.3617 - 2.3622 in) dia. J
• Replace connecting rod if out of specifications.
K
PBIC1641E
CONNECTING ROD BUSHING OIL CLEARANCE (SMALL END)

L
CONNECTING ROD SMALL END INNER DIAMETER
• Use inside micrometer to measure small end inner diameter.
Standard: M
33.025 - 33.038 mm (1.3002 - 1.3007 in) dia.
O
PBIC0120E
PISTON PIN OUTER DIAMETER P

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

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

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

• If out of the specifications, replace cylinder block and lower cylin-
der block as a unit.
FEM107
MAIN BEARING HOUSING INNER DIAMETER

• Install lower cylinder block without main bearings. Tighten mounting bolts to the specified torque. Refer to
EM-262, "Disassembly and Assembly".
• Use bore gauge to measure main bearing housing inner diameter.
Standard:
74.981 - 75.000 mm (2.9520 - 2.9528 in) dia.
• Replace cylinder block and lower cylinder block as a unit if out of
the specification.
PBIC2012E

CYLINDER BORE INNER DIAMETER

CYLINDER BLOCK
• Measure cylinder inner diameters at 6 positions; top, middle, and
bottom (A, B, C) in 2 directions (X, Y) using bore gauge. A
Cylinder inner diameter (Standard):

96.000 - 96.030 mm (3.7795 - 3.7807 in) dia. EM
Wear limit:
0.2 mm (0.008 in)
C
Out-of-round limit (Difference between X and Y):
0.02 mm (0.0008 in)
PBIC0391E
Taper limit (Difference between A and C): D
0.02 mm (0.0008 in)
• Horn or bore the applicable cylinder if clearance exceeds the limit,
or if any flaws or seizures are found on inner surface of cylinder. E
PBIC2246E
H
PISTON OUTER DIAMETER

• Use micrometer to measure piston skirt outer diameter.
I
Measurement position:
14 mm (0.55 in) upper from the lower end of piston
J
Standard:
95.930 - 95.950 mm (3.7768 - 3.7776 in) dia.
K
PBIC0125E
L
CALCULATION OF PISTON TO BORE CLEARANCE
• Calculate using piston skirt outer diameter and cylinder inner diameter (direction X, position B).
(Clearance) = (Cylinder inner diameter) − (Piston skirt outer diameter) M
Specifications at room temperature [20°C (68°F)]:

0.060 - 0.080 mm (0.0024 - 0.0031 in) N
• Replace piston and piston pin assembly if out of the specification.
CRANKSHAFT MAIN JOURNAL OUTER DIAMETER
O
Use micrometer to measure journal outer diameter.
Standard:
P
70.907 - 70.920 mm (2.7916 - 2.7921 in) dia.
• Calculate the main bearing oil clearance if indicated value is out of
standard, then use the undersize bearing. Refer to "MAIN BEAR-
ING OIL CLEARANCE".
FEM114

CYLINDER BLOCK
CRANKSHAFT PIN JOURNAL OUTER DIAMETER
Use micrometer to measure pin outer diameter.
CRANKSHAFT OUT-OF-ROUND AND TAPER

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

Taper limit : 0.01 mm (0.0004 in)
• Correct or replace crankshaft if the measured value exceeds the
PBIC1685E
limit.
• Measure the main bearing and connecting rod bearing oil clearance of the corrected journal if it is corrected.
Then select the main bearing and connecting rod bearing. Refer to "MAIN BEARING OIL CLEARANCE" and
"CONNECTING ROD BEARING OIL CLEARANCE".
CRANKSHAFT RUNOUT
• Place V-block onto surface plate to support No. 2 and No. 4 jour-
nals at both ends of crankshaft.
• Position dial indicator vertically onto No. 1, No. 3 and No. 5 journal.
• Rotate crankshaft to read needle movement on dial indicator. (Total
indicator reading)
Limit : 0.06 mm (0.0024 in)

• Replace crankshaft if it exceeds the limit.
PBIC2541E
CONNECTING ROD BEARING OIL CLEARANCE

Method by measurement
• Install connecting rod bearings to connecting rod and cap, and
tighten connecting nuts to the specified torque. Refer to EM-262,
"Disassembly and Assembly". Use inside micrometer to measure
connecting rod bearing inner diameter.
(Oil clearance) = (Connecting rod bearing inner diameter) −
(Crankshaft pin outer diameter)
Standard : 0.035 - 0.077 mm (0.0014 - 0.0030 in)

• If out of the specifications, check connecting rod big end inner
diameter and crankshaft pin outer diameter, and select appropriate
connecting rod bearing to adjust clearance to the specifications. PBIC1642E
Refer to “Connecting rod bearing undersize list” on the next page.

Method using plastigauge
• Remove contamination such as oil and dust completely from crankshaft pins and each bearing surface.
• Cut plastigauge slightly shorter than bearing width, and place it in crankshaft direction, avoiding oil holes.
• Install connecting rod bearings to cap, and tighten connecting rod nuts to the specified torque.
CAUTION:

CYLINDER BLOCK
• Remove connecting rod cap and bearings, and measure plasti-
gauge width using scale on plastigauge bag. A
CAUTION:
Take the same action mentioned in “Method by measurement”
if out of the specification.
EM
PBIC2247E
D
Undersize bearing usage
• Use undersize bearings if bearing clearance is out of the specifications for connecting rod bearings in stan-
dard size.
• Measure bearing inner diameter with bearing installed when using undersize bearings, and grind pins to E
adjust clearance to the specification.
Connecting rod bearing undersize list
Unit: mm (in)
F
Size Thickness
US 025 1.630 - 1.638 (0.0642 - 0.0645)
US 050 1.755 - 1.763 (0.0691 - 0.0694) G
US 075 1.880 - 1.888 (0.0740 - 0.0743)
US 100 2.005 - 2.013 (0.0789 - 0.0793)
H
CAUTION:
Keep corner radius of fillet R [3.3 - 3.7 mm (0.0130 - 0.146 in)]
when grinding crank pins to use undersize bearings. I
PBIC2248E
MAIN BEARING OIL CLEARANCE L
Method by measurement
• Install main bearings to cylinder block and lower cylinder block, and tighten lower cylinder block bolts to the
M
specified torque. Refer to EM-262, "Disassembly and Assembly". Measure main bearing inner diameter.
(Oil clearance) = (Bearing inner diameter) − (Crankshaft journal outer diameter)
Standard : 0.035 - 0.083 mm (0.0014 - 0.0033 in) N

• If out of the specification, check main bearing housing inner diameter and crankshaft journal outer diameter,
and select appropriate main bearing to adjust clearance to the specifications.
Refer to “Main bearing undersize list” on the next page. O
Method using plastigauge
• Remove contamination such as oil and dust completely from crankshaft journals and each bearing surface.
• Cut plastigauge slightly shorter than bearing width, and place it in crankshaft direction, avoiding oil holes. P
• Install lower cylinder block, and tighten to the specified torque. Refer to EM-262, "Disassembly and Assem-
bly".
CAUTION:

CYLINDER BLOCK
• Remove lower cylinder block and bearings, and measure plasti-
gauge width using scale on plastigauge bag.
CAUTION:
Take the same action mentioned in “Method by measurement”
if out of the specification.
PBIC0131E
Undersize bearing usage

• Use undersize bearings if bearing clearance is out of the specifications for main bearings in standard size.
• Measure bearing inner diameter with bearing installed when using undersize bearings, and grind crank jour-
nals to adjust clearance to the specification.
Main bearing undersize list
Unit: mm (in)
Size Thickness
US 025 2.130 - 2.138 (0.0839 - 0.0842)
US 050 2.255 - 2.263 (0.0888 - 0.0891)
US 075 2.380 - 2.388 (0.0937 - 0.0940)
US 100 2.505 - 2.513 (0.0986 - 0.0989)
CAUTION:
Keep corner radius of fillet R [2.8 - 3.2 mm (0.110 - 0.126 in)]
when grinding crank journals to use undersize bearings.
PBIC2249E
MAIN BEARING CRUSH HEIGHT

• Tighten lower cylinder block to the specified torque with main bear-
ings installed. Refer to EM-262, "Disassembly and Assembly". And
remove lower cylinder block. Refer to EM-262, "Disassembly and
Assembly". The bearing end must then be higher than the flat sur-
face.
Standard : Crush height must exist.

• Replace main bearings if out of the specification.
SEM502G
CONNECTING ROD BEARING CRUSH HEIGHT

CYLINDER BLOCK
• Tighten connecting rod bearing cap to the specified torque with
connecting rod bearing installed. Refer to EM-262, "Disassembly A
and Assembly". And remove connecting rod bearing cap. Refer to
EM-262, "Disassembly and Assembly". The bearing end must then
be higher than the flat surface.
EM
Standard : Crush height must exist.
• Replace connecting rod bearings if out of the specification. C
PBIC1646E
D
OIL JET
• Check nozzle for deformation and damage.
• Blow compressed air from nozzle, and check for clogs.
E
Standard : No deformation and no damage.
• Replace oil jet if it is out of the standard.
F
PBIC0392E
OIL JET RELIEF VALVE H

• Press check valve in oil jet relief valve using a clean plastic stick.
Check that valve moves smoothly with proper reaction force.
I
Standard:
Valve moves smoothly with proper reaction force.
• Replace oil jet relief valve if it is out of the standard. J
K
EMT0186D
FLYWHEEL RUNOUT (M/T MODELS)

Measurement position is approximately 240 mm (9.45 in) from the L
crankshaft center.
A : Dial indicator M
Runout (Total indicator reading):

Limit: 0.1 mm (0.004 in) N
• Replace flywheel if it is out of the standard.
PBIC4006E
O

GENERAL SPECIFICATIONS

Displacement cm3 (cu in) 2,953 (180.19)
Bore and stroke mm (in) 96 x 102 (3.78 x 4.02)
Compression 2
Oil 1
Number of main bearings 5
Standard 2,844 (28.4, 29, 412)
Compression pressure
Minimum 2,452 (24.5, 25, 356)
kPa (bar, kg/cm2, psi)/200 rpm
Differential limit between cylinders 294 (2.9, 3.0, 43)
Valve timing
PBIC0517E
Unit: degree
a b c d e
232 220 8 46 50

Unit: mm (in)
Items Limit
Intake manifold 0.2 (0.008)
Surface distortion
Exhaust manifold 0.2 (0.008)
CYLINDER HEAD

Unit: mm (in)
Items Standard Limit A
Head surface distortion Less than 0.03 (0.0012) 0.2 (0.008)
EM
SEM368G
E
Idler gear end play 0.070 - 0.14 (0.0028 - 0.0055) 0.2 (0.008)
Idler gear oil clearance 0.023 - 0.053 (0.0009 - 0.0021) 0.1 (0.004)
F
VALVE
Valve
G
Unit: mm (in)
PBIC0413E
K
Intake
Valve length “a” 113.5 (4.47)
Exhaust
Intake L
“b” 3.8 - 4.2 (0.150 - 0.165)
Exhaust
Intake
Valve margin “c” 1.5 (0.059) M
Exhaust
Intake 6.962 - 6.977 (0.2741 - 0.2747)
Exhaust 6.945 - 6.960 (0.2734 - 0.2740) N
Intake 31.9 - 32.1 (1.256 - 1.264)
Exhaust 29.9 - 30.1 (1.177 - 1.185)
O
Intake
Exhaust
Valve Clearance P
Unit: mm (in)
Items Cold*
Intake and Exhaust 0.30 - 0.40 (0.012 - 0.016)
Valve Spring

55.51 (2.1854)
Free length mm (in)
55.81 (2.1972)
180 - 206 (18.4 - 21.0, 40 - 46) at 40.8 (1.606)
Installation load N (kg, lb) at height mm (in)
216.2 - 243.8 (22.1 - 24.9, 49 - 55) at 40.8 (1.606)
1.90 (0.0748)
Square mm (in)
1.95 (0.0768)
Available Shims
Unit: mm (in)
Stamp Thickness
2.35 2.35 (0.0925)
2.40 2.40 (0.0945)
2.45 2.45 (0.0965)
2.50 2.50 (0.0984)
2.55 2.55 (0.1004)
2.60 2.60 (0.1024)
2.65 2.65 (0.1043)
2.70 2.70 (0.1063)
2.75 2.75 (0.1083)
2.80 2.80 (0.1102)
2.85 2.85 (0.1122)
2.90 2.90 (0.1142)
2.95 2.95 (0.1161)
3.00 3.00 (0.1181)
3.05 3.05 (0.1201)
JEM184G
Valve Lifter
Unit: mm (in)
Items Standard
Lifter guide inner diameter 34.495 - 34.515 (1.3581 - 1.3589)
Clearance between lifter and lifter guide 0.030 - 0.065 (0.0012 - 0.0026)
Valve Guide

Unit: mm (in)
A
EM
D
PBIC0420E
Items Standard
E
Outer diameter 11.023 - 11.034 (0.4340 - 0.4344)
Valve guide
Cylinder head valve guide hole diameter 10.996 - 10.975 (0.4329 - 0.4321)
F
Intake 0.023 - 0.053 (0.0009 - 0.0021)
Stem to guide clearance
Exhaust 0.040 - 0.070 (0.0016 - 0.0028) G
Intake 0.1 (0.004)
Valve deflection limit
Exhaust 0.1 (0.004)
H
Projection length 12.8 - 13.2 (0.504 - 0.520)

Unit: mm (in) I
Camshaft journal clearance 0.045 - 0.090 (0.0018 - 0.0035) 0.1 (0.004)
J
Inner diameter of camshaft bearing 30.000 - 30.021 (1.1811 - 1.1819) —
Outer diameter of camshaft journal 29.931 - 29.955 (1.1784 - 1.1793) —
Camshaft runout [TIR*] — 0.04 (0.0016) K
Camshaft end play 0.065 - 0.169 (0.0026 - 0.0067) 0.2 (0.008)
SEM671 O
INT 40.468 - 40.508 (1.5932 - 1.5948)
Cam height “A”
EXH 40.83 - 40.87 (1.6075 - 1.6091)
P
Wear limit of cam height 0.15 (0.0059)
CYLINDER BLOCK

Unit: mm (in)
SEM370G
Surface flatness Limit 0.1 (0.004)

Grade No. 1 96.000 - 96.010 (3.7795 - 3.7799)
Standard Grade No. 2 96.010 - 96.020 (3.7799 - 3.7803)
Cylinder bore Inner diameter
Grade No. 3 96.020 - 96.030 (3.7803 - 3.7807)
Wear limit 0.2 (0.008)
Out-of-round (X − Y) Less than 0.02 (0.0008)
Taper (A − C) Less than 0.02 (0.0008)
Main bearing housing 74.981 - 75.000 (2.9520 - 2.9528)
Crankshaft journal bearing inner diameter (With bearing) 70.955 - 70.990 (2.7935 - 2.7949)
Difference in inner diameter
Limit Less than 0.05 (0.0020)
between cylinders
PISTON, PISTON RING AND PISTON PIN

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

Piston skirt diameter “A” Standard
Grade No. 2 95.940 - 95.950 (3.7772 - 3.7776)
“a” dimension 14 (0.55)
Piston pin bore diameter 32.997 - 33.005 (1.2991 - 1.2994)
Piston clearance to cylinder block 0.060 - 0.080 (0.0024 - 0.0031)
Piston Ring
Unit: mm (in)

Top 0.05 - 0.07 (0.0020 - 0.0028) 0.1 (0.004)
Oil ring 0.02 - 0.06 (0.0008 - 0.0024) 0.15 (0.0059)

Top 0.25 - 0.45 (0.0098 - 0.0177) 1.5 (0.059)
A
End gap 2nd 0.50 - 0.65 (0.0197 - 0.0256) 1.5 (0.059)
Oil (rail ring) 0.25 - 0.45 (0.0098 - 0.0177) 1.5 (0.059)
Piston Pin EM
Unit: mm (in)
Piston pin outer diameter 32.993 - 33.000 (1.2989 - 1.2992)

Interference fit of piston pin to piston −0.003 to 0.012 (−0.0001 to 0.0005)
C
Standard 0.025 - 0.045 (0.0010 - 0.0018)

Piston pin to connecting rod bushing clearance
Limit 0.045 (0.0018) D
*: Values measured at ambient temperature of 20°C (68°F)
CONNECTING ROD
Unit: mm (in)
E
Center distance 154.5 (6.083)

Bend [per 100 (3.94)] Limit 0.05 (0.0020) F
Connecting rod small end inner diameter 35.087 - 36.000 (1.3814 - 1.4173)
Piston pin bushing inner diameter* 33.025 - 33.038 (1.3002 - 1.3007) G
Connecting rod big end inner diameter* 59.987 - 60.000 (2.3617 - 2.3622)
Standard 0.10 - 0.22 (0.0039 - 0.0087)
Side clearance H
Limit 0.22 (0.0087)
I
CRANKSHAFT
Unit: mm (in)
Main journal dia. “Dm” 70.907 - 70.920 (2.7916 - 2.7921)

J
Pin journal dia. “Dp” Grade No. 0 56.913 - 56.926 (2.2407 - 2.2412)
Taper: (Difference between “A” K
and “B”)
Out–of–round: (Difference be-
tween “X” and “Y”) L
Standard 0.055 - 0.140 (0.0022 - 0.0055)
Side clearance M
Limit 0.250 (0.0098)
SBIA0535E
SEM645
MAIN BEARING
Undersize

Unit: mm (in)
FEM127
Size Thickness Main journal diameter “Dm”

Standard 2.005 - 2.013 (0.0789 - 0.0793)
US 025 2.130 - 2.138 (0.0839 - 0.0842)
Grind so that bearing clearance is the spec-
US 050 2.255 - 2.263 (0.0888 - 0.0891)
ified value.
US 075 2.380 - 2.388 (0.0937 - 0.0940)
US 100 2.505 - 2.513 (0.0986 - 0.0989)
Main Bearing Oil Clearance

Unit: mm (in)
Items Standard
Main bearing oil clearance 0.035 - 0.083 (0.0014 - 0.0033)
THRUST BEARING
Unit: mm (in)
Grade symbol Thickness of thrust bearing
A 2.295 - 2.325 (0.0904 - 0.0915)
B 2.320 - 2.350 (0.0913 - 0.0925)
C 2.345 - 2.375 (0.0923 - 0.0935)
OS 020 2.495 - 2.525 (0.0982 - 0.0994)
• OS 020 has part No. of 12280 2W215 and OS 0.20 marked on bearing surface.
Undersize
Unit: mm (in)
Grade number Thickness Width

Standard 1.505 - 1.513 (0.0593 - 0.0596)
US 025 1.630 - 1.638 (0.0642 - 0.0645)
US 050 1.755 - 1.763 (0.0691 - 0.0694) 25.9 - 26.1 (1.020 - 1.028)
US 075 1.880 - 1.888 (0.0740 - 0.0743)
US 100 2.005 - 2.013 (0.0789 - 0.0793)
Connecting Rod Bearing Oil Clearance

Unit: mm (in)
Items Standard
Connecting rod bearing oil clearance 0.035 - 0.077 (0.0014 - 0.0030)
FLYWHEEL

Unit: mm (in)
Items Limit A
Flywheel runout [TIR]* 0.1 (0.004)
EM

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ENGINE

Revision: 2007 November EM-1 E25

ENGINE ASSEMBLY ......................................... 74 EXHAUST MANIFOLD (ZD30DD) .................... 131

CYLINDER BLOCK ........................................... 78 EXHAUST MANIFOLD (ZD30DDTi) ................ 132

Revision: 2007 November EM-2 E25

SERVICE INFORMATION ......................... 175 TURBOCHARGER AND THREE WAY CATA-

Revision: 2007 November EM-3 E25

Revision: 2007 November EM-4 E25

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

Revision: 2007 November EM-5 E25

REMOVAL OF LIQUID GASKET

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

Revision: 2007 November EM-6 E25

Revision: 2007 November EM-7 E25

KV10116200 Disassembling valve mechanism

KV10112100 Tightening bolts for connecting rod bearing

KV10117100 Loosening or tightening heated oxygen sen-

KV10107902 Replacing valve oil seal

KV10115600 Installing valve oil seal

Revision: 2007 November EM-8 E25

ST16610001 Removing pilot bush

Commercial Service Tool INFOID:0000000003397068

Tool name Description

Spark plug wrench Removing and installing spark plug

Revision: 2007 November EM-9 E25

Pulley puller Removing crankshaft pulley

1. Compression tester Checking compression pressure

Valve seat cutter set Finishing valve seat dimensions

TORX socket Removing and installing flywheel

Piston ring expander Removing and installing piston ring

Revision: 2007 November EM-10 E25

Valve guide reamer 1: Reaming valve guide inner hole

Oxygen sensor thread cleaner Reconditioning the exhaust system threads F

Manual lift table caddy Removing and installing the engine

Revision: 2007 November EM-11 E25

1. Locate the area where noise occurs.

Revision: 2007 November EM-12 E25

Operating condition of engine A

Piston to piston pin oil D

Revision: 2007 November EM-13 E25

Removal and Installation of Engine Room Right Side Cover INFOID:0000000003397072

2. Tighten bolt (C) shown in the figure to specified torque.

Removal and Installation of Engine Room Rear Cover INFOID:0000000003397073

Revision: 2007 November EM-14 E25

Revision: 2007 November EM-15 E25

1. Water pump 2. Fan pulley 3. Power steering oil pump

• Refer to GI-8, "Component" for symbol marks in the figure.

Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Revision: 2007 November EM-16 E25

Revision: 2007 November EM-17 E25

Revision: 2007 November EM-18 E25

1. PCV hose 2. Clamp 3. Air duct K

• Refer to GI-8, "Component" for symbol marks in the figure.

Revision: 2007 November EM-19 E25

1 : Air duct (inlet)

a. Remove PCV hose (6).

Revision: 2007 November EM-20 E25

Revision: 2007 November EM-21 E25

1. Electric throttle control actuator 2. Gasket 3. PCV hose

• Refer to GI-8, "Component" for symbol marks in the figure.

Revision: 2007 November EM-22 E25

8. Remove intake manifold support.

Revision: 2007 November EM-23 E25