Engine Mechanical: Section

ENGINE
EM
A
EM
SECTION
ENGINE MECHANICAL C
E
CONTENTS
MRA8DE Removal and Installation .........................................18 F
Inspection ................................................................19
PRECAUTION ............................................... 3
CAMSHAFT VALVE CLEARANCE .................. 20
G
PRECAUTIONS ................................................... 3 Inspection and Adjustment ......................................20
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN- COMPRESSION PRESSURE ........................... 23
SIONER" ................................................................... 3 Inspection ................................................................23 H
Precaution for Procedure without Cowl Top Cover...... 3
Precautions For Engine Service ................................ 3
REMOVAL AND INSTALLATION ............... 24
Parts Requiring Angle Tightening ............................. 4 ENGINE ROOM COVER ................................... 24 I
Liquid Gasket ............................................................ 4 Exploded View .........................................................24
Removal and Installation .........................................24
PREPARATION ............................................ 6
J
AIR CLEANER AND AIR DUCT ....................... 25
PREPARATION ................................................... 6
Exploded View .........................................................25
Special Service Tools ................................................ 6
Commercial Service Tools ........................................ 7 K
Inspection ................................................................26
SYMPTOM DIAGNOSIS .............................. 10 INTAKE MANIFOLD ......................................... 27
NOISE, VIBRATION AND HARSHNESS Exploded View .........................................................27 L
(NVH) TROUBLESHOOTING ............................10 Removal and Installation .........................................27
NVH troubleshooting Chart ..................................... 10 EXHAUST MANIFOLD ...................................... 30
Exploded View .........................................................30 M
PERIODIC MAINTENANCE ......................... 12
SPARK PLUG ....................................................12 Inspection ................................................................32
Exploded View ........................................................ 12 N
OIL PAN ............................................................ 33
Removal and Installation ......................................... 12
Exploded View .........................................................33
Inspection ................................................................ 13
Removal and Installation (Lower Oil Pan) ...............33
Inspection ................................................................35 O
DRIVE BELT .......................................................15
Exploded View ........................................................ 15 Removal and Installation (Upper Oil Pan) ...............35
Removal and Installation ......................................... 15 Inspection ................................................................39
Inspection ................................................................ 16 P
FUEL INJECTOR AND FUEL TUBE ................ 40
Adjustment .............................................................. 16
Exploded View .........................................................40
Exploded View ........................................................ 16
Removal and Installation ......................................... 16
Inspection ................................................................43
AIR CLEANER FILTER ......................................18
IGNITION COIL ................................................. 45
Exploded View ........................................................ 18
Exploded View .........................................................45
Revision: December 2015 EM-1 2016 Sentra NAM

Removal and Installation ........................................ 45 CVT : Exploded View .............................................. 86
CVT : Removal and Installation .............................. 86
ROCKER COVER .............................................. 46 CVT : Inspection ..................................................... 89
Exploded View ........................................................ 46
Removal and Installation ........................................ 46 UNIT DISASSEMBLY AND ASSEMBLY ... 90
TIMING CHAIN .................................................. 48 FLYWHEEL ....................................................... 90
Exploded View ........................................................ 48 Exploded View ........................................................ 90
Removal and Installation ........................................ 49 Removal and Installation ......................................... 90
Inspection ............................................................... 58 Inspection ................................................................ 90
CAMSHAFT ....................................................... 60 DRIVE PLATE ................................................... 92
Exploded View ........................................................ 60 Exploded View ........................................................ 92
Removal and Installation ........................................ 60 Removal and Installation ......................................... 92
Inspection ............................................................... 64 Inspection ................................................................ 93
OIL SEAL ........................................................... 69 CYLINDER BLOCK ........................................... 94
Exploded View ........................................................ 94
VALVE OIL SEAL ..................................................... 69
Disassembly and Assembly .................................... 95
VALVE OIL SEAL : Removal and Installation ......... 69
Inspection .............................................................. 103
FRONT OIL SEAL ..................................................... 70
HOW TO SELECT PISTON AND BEARING .. 112
FRONT OIL SEAL : Removal and Installation ........ 70
Description ............................................................ 112
REAR OIL SEAL ....................................................... 70 Piston .................................................................... 112
REAR OIL SEAL : Removal and Installation .......... 70 Connecting Rod Bearing ..................................... 113
Main Bearing ........................................................ 115
CYLINDER HEAD .............................................. 72
Exploded View ........................................................ 72 SERVICE DATA AND SPECIFICATIONS
Removal and Installation ........................................ 72 (SDS) ......................................................... 118
Exploded View ........................................................ 74
Disassembly and Assembly .................................... 74 SERVICE DATA AND SPECIFICATIONS
Inspection ............................................................... 79 (SDS) ................................................................ 118
General Specification ............................................ 118
UNIT REMOVAL AND INSTALLATION ..... 82 Drive Belt .............................................................. 118
Spark Plug ............................................................ 118
ENGINE ASSEMBLY ......................................... 82 Exhaust Manifold .................................................. 119
M/T ............................................................................. 82 Camshaft ............................................................... 119
M/T : Exploded View ............................................... 82 Cylinder Head ....................................................... 121
M/T : Removal and Installation ............................... 82 Cylinder Block ....................................................... 123
M/T : Inspection ...................................................... 85 Connecting Rod Bearing ....................................... 127
Main Bearing ......................................................... 127
CVT ............................................................................ 86

PRECAUTIONS
< PRECAUTION > [MRA8DE]
PRECAUTION A
PRECAUTIONS
Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT EM
PRE-TENSIONER" INFOID:0000000012787714
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 SR and SB section 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, it is recommended that all mainte-
nance and repair be performed by an authorized NISSAN/INFINITI dealer. E
• Improper repair, 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 SR section.
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
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING:
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the H
Ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
causing serious injury.
• When using air or electric power tools or hammers, always switch the Ignition OFF, disconnect the I
battery or batteries, and wait at least three minutes before performing any service.
Precaution for Procedure without Cowl Top Cover INFOID:0000000012787715
J
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. K
M
PIIB3706J
Precautions For Engine Service INFOID:0000000012787716

N
DISCONNECTING FUEL PIPING

• Before starting work, check no fire or spark producing items are in the work area. O
• Release fuel pressure before disconnecting and disassembly.
• After disconnecting pipes, plug openings to stop fuel leakage.
P
DRAINING ENGINE COOLANT
Drain engine coolant and engine oil when the engine is cooled.
INSPECTION, REPAIR AND REPLACEMENT

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.

PRECAUTIONS
REMOVAL AND DISASSEMBLY
• When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
• Exercise maximum care to avoid damage to mating or sliding surfaces.
• Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
• Must cover openings of engine system with a tape or equivalent, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
ASSEMBLY AND INSTALLATION

• Use torque wrench to tighten bolts or nuts to specification.
• When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified,
do exactly as specified.
• Replace with new gasket, packing, oil seal or O-ring.
• Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for
any restriction and blockage.
• Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.
• After disassembling, or exposing any internal engine parts, change engine oil and replace oil filter with a new
one.
• Release air within route when refilling after draining engine coolant.
• After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle Tightening INFOID:0000000012787717
• Use the Tool for the final tightening of the following engine parts:
Tool number : KV10112100 (BT-8653-A)

- Camshaft sprocket (INT) bolt
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angle
tightening)
• 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.
Liquid Gasket INFOID:0000000012787718
REMOVAL OF LIQUID GASKET SEALING

CAUTION:
Do not damage the mating surfaces.
• After removing the bolts and nuts, separate the mating surface and
remove the liquid gasket using Tool (A).
Tool Number (A) : KV10111100 (J-37228)

• In areas where the cutter is difficult to use, use a plastic hammer to
lightly tap (1) the cutter where the liquid gasket is applied. Use a
plastic hammer to slide (2) the cutter by tapping on the side.
AWBIA1249GB

PRECAUTIONS
LIQUID GASKET APPLICATION PROCEDURE
1. Using suitable tool (A), remove old liquid gasket adhering to the A
liquid gasket application surface and the mating surface.
• Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes. EM
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. C
D
JPBIA0053ZZ
3. Attach liquid gasket tube to the suitable tool.

Use Genuine Silicone RTV Sealant, or equivalent. Refer to E
GI-22, "Recommended Chemical Products and Sealants".
4. Apply liquid gasket without gaps to the specified location accord-
ing to the specified dimensions. F
• If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
G
EMA0622D
H
• As for bolt holes (B), normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Check to read the text of this manual. I
(A) : Groove
: Inside J
• Within five minutes of liquid gasket application, install the mat-
ing component.
• If liquid gasket protrudes, wipe it off immediately. K
• Do not retighten mounting bolts or nuts after the installation.
• After 30 minutes or more have passed from the installation, fill JPBIA0010ZZ
engine oil and engine coolant.

L
CAUTION:
If there are specific instructions in the procedures contained in this manual concerning liquid gasket
application, observe them.
M

PREPARATION
< PREPARATION > [MRA8DE]
PREPARATION
PREPARATION
Special Service Tools INFOID:0000000012787719
The actual shape of the tools may differ from those illustrated here.
Tool number Description
(TechMate No.)
Tool name
KV10111100 Removing oil pan (upper and lower) etc.
(J-37228)
Seal cutter
S-NT046
16441 6N210 Removing fuel tube quick connectors in en-

(J-45488) gine room
Quick connector release
PBIC0198E
KV10116200 Disassembling and assembling valve mecha-

(J-26336-B) nism
Valve spring compressor Part (1) is a component of KV10116200, but
1. KV10115900 Part (2) is not.
( — )
Attachment
2. KV10109220
(J-26336-B and J-26336-20)
Adapter PBIC1650E
KV10112100 Tightening bolts for main bearing cap, cylinder

(BT-8653-A) head, etc.
Angle wrench
S-NT014
KV10117100 Loosening or tightening heated air fuel ratio

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

(J-38959)
Valve oil seal puller
NT011

PREPARATION
Tool number Description
(TechMate No.) A
Tool name
KV10115600 Installing valve oil seal
(J-38958) Use side (G). EM
Valve oil seal drift a: 20 (0.79) dia. d: 8 (0.31) dia.
b: 13 (0.51) dia. e: 10.7 (0.421)
c: 10.3 (0.406) dia. f: 5 (0.20)
H: Side B C
Unit: mm (in)
JPBIA0396ZZ
EM03470000 Installing piston assembly into cylinder bore D

(J-8037)
Piston ring compressor
E
S-NT044 F
ST16610001 Removing pilot converter
(J-23907)
Pilot bushing puller G
H
S-NT045
KV11103000 Removing crankshaft pulley

( — ) I
Pulley puller
NT676
K
KV11105210 Lock drive plate
(J-44716)
Stopper plate
L
M
AWBIA1811ZZ
Commercial Service Tools INFOID:0000000012787720

PREPARATION
(TechMate No.) Description
Tool name
( — ) Removing and installing spark plug
Spark plug wrench a: 14 mm (0.55 in)
JPBIA0399ZZ
( — ) Crankshaft pulley removing and installing

Pulley holder
ZZA1010D
( — ) Finishing valve seat dimensions

Valve seat cutter set
S-NT048
( — ) Removing and installing piston ring

Piston ring expander
S-NT030
( — ) Removing and installing valve guide

Valve guide drift
PBIC4012E
( — ) 1: Reaming valve guide inner hole

Valve guide reamer 2: Reaming hole for oversize valve guide
PBIC4013E
(J-43897-18) Reconditioning the exhaust system threads

(J-43897-12) before installing a new air fuel ratio sensor
Oxygen sensor thread cleaner (Use with anti-seize lubricant shown below.)
A: J-43897-18 [18 mm (0.71 in) dia.] for zir-
conia heated oxygen sensor
B: J-43897-12 [12 mm (0.47 in) dia.] for tita-
nia heated oxygen sensor
C: Mating surface shave cylinder
JPBIA0238ZZ D: Flutes

PREPARATION
(TechMate No.) Description
Tool name A
( — ) Lubricating oxygen sensor thread cleaning
Anti-seize lubricant (Permatex 133AR tool when reconditioning exhaust system
or equivalent meeting MIL specifica- threads EM
tion MIL-A-907)
C
AEM489
( — ) Removing and installing engine

Manual lift table caddy D
ZZA1210D
F
( — ) Pressing the tube of liquid gasket
Tube presser
H
S-NT052
( — ) Loosening nuts, screws and bolts

Power tool
I
PIIB1407E
(J-45816) Removing and installing CVT drive plate bolts K

E20 Socket
LBIA0285E M

NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [MRA8DE]
SYMPTOM DIAGNOSIS
NVH troubleshooting Chart INFOID:0000000012787721
JPBIA6227GB
1. Locate the area where noise occurs.

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

< SYMPTOM DIAGNOSIS > [MRA8DE]
4. Check specified noise source.
If necessary, repair or replace these parts. A
Operating condition of engine

Location Type of Before After When Source of
Check item
Refer- EM
of noise noise When When While noise ence page
warm- warm- start-
idling racing driving
up up ing
Top of en- Ticking or Tappet C
C A — A B — Valve clearance EM-20
gine clicking noise
Rocker
cover Camshaft Camshaft journal oil
Cylinder Rattle C A — A B C bearing clearance EM-119 D
head noise Camshaft runout
Piston to piston pin oil

Slap or Piston pin clearance E
— A — B B — EM-123
knock noise Connecting rod bushing
oil clearance
Piston to cylinder bore
clearance
F
Crank-
shaft pul- Piston ring side clear-
Slap or Piston
ley A — — B B A ance EM-123
rap slap noise
Cylinder Piston ring end gap G
block Connecting rod bend
(Side of and torsion
engine) Connect- Connecting rod bushing
Oil pan ing rod oil clearance EM-123 H
Knock A B C B B B
bearing Connecting rod bearing EM-127
noise oil clearance
Main bearing oil clear- I
Main bear- EM-127
Knock A B — A B C ance
ing noise EM-123
Crankshaft runout
Timing J
Front of Timing chain cracks
chain and
engine Tapping or and wear EM-48
A A — B B B chain ten-
Front cov- ticking Timing chain tensioner EM-58
sioner
er operation
noise K
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip- L
ing EM-15
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
M
Water
Squall
A B — B A B pump Water pump operation CO-19
Creak
noise
N
A: Closely related B: Related C: Sometimes related —: Not related

SPARK PLUG
< PERIODIC MAINTENANCE > [MRA8DE]
PERIODIC MAINTENANCE
SPARK PLUG
Exploded View INFOID:0000000012787722
ALBIA0966ZZ
1. Ignition coil 2. Spark plug 3. Rocker cover
Removal and Installation INFOID:0000000012787723
REMOVAL
1. Remove ignition coil. Refer to EM-45, "Removal and Installation".
2. Remove spark plug using suitable tool.
(a) : 14 mm (0.55 in)

CAUTION:
Do not drop or shock spark plug.
JPBIA0030ZZ
INSTALLATION
Installation is in the reverse order of removal.
DENSO
Standard type* PLZKAR6A-11 (except California)
DILKAR6A-11 (California)
Gap (nominal) 1.1 mm (0.043 in)

SPARK PLUG
*: Always check with the Parts Department for the latest parts information.
CAUTION: A
Always tighten the spark plug to specified torque to align the orientation of electrodes. The ground
electrode of a genuine spark plug is positioned in the area of maximum ignitability by tightening to the
specified torque. When replacing spark plugs, use genuine spark plugs of which the ground electrode
is adjusted. EM
NOTE:
The ground electrode of the spark plug is positioned in the area of maximum ignitability to improve combustion
efficiency in the cylinder, reduce CO2 (carbon dioxide) emission and improve fuel economy. C
JPBIA5996GB
I
1. Ground electrode of spark plug A. Top view B. Air-fuel mixture flow
C. Poor ignitability region
J
Inspection INFOID:0000000012787724
INSPECTION AFTER REMOVAL

K
Use the standard type spark plug for normal condition.
Spark plug (Standard type) : Refer to EM-118, "Spark Plug".

L
CAUTION:
• Do not drop or shock spark plug.
• Do not use a wire brush for cleaning.
• If plug tip is covered with carbon, spark plug cleaner may be M
used.
Cleaner air pressure : Less than 588 kPa (6 kg/cm2, N

85 psi)
Cleaning time : Less than 20 seconds
O
SMA773C

SPARK PLUG
• Spark plug gap adjustment is not required between replace-
ment intervals.
• Measure spark plug gap. when it exceeds the limit, replace
spark plug even if it is with in the specified replacement mile-
age. Refer to EM-118, "Spark Plug".
JPBIA0031ZZ

DRIVE BELT
DRIVE BELT
A
EM
JPBIA4302ZZ
E
1. Generator 2. Drive belt auto-tensioner 3. Crankshaft pulley
4. A/C compressor (with A/C models) 5. Water pump 6. Drive belt
Idler pulley (without A/C models) F
A. Possible use range B. New drive belt range C. Indicator
Removal and Installation INFOID:0000000012787726 G
REMOVAL
1. Remove the front fender protector (RH) front side bolts and clips. Refer to EXT-27, "FENDER PROTEC- H
TOR : Exploded View".
2. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with
a wrench securely. Then move the wrench handle in the direc- I
tion of arrow (loosening direction of drive belt auto-tensioner).
WARNING:
Avoid placing hand in a location where pinching may occur J
if the holding tool accidentally comes off.
3. Insert a rod approximately 6 mm (0.24 in) in diameter into the
hole (B) of the retaining boss to lock drive belt auto-tensioner.
K
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed.
4. Remove drive belt. JPBIA4351ZZ
L
INSTALLATION
1. Install drive belt.
CAUTION: M
• Confirm drive belt is completely set to pulleys.
• Check for engine oil and engine coolant, be sure they are not adhered to drive belt and each pul-
ley groove.
N
2. Release drive belt auto-tensioner, and apply tension to drive belt.
WARNING:
Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes
off. O
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to
EM-15, "Exploded View". P
5. Install the front fender protector (RH) front side bolts and clips. Refer to EXT-27, "FENDER PROTECTOR
: Exploded View".

DRIVE BELT
JPBIA4302ZZ
1. Generator 2. Drive belt auto-tensioner 3. Crankshaft pulley

4. A/C compressor (With A/C models) 5. Water pump 6. Drive belt
Idler pulley (without A/C models)
A. Possible use range B. New drive belt range C. Indicator
WARNING:
Perform this step when engine is stopped.
• Check that the indicator of drive belt auto-tensioner is within the possible use range.
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold.
• When new drive belt is installed, the indicator should be within the new drive belt range.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator is out of the possible use range or belt is damaged, replace drive belt.
Adjustment INFOID:0000000012787728
Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

JPBIA4304GB
1. Front cover 2. Drive belt auto-tensioner
Removal
1. Remove engine under cover. Refer to EXT-31, "ENGINE UNDER COVER : Exploded View".
2. Remove engine room cover. Refer to EM-24, "Removal and Installation".
3. Partially remove fender protector side cover (RH). Refer to EXT-27, "FENDER PROTECTOR : Exploded
View".
DRIVE BELT
4. Remove drive belt. Refer to EM-15, "Exploded View".
5. Support engine (1) and transaxle (2) using suitable jack (A). A
CAUTION:
• Position a suitable jack under the engine and transaxle
assembly as shown. EM
• Do not damage the front exhaust tube or transaxle oil pan
with the jack.
C
ALBIA0894GB
D
6. Remove upper torque rod (RH) (if equipped) and engine mounting insulator (RH). Refer to EM-82, "M/T :
Exploded View" (for M/T) or EM-86, "CVT : Exploded View" (for CVT). E
7. Remove drive belt auto-tensioner.
Installation
Installation is in the reverse order of removal. F
CAUTION:
When installing drive belt auto-tensioner, be careful not to interfere with water pump pulley.
G

AIR CLEANER FILTER
AIR CLEANER FILTER
JSBIA2746GB
1. Mass air flow sensor 2. Mass air flow sensor gasket 3. Clamp
4. Air duct (suction side) 5. Resonator 6. Clamp
7. PCV hose 8. Clamp 9. Clamp
10. Air cleaner cover 11. Mounting rubber 12. Air cleaner filter
13. Air cleaner body 14. Air duct inlet (lower) 15. Air duct inlet (upper)
16. Grommet 17. Bracket 18. Grommet
REMOVAL
1. Remove air duct inlet (upper) (1).
2. Unhook the tabs (A) of both ends of the air cleaner cover.
JPBIA4352ZZ

AIR CLEANER FILTER
3. Remove the air cleaner filter (1) and air cleaner body (2) from
the air cleaner cover. A
4. Remove the air cleaner filter from the air cleaner body.
EM
JPBIA4353ZZ
D
INSTALLATION
• Tabs shall be fixed after inserting air cleaner body protrusion to air cleaner case notch hole.
• Make sure that whether air cleaner body has been firmly installed by shaking it. E
F
Examine the air cleaner filter for stains, clogging, or damage.
• Remove dirt and foreign objects (such as dead leaves) on air cleaner filter surface and inside air cleaner
cover and air cleaner body. G
• If clogging or damage is observed, replace the air cleaner filter.
CAUTION:
Do not clean the viscous paper type air cleaner filter by blowing as there is risk of deterioration of its H
performance.

CAMSHAFT VALVE CLEARANCE
Inspection and Adjustment INFOID:0000000012787734
INSPECTION
Perform inspection after removal, installation or replacement of camshaft or valve-related parts, or if there are
unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-46, "Removal and Installation".
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover.
(C) : White paint mark (Not used for service)
JSBIA2740ZZ
• At this time, check that both intake and exhaust cam lobes of
No. 1 cylinder face inside ( ) as shown.
(1) : Camshaft (INT)

(2) : Camshaft (EXH)
: Engine front
• If they do not face inside, rotate crankshaft pulley once more

(360 degrees) and align as shown.
JPBIA4347ZZ
b. Measure the clearance between valve lifter and camshaft using

suitable tool as shown.
Valve clearance : Refer to EM-119, "Camshaft".
PBIC3192J
• Measure the valve clearances at locations marked “×” [loca-

tions indicated with black arrow ( )] as shown using suitable
tool.
(A) : Exhaust side

(B) : Intake side
(1) : No. 1 cylinder
JSBIA2741ZZ
: Engine front

Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. A
EXH × ×
No. 1 cylinder at compression TDC
INT × ×
EM
c. Set No. 4 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) one revolution (360 degrees) and
align TDC mark (no paint) (B) to timing indicator (A) on front C
cover.

D
JSBIA2740ZZ
F
• Measure the valve clearance at locations marked “×” [loca-
tions indicated with black arrow ( )] as shown using suitable
tool. G
(A) : Exhaust side
(B) : Intake side
H
I
JSBIA2744ZZ
: Engine front
J
Measuring position No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL.
EXH × ×
No. 4 cylinder at compression TDC
INT × × K
3. If out of standard, perform adjustment. Refer to “ADJUSTMENT”.

ADJUSTMENT L
• Perform adjustment depending on selected head thickness of valve lifter.
1. Remove camshaft. Refer to EM-60, "Removal and Installation".
M
2. Remove valve lifters at the locations that are out of the standard.
3. Measure the center thickness of the removed valve lifters using
suitable tool (A).
N
PBIC3195J
4. Use the equation below to calculate valve lifter thickness for replacement.
Valve lifter thickness calculation: t = t1 + (C1 – C2)

t = Valve lifter thickness to be replaced

t1 = Removed valve lifter thickness
C1 = Measured valve clearance
C2 = Standard valve clearance:
Intake : 0.29 mm (0.011 in)
Exhaust : 0.32 mm (0.013 in)
• Thickness of new valve lifter (B) can be identified by stamp
mark (A) on the reverse side (inside the cylinder).
• Stamp mark “302” indicates 3.02 mm (0.1189 in) in thickness.
PBIC3196J
NOTE:
Available thickness of valve lifter: 26 sizes range 3.00-3.50 mm (0.1181-0.1378 in) in steps of 0.02 mm
(0.0008 in) (when manufactured at factory). Refer to EM-119, "Camshaft".
5. Install the selected valve lifter.
6. Install camshaft. Refer to EM-60, "Removal and Installation".
7. Install timing chain and related parts. Refer to EM-49, "Removal and Installation".
8. Manually rotate crankshaft pulley a few rotations.
9. Check that the valve clearances are within the standard. Refer to “INSPECTION”.
10. Installation of remaining components is in the reverse order of removal.
11. Warm up the engine, and check for unusual noise and vibration.

COMPRESSION PRESSURE
COMPRESSION PRESSURE
A
1. Warm up the engine to full operating temperature. EM

2. Release fuel pressure. Refer to EC-147, "Work Procedure".
3. Remove ignition coil and spark plug from each cylinder. Refer to EM-12, "Exploded View".
4. Connect engine tachometer (not required in use of CONSULT). C
5. Install compression gauge (B) with an adapter (A) into spark
plug hole.
D
F
PBIC3541J
G
• Use the adapter whose pick 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.
H
(a) : 20 mm (0.79 in) or less
J
JPBIA0171ZZ
6. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge
pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each K
cylinder.
Compression pressure : Refer to EM-118, "General Specification". L

CAUTION:
Always use a fully charged battery to obtain the specified engine speed.
• If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the M
engine speed again with normal battery gravity.
• If compression pressure is below minimum value, check valve clearances, and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, and cylinder
head gasket). After checking, measure compression pressure again. N
• 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- O
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remains P
low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
7. After inspection is completed, install removed parts.
8. Start the engine, and check that the engine runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-55, "Diagnosis Description".

ENGINE ROOM COVER
< REMOVAL AND INSTALLATION > [MRA8DE]
REMOVAL AND INSTALLATION

ENGINE ROOM COVER
JSBIA2748ZZ
1. Engine room cover 2. Mounting rubber (Black) 3. Mounting rubber (Gray)
REMOVAL
Remove engine room cover by pulling straight up to release mounting rubber.
CAUTION:
Do not damage or scratch engine room cover when installing or removing.
INSTALLATION

AIR CLEANER AND AIR DUCT
A
EM
J
JSBIA2746GB
1. Mass air flow sensor 2. Mass air flow sensor gasket 3. Clamp K
4. Air duct (suction side) 5. Resonator 6. Clamp
7. PCV hose 8. Clamp 9. Clamp
10 Air cleaner cover 11. Mounting rubber 12. Air cleaner filter L
13. Air cleaner body 14. Air duct inlet (lower) 15. Air duct inlet (upper)
16. Mounting rubber 17. Bracket 18. Grommet
M
REMOVAL N
NOTE:
Mass air flow sensor is removable under the car-mounted condition.
1. Remove engine room cover. Refer to EM-24, "Exploded View". O
2. Remove air duct inlet (upper).
3. Remove air cleaner filter from the air cleaner cover.
4. Disconnect the harness connector from mass air flow sensor and remove harness clamp from air cleaner P
body assembly.
5. Disconnect PCV hose and transaxle breather hose.
6. Remove air cleaner body.
7. Remove air duct (suction side).
• Add matching marks if necessary for easier installation.
8. Remove air cleaner cover.

9. Remove mass air flow sensor from air cleaner cover (if necessary).
CAUTION:
Handle the mass air flow sensor with following cares.
• Do not shock the mass air flow sensor.
• Do not disassemble the mass air flow sensor.
• Do not touch the sensor of the mass air flow sensor.
10. Remove air duct inlet (lower) with the following procedure:
a. Remove front combination lamp (LH). Refer to EXL-127, "Removal and Installation".
b. Remove air duct inlet (lower).
INSTALLATION
CAUTION:
Do not reuse gasket.
• Align marks. Attach each joint. Screw clamps firmly.
• Tabs shall be fixed after inserting air cleaner body assembly protrusion to air cleaner case notch hole.
• Make sure whether air cleaner body has been firmly installed by shaking it.

Inspect air duct (suction side), air duct inlet (upper), air duct inlet (lower) and resonator for crack or tear.
• If anything is found, replace air duct (suction side), air duct inlet (upper), air duct inlet (lower) and resonator.

INTAKE MANIFOLD
INTAKE MANIFOLD
A
EM
L
JSBIA2749GB
1. Clamp 2. PCV hose 3. Bracket M

4. Intake manifold gasket 5. Intake manifold 6. Mount rubber
7. Clamp 8. EVAP hose 9. EVAP canister purge volume
control solenoid valve
N
10. Electric throttle control actuator gas- 11. Electric throttle control actuator 12. Clamp
ket
13. Water hose 14. Water hose A. To brake booster
B. To water outlet C. Electric throttle control actuator ex-
O
ploded view
Removal and Installation INFOID:0000000012787742 P
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill-
ing.
REMOVAL
1. Remove engine room cover. Refer to EM-24, "Removal and Installation".

INTAKE MANIFOLD
2. Remove air cleaner body. Refer to EM-25, "Exploded View".
3. Disconnect the radiator hose (upper) from the water outlet. Refer to CO-15, "Exploded View".
4. Disconnect water hoses from electric throttle control actuator.
5. Disconnect the harness connector from electric throttle control actuator.
6. Remove electric throttle control actuator.
CAUTION:
• Handle carefully to avoid any shock to electric throttle control actuator.
• Do not disassemble electric throttle control actuator.
7. Pull out oil level gauge.
CAUTION:
Cover the oil level gauge guide openings to avoid entry of foreign materials.
8. Disconnect vacuum hose and EVAP hose from intake manifold.
9. Disconnect PCV hose from intake manifold.
10. Disconnect harness connectors from the runner control valve, runner control valve position sensor and
the tuning valve.
11. Loosen intake manifold nuts and bolts in the reverse order as
shown.
: Engine front
CAUTION:
Cover engine openings to avoid entry of foreign materials.
NOTE:
Disregard the numerical order No.6 in removal.
JSBIA2750ZZ
12. Remove intake manifold and intake manifold gasket.

INSTALLATION
Intake Manifold
1. Securely install intake manifold gasket to the mounting groove of the intake manifold.
CAUTION:
Do not reuse intake manifold gasket.
2. Install intake manifold with the following procedure:
a. Tighten intake manifold nuts and bolts in the numerical order as
shown.
: Engine front
b. Tighten No. 1 bolt again.
JSBIA2750ZZ
3. Tighten bolts of electric throttle control actuator equally and diagonally in several steps.
CAUTION:
Do not reuse gasket.
NOTE:
After installation, it is necessary to re-calibrate the electric throttle control actuator as follows:
• Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the elec-
tric throttle control actuator. Refer to EC-143, "Description".
• Perform “Idle Air Volume Learning” after repair when replacing electric throttle control actuator. Refer to EC-
144, "Description".

INTAKE MANIFOLD
INSPECTION AFTER INSTALLATION
Check for engine oil leaks and engine coolant leaks with engine at operating temperature and running at idle. A
WARNING:
Do not touch engine immediately after stopping as engine is extremely hot.
EM

EXHAUST MANIFOLD
EXHAUST MANIFOLD
CALIFORNIA
ALBIA0974ZZ
1. Air fuel ratio sensor 2. Exhaust manifold heat shield (up- 3. Exhaust manifold and three way catalyst
per)
4. Exhaust manifold heat shield (rear) 5. Exhaust manifold heat shield (front) 6. Exhaust manifold gasket
7. Cylinder head

EXHAUST MANIFOLD
EXCEPT CALIFORNIA
A
EM
H
ALBIA0975ZZ
1. Air fuel ratio sensor 2. Bracket 3. Exhaust manifold

4. Exhaust manifold gasket 5. Cylinder head 6. Exhaust manifold heat shield I
J
REMOVAL
1. Remove the cowl top. Refer to EXT-26, "Removal and Installation".
2. Remove front exhaust tube. Refer to EX-6, "Removal and Installation". K
3. Disconnect the harness connector from air fuel ratio sensor and remove air fuel ratio sensor (if neces-
sary).
4. Remove exhaust manifold cover. L
5. Remove exhaust manifold.
• Loosen nuts in reverse order as shown.
M
: Engine front
NOTE:
Disregard the numerical order No. 6-8 in removal. N
ALBIA0976ZZ
P
6. Remove exhaust manifold gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
INSTALLATION

EXHAUST MANIFOLD
1. Install exhaust manifold gasket (1) to cylinder head as shown.
CAUTION:
Do not reuse exhaust manifold gasket.
ALBIA1000ZZ
2. Install exhaust manifold with the following procedure:

a. Tighten nuts in numerical order as shown.
: Engine front
NOTE:
• Tighten nuts the No.1-3 in two steps.
• The numerical order No.6-8 shows the second step.
ALBIA0976ZZ


Surface Distortion
• Using straightedge (A) and feeler gauge (B), check the surface dis-
tortion of exhaust manifold mating surface in each exhaust port
and entire part.
Limit : Refer to EM-119, "Exhaust Manifold".

• If it exceeds the limit, replace exhaust manifold.
ALBIA0962ZZ

OIL PAN
OIL PAN
A
EM
L
AWBIA1427ZZ
1. O-ring 2. Oil pan (upper) 3. Oil level gauge guide M

4. O-ring 5. Oil level gauge 6. Oil pump drive chain
7. Crankshaft sprocket 8. Oil pump sprocket 9. Oil pump chain tensioner
10. Oil pump 11. Drain plug 12. Drain plug washer N
13. Oil pan (lower) 14. Oil filter 15. Clamp
16. Water hose 17. Oil cooler 18. Crankshaft position sensor
19. Rear oil seal A. Refer to LU-10 B. To thermostat housing O
C. To thermostat housing (M/T models) D. Oil pan side
To CVT oil warmer (CVT models)
Removal and Installation (Lower Oil Pan) INFOID:0000000012787747

P
REMOVAL
1. Drain engine oil. Refer to LU-8, "Draining".

OIL PAN
2. Remove oil pan (lower) bolts in reverse order as shown.
: Engine front
NOTE:
Disregard the numerical order No.7 and 11 in removal.
JPBIA4364GB
3. Insert Tool (A) between oil pan (upper) and oil pan (lower).
CAUTION:
• Do not damage the mating surface.
• Do not insert a screwdriver. This damages the mating sur-
faces.
• Slide Tool by tapping on the side of Tool (A) using a plastic
hammer.
Tool number (A) : KV10111100 (J-37228)

4. Remove oil pan (lower).
JPBIA4365ZZ
INSTALLATION
1. Install oil pan (lower) as follows:
a. Use a suitable tool (A) to remove old liquid gasket from mating
surfaces.
• Also remove old liquid gasket from mating surface of oil pan
(upper).
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surface when clean-
ing off old liquid gasket.
JPBIA4366ZZ

OIL PAN
b. Apply a continuous bead of liquid gasket (A) using suitable tool
as shown. A
(1) : Oil pan (lower)

(b) : 7.5-9.5mm (0.295 - 0.374 in) EM
(c) : 4.0 - 5.0 mm (0.157 - 0.197 in)
: Engine outside
: Engine front C
Use Genuine Silicone RTV Sealant, or equivalent. Refer to
CAUTION: D
• Installation should be done within 5 minutes after apply-
ing liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after E
the components are installed to allow the sealant to cure.
G
JPBIA4367ZZ
c. Tighten bolts in numerical order as shown.

H
: Engine front
NOTE:
I
• Tighten bolts the No.1 and 2 in two steps.
• The numerical order No.7 and 11 shows the second steps.
JPBIA4364GB
K
2. Install oil pan drain plug.
CAUTION:
• Do not reuse drain plug washer. L
• Refer to exploded view installation direction of drain plug washer. Refer to EM-33, "Exploded
View".
3. Refill the engine with engine oil. Refer to LU-9, "Refilling". M
INSPECTION AFTER REMOVAL N

Clean oil strainer if any object attached.
O
1. Check the engine oil level and adjust engine oil. Refer to LU-7, "Inspection".
2. Start engine, and check for leaks of engine oil.
3. Stop engine and wait for 10 minutes. P
4. Check the engine oil level again. Refer to LU-7, "Inspection".
Removal and Installation (Upper Oil Pan) INFOID:0000000012787749
NOTE:
ing.

OIL PAN
REMOVAL
1. Remove the engine and transaxle assembly. Refer to EM-82, "M/T : Exploded View" (M/T) or EM-86,
"CVT : Exploded View" (CVT).
2. Remove the clutch cover and clutch disc (M/T models). Refer to CL-17, "Exploded View".
3. Remove the flywheel (M/T) or drive plate (CVT). Refer to EM-90, "Exploded View" (M/T) or EM-92,
"Exploded View" (CVT).
4. Mount the engine on an engine stand. Refer to EM-72, "Removal and Installation".
5. Remove the generator. Refer to CHG-29, "Exploded View".
6. Remove oil pan (lower). Refer to EM-33, "Removal and Installation (Lower Oil Pan)".
7. Remove oil filter. Refer to LU-10, "Removal and Installation".
8. Remove timing chain. Refer to EM-48, "Exploded View".
9. Remove oil level gauge and oil level gauge guide.
10. Remove oil pump (if necessary). Refer to LU-15, "Removal and Installation".
NOTE:
The oil pan (upper) can be removed and installed without removing the oil pump.
11. Remove oil pan (upper) with the following procedure:
a. Loosen bolts in reverse order as shown.
: Engine front
JPBIA4427ZZ
b. Using suitable tool as shown by the arrow ( ) open up a crack

between oil pan (upper) and cylinder block.
: Engine front
CAUTION:
Do not use suitable tool anywhere other than shown, seal-
ant used is more adhesive than previous types when
shipped.
JPBIA4428ZZ
c. Insert Tool (A) between oil pan (upper) and cylinder block.
Tool Number (A) : KV10111100 (J-37228)

CAUTION:
Do not damage the mating surface.
• In areas where the cutter is difficult to use, use a plastic ham-
mer to lightly tap (1) the cutter where the liquid gasket is
applied. Use a plastic hammer to slide (2) the cutter by tapping
on the side.
AWBIA1249GB
12. Remove O-ring between cylinder block and oil pan (upper).
INSTALLATION
CAUTION:
Do not reuse O-rings or washers.

OIL PAN
1. Install oil pan (upper) with the following procedure:
a. Use a suitable tool (A) to remove old liquid gasket from mating A
surfaces.
• Remove the old liquid gasket from mating surface of cylinder
block. EM
• Remove old liquid gasket from the bolt holes and threads.
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket. C
JPBIA4429ZZ
D
b. Apply a continuous bead of liquid gasket (D) using suitable tool

as shown. E
(1) : Oil pan (upper)

(A) : 2 mm (0.08 in) protruded to outside
F
(B) : 2 mm (0.08 in) protruded to rear oil seal mounting side
(c) : 5.5 - 7.5 mm (0.217 - 0.295 in)
(e) : 4.0 - 5.0 mm (0.157 - 0.197 in)
G
: Engine front
: Engine outside
H
CAUTION:
• Installation should be done with 5 minutes after applying I
liquid gasket.
• Do not fill the engine with oil for at least 30 minutes after
J
NOTE:
Apply liquid gasket to the outside of bolt holes show by mark
K
JPBIA4430ZZ
c. Install new O-ring at cylinder block side.

CAUTION: L
• Install avoiding misalignment of O-ring.
• Do not reuse O-ring.
d. Tighten bolts in numerical order as shown. M
: Engine front
N
JPBIA4427ZZ P
2. Install rear oil seal with the following procedure:

CAUTION:
• The installation of rear oil seal should be completed within 5 minutes after installing oil pan
(upper).
• Always replace rear oil seal with new one.
• Do not touch oil seal lip.

OIL PAN
• Do not reuse rear oil seal.
a. Wipe off liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block
using suitable tool.
b. Apply engine oil to entire outside area of rear oil seal.
c. Press-fit the rear oil seal using a suitable drift (A) with outer
diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in).
JPBIA4414ZZ
• Press-fit to the specified dimensions as shown.
(1) : Rear oil seal

(A) : Cylinder block rear end surface
CAUTION:
• Do not touch the grease applied to the oil seal lip.
• Be careful not to damage the rear oil seal mounting part of
oil pan (upper) and cylinder block or the crankshaft.
• Press-fit straight, checking that rear oil seal does not curl
or tilt.
NOTE: PBIC3952E
The standard surface of the dimension is the rear end surface of

cylinder block.
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If there is less than
required quantity, fill to the specified level. Refer to MA-12, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and 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 make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec-
ified level, if necessary.
• Summary of the inspection items:
Item Before starting engine Engine running After engine stopped

Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission/ A/T and CVT Models Leakage Level/Leakage Leakage

transaxle fluid M/T Models Level/Leakage Leakage Level/Leakage
Other oils and fluids* Level Leakage Level

OIL PAN
A
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
*Power steering fluid, brake fluid, etc. EM
INSPECTION AFTER REMOVAL C

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

FUEL INJECTOR AND FUEL TUBE
ALBIA2925ZZ
1. Rocker cover 2. Fuel tube 3. Fuel tube protector

4. O-ring (blue) 5. Fuel injector 6. O-ring (brown)
7. Injector clip 8. Bracket 9. Bracket
10. Bracket
WARNING:
• Put a “CAUTION: FLAMMABLE” sign in the workshop.
• Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
• Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
CAUTION:
Do not remove or disassemble parts unless instructed.
NOTE:
ing.
REMOVAL
1. Remove engine room cover. Refer to EM-24, "Exploded View".
2. Release the fuel pressure. Refer to EC-147, "Work Procedure".
3. Remove intake manifold. Refer to EM-27, "Exploded View".
4. Disconnect quick connector with the following procedure. Disconnect fuel feed tube from fuel tube.
NOTE:
There is no fuel return path.
a. Remove quick connector cap (engine side) from quick connector connection.

b. With the sleeve (B) side of Tool (A) facing quick connector,
install Tool (A) onto fuel tube. A
Tool Number (A) : 16441 6N210 (J-45488)

c. Insert Tool (A) into quick connector (2) until sleeve (B) contacts EM
and goes no further. Hold quick connector release on that posi-
tion (C).
C
(D) : Insert and retain
CAUTION: JPBIA2255ZZ
Inserting quick connector release hard will not disconnect D

quick connector. Hold quick connector release where it contacts and goes no further.
d. Draw and pull out quick connector straight from fuel tube (1).
CAUTION: E
• Pull quick connector (E) holding position (C).
• Do not pull with lateral force applied. O-ring inside quick connector may be damaged.
• Prepare container and cloth beforehand as fuel will leak out.
• Avoid fire and sparks. F
• Keep parts away from heat source. Especially, be careful when welding is performed around
them.
• Do not expose parts to battery electrolyte or other acids. G
• Do not bend or twist connection between quick connector and fuel feed tube during installation/
removal.
• To keep the connecting portion clean and to avoid dam-
age and foreign materials, cover them completely with H
plastic bags, etc. (A) or something similar.
JPBIA2888ZZ
K
5. Disconnect harness connector from fuel injector.
6. Loosen fuel tube protector bolts and remove fuel tube protector.
L
7. Remove fuel tube and fuel injector assembly.
• Loosen bolts in the reverse order as shown.
: Engine front M
CAUTION:
• When removing, be careful to avoid any interference with
fuel injector. N
• Use a shop cloth to absorb any fuel leaks from fuel tube.
O
ALBIA2926ZZ
P
8. Remove fuel injector from fuel tube with the following procedure:

a. Open and remove clip (2).
b. Remove fuel injector (3) from fuel tube (1) by pulling straight.
CAUTION:
• Be careful with remaining fuel that may leak from fuel
tube.
• Be careful not to damage fuel injector nozzle during
removal.
• Do not bump or drop fuel injector.
• Do not disassemble fuel injector.
ALBIA2927ZZ
INSTALLATION
1. Install O-rings to fuel injector.
CAUTION:
• Upper and lower O-rings are different. Be careful not to confuse them.
Fuel tube side : Blue

Nozzle side : Brown
• Handle O-ring with bare hands. Do not wear gloves.
• Lubricate O-ring with new engine oil.
• Do not clean O-ring with solvent.
• Check that O-ring and its mating part are free of foreign material.
• When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring is stretched while installing, do not insert it quickly into fuel
tube.
• Insert O-ring straight onto fuel injector. Do not decenter or twist it.
2. Install fuel injector to fuel tube with the following procedure:
a. Insert clip (2) into clip mounting groove (F) on fuel injector (4).
(3) : O-ring (blue)

(5) : O-ring (brown)
• Insert clip so that protrusion (G) of fuel injector matches cut-
out (D) of clip.
CAUTION:
• Do not reuse clip. Replace it with a new one.
• Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
• Insert it while matching it to the axial center.
• Insert fuel injector so that protrusion (B) of fuel tube matches
cut-out (C) of clip.
• Check that fuel tube flange (A) is securely locked in flange
groove (E) on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
PBIC3155J
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head.
CAUTION:
For installation, be careful not to interfere with fuel injector nozzle.
4. Install fuel tube and injector assembly onto cylinder head.

• Tighten bolts in the order as shown.
A
: Engine front
EM
ALBIA2926ZZ
D
5. Connect harness connector to fuel injector.
6. Install fuel tube protector.
7. Connect fuel feed tube with the following procedure: E
a. Check for damage or foreign material on the fuel tube and quick connector.
b. Apply new engine oil lightly to area around the top of fuel tube.
F
c. Align center to insert quick connector straightly into fuel tube.
• Insert quick connector (1) to fuel tube until the top spool (3) on
fuel tube is inserted completely and the 2nd level spool (D) is
positioned slightly below quick connector bottom end. G
(B) : Insertion direction

(E) : Fitted condition H
CAUTION:
• Hold (A) position when inserting fuel tube into quick
connector. I
• Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector. JPBIA2256ZZ
• Insert until you hear a “click” sound and actually feel

the engagement. J
• To avoid misidentification of engagement with a similar sound, be sure to perform the next
step.
d. Pull quick connector hard by hand holding position. Check it is completely engaged (connected) so that it K
does not come out from fuel tube.
e. Install quick connector cap (engine side) to quick connector connection.
• Install quick connector cap (engine side) with the side arrow facing quick connector side (fuel feed tube L
side).
CAUTION:
• Check that the quick connector and fuel tube are securely engaged with the quick connector
M
cap (engine side) mounting groove.
• Quick connector may not be connected correctly if quick connector cap (engine side) cannot
be installed easily. Remove the quick connector cap (engine side), and then check the connec-
tion of quick connector again. N
f. Install fuel feed hose to hose clamp.
O
INSPECTION AFTER INSTALLATION P

Check on Fuel Leakage
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leaks at connection points. Refer to.
NOTE:
Use mirrors for checking at points out of clear sight.

2. Start the engine. With engine speed increased, check again that there are no fuel leaks at connection
points.
• Perform procedures for “Throttle Valve Closed Position Learning” after finishing repairs. Refer to EC-
143, "Description".
• If electric throttle control actuator is replaced, perform procedures for “Idle Air Volume Learning” after
finishing repairs. Refer to EC-144, "Description".
CAUTION:
Do not touch the engine immediately after stopping, as the engine becomes extremely hot.

IGNITION COIL
IGNITION COIL
A
EM
I
ALBIA0966ZZ
1. Ignition coil 2. Spark plug 3. Rocker cover J
K
REMOVAL
1. Remove the engine room cover. Refer to EM-24, "Exploded View".
2. Disconnect the harness connector from the ignition coil. L
3. Remove the ignition coil.
CAUTION:
Do not drop or shock it. M
INSTALLATION
N

ROCKER COVER
ROCKER COVER
AWBIA1444ZZ
1. Oil filler cap 2. Rocker cover protector 3. Oil filler tube

4. O-ring 5. Rocker cover 6. Rocker cover gasket
A. Refer to INSTALLATION
REMOVAL
2. Remove rocker cover protector.
3. Remove ignition coils. Refer to EM-45, "Exploded View".
CAUTION:
• Do not drop or shock ignition coil.
• Do not disassemble ignition coil.
4. Move ignition harness aside.
5. Remove rocker cover.

ROCKER COVER
• Loosen bolts in reverse order as shown.
A
EM
ALBIA0964ZZ
D
6. Remove PCV valve and PCV hose (if necessary).
7. Remove rocker cover gasket from rocker cover.
INSTALLATION E
1. Install the rocker cover gasket to rocker cover.
CAUTION:
• Do not reuse gasket. F
• Check the gasket is not dropped.
2. Install rocker cover.
• Tighten bolts in two steps separately in numerical order as G
shown.
Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb) H

Step 2 : 8.33 N·m (0.85 kg-m, 74 in-lb)
3. Installation of remaining components is in the reverse order of
removal. I
CAUTION:
Do not reuse O-ring.
ALBIA0964ZZ J

Check for engine oil leaks and engine coolant leaks with engine at operating temperature and running at idle.
K
WARNING:
Do not touch engine immediately after stopping as engine is extremely hot.
L

TIMING CHAIN
TIMING CHAIN
AWBIA1493ZZ
1. Timing chain slack guide 2. Timing chain tensioner 3. Timing chain

4. Oil pump drive chain 5. Crankshaft sprocket 6. Crankshaft key
7. Oil pump sprocket 8. Front cover 9. O-ring
10. O-ring 11. Valve timing control solenoid valve cover 12. O-ring
Valve timing control solenoid valve
13. 14. Valve timing control solenoid valve (INT) 15. Crankshaft pulley bolt
(EXH)
16. Crankshaft pulley 17. Front oil seal 18. Oil pump drive chain tensioner

TIMING CHAIN
19. O-ring 20. Timing chain tension guide 21. Camshaft sprocket (INT)
22. Camshaft sprocket (EXH) 23. O-ring A. Refer to EM-60 A
B. Refer to INSTALLATION
Removal and Installation INFOID:0000000012787759 EM
REMOVAL
CAUTION: C
The rotating direction is shown from the engine front.
1. Disconnect battery negative terminal. Refer to PG-74, "Exploded View".
2. Drain engine oil. Refer to LU-8, "Draining". D
CAUTION:
Perform this step when engine is cold.
3. Remove intake manifold. Refer to EM-27, "Exploded View". E
4. Remove the rocker cover. Refer to EM-46, "Exploded View".
5. Remove fender protector side cover (RH). Refer to EXT-27, "FENDER PROTECTOR : Exploded View".
6. Support engine (1) and transaxle (2) using suitable jack (A). F
CAUTION:
• Position a suitable jack under the engine and transaxle
assembly as shown. G
• Do not damage the front exhaust tube or transaxle oil pan
with the jack.
ALBIA0894GB I
7. Remove upper torque rod and engine mounting insulator (RH). Refer to EM-82, "M/T : Exploded View"
(M/T) or EM-86, "CVT : Exploded View" (CVT). J
8. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft pulley (1) clockwise and align TDC mark (no
paint) (B) to timing indicator (A) on front cover. K
PBIC3960E
N
b. At the same time, check that the cam lobes of the No. 1 cylinder
are located ( ) as shown.
(1) : Camshaft (INT) O

: Engine front
P
• If not, rotate crankshaft pulley one revolution (360 degrees)
and align as shown.
JPBIA4347ZZ
9. Remove crankshaft pulley with the following procedure:

a. Remove drive belt. Refer to EM-15, "Removal and Installation".
TIMING CHAIN
b. Lock crankshaft pulley (1) using suitable tool (A), loosen crank-
shaft pulley bolt, and locate bolt seating surface at 10 mm (0.39
in) from its original position.
CAUTION:
Do not remove the crankshaft pulley bolt as it will be used
as a supporting point for the Tool.
PBIC3961E
c. Attach Tool (A) in the M6 thread hole on crankshaft pulley (1),

and remove crankshaft pulley.
Tool number (A) : KV11103000 ( — )
PBIC3962E
10. Remove oil pan (lower). Refer to EM-33, "Exploded View".

NOTE:
If crankshaft sprocket and oil pump drive component are not removed, this step is unnecessary.
11. Remove intake valve timing control solenoid valve.
12. Remove drive belt auto-tensioner. Refer to EM-16, "Exploded View".
13. Remove front cover with the following procedure:
JPBIA4393ZZ

TIMING CHAIN
b. Cut liquid gasket by prying the position ( ) shown using suit-
able tool, and then remove the front cover. A
CAUTION:
• Be careful not to damage the mating surface.
• Do not use suitable tool anywhere other than shown, seal- EM
shipped.
JPBIA4394ZZ
D
14. Remove front oil seal from front cover.
CAUTION:
Be careful not to damage front cover.
E
• Pull out front oil seal using suitable tool.
15. Remove valve timing control cover (if necessary).
• Loosen bolts in reverse order as shown.
NOTE: F
Disregard the numerical order No.1 in removal.
JPBIA4368ZZ
I
16. Remove timing chain tensioner with the following procedure:
a. Insert a stopper pin (A) into the top groove with the timing chain
tensioner plunger pressed. J
NOTE:
Timing chain tensioner plunger is securely locked by inserting a
stopper pin. K
b. Remove timing chain tensioner (1).
P
JPBIA4395ZZ

TIMING CHAIN
17. Remove slack guide (2), tension guide (3) and timing chain (1).
CAUTION:
Do not rotate each crankshaft and camshaft individually
while timing chain is removed. It causes interference
between valve and piston.
NOTE:
If timing chain is difficult to remove, remove camshaft sprocket
(EXH) first to remove timing chain.
JPBIA4396ZZ
18. Remove crankshaft sprocket and oil pump drive component with the following procedure:
a. Push oil pump drive chain tensioner (1) in the direction as
shown.
b. Insert a stopper pin (A) into the body hole (B).
c. Remove oil pump chain tensioner.
• When the holes on lever and tensioner body cannot be
aligned, align these holes by slightly moving the oil pump
chain tensioner slack guide.
JPBIA4397ZZ
d. Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A),
and then loosen the oil pump sprocket bolt and remove it.

: Engine front
CAUTION:
• Secure the oil pump shaft with the WAF part.
• Do not loosen the oil pump sprocket bolt by tightening
the oil pump drive chain.
JPBIA4398ZZ

TIMING CHAIN
INSTALLATION A
CAUTION:
Do not reuse O-rings.
NOTE: EM
The figure shows the relationship between the matching mark on
each timing chain and that on the corresponding sprocket, with the
components installed. C
(1) : Timing chain
(2) : Camshaft sprocket (EXH)
D
(3) : Slack guide
(4) : Timing chain tensioner
(5) : Crankshaft sprocket
E
(6) : Oil pump drive chain
(7) : Oil pump sprocket
(8) : Oil pump drive chain tensioner
F
(9) : Tension guide
(10) : Camshaft sprocket (INT)
(A) : Matching mark (dark blue link)
G
(B) : Matching mark (outer groove)
(C) : Crankshaft key position (straight up)
(D) : Matching mark (stamping)
H
(E) : Matching mark (copper link)
(F) : Matching mark (yellow link)
(G) : Matching mark (outer groove) JPBIA4399ZZ
I
1. Check that crankshaft key points straight up.
2. Install crankshaft sprocket (2), oil pump sprocket (3) and oil
pump drive chain (1). J
(A) : Matching mark (stamping)

(B) : Matching mark (yellow link) K
(C) : Matching mark (dark blue link)
• Install it by aligning matching marks on each sprockets and oil
pump drive chain. L
• If these matching marks are not aligned, rotate the oil pump
shaft slightly to correct the position.
CAUTION: JPBIA4400ZZ
Check matching mark position of each sprocket after M

installing the oil pump drive chain.

TIMING CHAIN
3. Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A),
and then tighten the oil pump shaft sprocket bolt.

: Engine front
CAUTION:
• Secure the oil pump shaft with the WAF part.
• Do not loosen the oil pump shaft sprocket bolt by tighten-
ing the oil pump drive chain.
JPBIA4398ZZ
4. Install oil pump chain tensioner (1).

• Fix the face of the oil pump tensioner at the most compressed
position using a stopper pin (A), and then install it.
• Securely pull out ( ) the stopper pin after installing the oil
pump chain tensioner.
• Check matching mark position of oil pump drive chain and
each sprocket again.
JPBIA4401ZZ

TIMING CHAIN
5. Align the matching marks of each sprocket with the matching
marks of timing chain. A

(2) : Camshaft sprocket (INT) EM
(3) : Timing chain
(A) : Matching mark (dark blue link)
(B) : Matching mark (outer groove) C
(C) : Matching mark (outer groove)
(D) : Matching mark (copper link)
(E) : Matching mark (stamping) D
• If these matching marks are not aligned, rotate the camshaft
slightly by holding the hexagonal portion to correct the posi-
tion. E
CAUTION:
Check matching mark position of each sprocket and timing
chain again after installing the timing chain.
F
G
JPBIA4402ZZ
6. Install the slack guide (2) and the tension guide (3).
H
(1) : Timing chain
N
JPBIA4396ZZ
7. Install timing chain tensioner. O

• Lock the plunger at the most compressed position using a stopper pin, and then install it.
• Securely pull out the stopper pin after installing the timing chain tensioner.
CAUTION:
• After installing tensioner on the cam side, pull out lock pin. P
• If plunger pops out after pulling out lock pin without installing the tensioner to the engine, do not
use the tensioner. (If used, the plunger does not side smoothly.)
• To reuse tensioner on the cam side:
After installation, pick up and move ratchet clip toward the tip of the plunger and position the
tensioner parallel to the groove of the plunger.
8. Check matching mark position of timing chain and each sprocket again.
9. Install front oil seal. Refer to EM-70, "FRONT OIL SEAL : Removal and Installation".
TIMING CHAIN
CAUTION:
Do not reuse front oil seal.
10. Install front cover with the following procedure:
a. Install valve timing control cover (if removed).
• Apply a continuous bead of liquid gasket (E) using suitable
tool to valve timing control cover as shown.
(1) : Front cover

(2) : Valve timing control cover
(A) : Start and end of gasket application
(B) : Liquid gasket application area
(E) : Gasket
(c) : 4.0 - 5.6 mm (0.157 - 0.220 in)
(d) : 3.4 - 4.4 mm (0.134 - 0.173 in)
CAUTION:
ing liquid gasket.
the components are installed to allow the sealant to
cure.
NOTE:
The start and end of gasket application must overlap 5 mm or
more with one another.
JPBIA4369ZZ
• Tighten bolts in numerical order as shown.

NOTE:
Tighten bolt the No.1 in two step. The numerical order No.6
shows the second step.
JPBIA4368ZZ
b. Install new O-ring to cylinder block.

CAUTION:
• Do not misalign O-ring.

TIMING CHAIN
c. Apply a continuous bead of liquid gasket (D) using suitable tool
to front cover as shown. A
(1) : Cylinder head

(2) : Front cover EM
(A) : Liquid gasket application area
(b) : 4.0 - 5.6 mm (0.157 - 0.220 in)
(c) : 3.4 - 4.4 mm (0.134 - 0.173 in) C
: Engine outside

GI-22, "Recommended Chemical Products and Sealants". D
CAUTION:
ing liquid gasket. E
F
G
JPBIA4403ZZ
d. Check that matching marks of timing chain and each sprocket are still aligned. Then install front cover.
CAUTION: H
• Check O-ring on cylinder block is correctly installed.
• Be careful not to damage front oil seal by interference with front end of crankshaft.
e. Install front cover, and tighten bolts in numerical order as shown. I
• Refer to the following for the installation position of bolts.
M6 bolt : No. 1 J
M10 bolts : No. 6, 7, 10, 13, 21
M12 bolts : No. 2, 4, 8, 11
K
M8 bolts : Except the above
f. After all bolts are tightened, retighten them to specified torque in
numerical order as shown. L
CAUTION:
Be sure to wipe off any excessive liquid gasket.
JPBIA4393ZZ
11. Install crankshaft pulley with the following procedure: P

a. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
CAUTION:
Do not damage front oil seal lip.

TIMING CHAIN
b. Secure crankshaft pulley (1) using suitable tool (A).
c. Apply new engine oil to thread and seat surfaces of crankshaft
pulley bolt.
d. Tighten crankshaft pulley bolt.
Crankshaft pulley bolt : 29.4 N·m (3.0 kg-m, 22 ft-lb)
PBIC3961E
e. Put a paint mark (B) on crankshaft pulley (2), matching with any
one of six easy to recognize angle marks (A) on crankshaft pul-
ley bolt (1) flange.
f. Turn another 60 degrees clockwise (angle tightening).
• Check the tightening angle with movement of one angle mark.
g. Check that crankshaft rotates clockwise smoothly.
PBIC3963E


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

• 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".
NOTE:

TIMING CHAIN
Item Before starting engine Engine running After engine stopped A

EM
Other oils and fluids* Level Leakage Level C
*Power steering fluid, brake fluid, etc. D

CAMSHAFT
CAMSHAFT
AWBIA1462ZZ
1. Camshaft position sensor (EXH) 2. O-ring 3. Camshaft bracket

4. Camshaft (EXH) 5. Camshaft sprocket (EXH) 6. Camshaft sprocket (INT)
7. Camshaft (INT) 8. Valve lifter (EXH) 9. Valve lifter (INT)
10. Signal plate (INT) 11. Signal plate (EXH) 12. O-ring
13. Camshaft position sensor (INT) A. Refer to INSTALLATION
CAUTION:
The rotating direction is shown from the engine front.
REMOVAL
2. Remove rocker cover. Refer to EM-46, "Exploded View".
3. Remove timing chain. Refer to EM-48, "Exploded View".
NOTE:
Removal of oil pump drive related part is not necessary.
4. Remove camshaft position sensor (INT) and camshaft position sensor (EXH) from camshaft bracket.
CAMSHAFT
CAUTION:
• Handle camshaft position sensor (INT) and camshaft position sensor (EXH) carefully and avoid A
impacts.
• Do not disassemble camshaft position sensor (INT) and camshaft position sensor (EXH).
• Do not place sensor where it is exposed to magnetism.
EM
5. Put painted matching mark (A) on the camshaft sprocket (INT)
(2), camshaft sprocket (EXH) (3) and the camshaft bracket (1)
as shown.
NOTE: C
When camshaft alignment is as show in installation, it prevents
the knock pin of the camshaft (INT) from engaging with the
incorrect pin hole when installing the camshaft sprocket (INT). D
E
JPBIA4404ZZ
6. Remove camshaft sprockets (INT and EXH).

• Secure hexagonal part (A) of camshaft using suitable tool. F
Loosen camshaft sprocket bolts and remove camshaft
sprocket.
G
(1) : Camshaft sprocket (INT)
CAUTION: H
• Do not rotate crankshaft or camshaft while timing chain
is removed. It causes interference between valve and
piston. I
• Do not loosen the bolts with securing anything other JPBIA4405ZZ
than the camshaft hexagonal part.
7. Remove camshaft bracket with the following procedure: J

M
ALBIA0965ZZ
b. Cut liquid gasket by prying the position ( ) shown using suit- N

able tool, and then remove the camshaft bracket.
: Engine front O
CAUTION:
• Do not damage the mating surface.
• Do not use suitable tool anywhere other than shown, seal- P
shipped.
JPBIA4407ZZ
8. Remove camshafts.
9. Remove valve lifters (if necessary).

CAMSHAFT
• Identify installation positions, and store them without mixing them up.
10. Remove signal plate from camshaft (if necessary).
INSTALLATION
CAUTION:
Do not reuse O-rings.
1. Install valve lifters.
• Install them in the original positions.
2. Install camshafts.
• Clean camshaft journal to remove any foreign material.
• Distinguish between the intake and the exhaust by looking at
the different shapes of the front and rear ends of the camshaft
or using the identification colors (A) and (B).

Identification color M1 (A) M2 (B)

Camshaft (EXH) No Blue
Camshaft (INT) Yellow No JPBIA4408ZZ
• Install camshafts so that camshaft dowel pins (A) on the front

side are positioned as shown.

NOTE:
Though camshaft does not stop at the positions as shown, for
the placement of cam nose, it is generally accepted camshaft
is placed for the same direction as shown.
JPBIA4409ZZ
3. Install camshaft bracket with the following procedure:

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

CAMSHAFT
b. Apply liquid gasket (A) to camshaft bracket as shown.
A
(b) : Plug hole inner wall
(c) : 3.4 - 4.4 mm (0.134 - 0.173 in)
: Engine front EM
: Engine outside

C
CAUTION:
ing liquid gasket. D
E
G
JPBIA4410ZZ
c. Tighten bolts of camshaft brackets in the following steps, in

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

: 13, 14, and 15
M6 bolts [thread length: 35.0 mm (1.378 in)] ALBIA0965ZZ
K
: Except the above
i. Tighten bolts to the specified torque in three steps in the order as shown.
L
Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 5.88 N·m (0.60 kg-m, 52 in-lb)
Step 3 : 9.5 N·m (0.97 kg-m, 84 in-lb) M
CAUTION:
After tightening bolts of camshaft bracket, be sure to wipe off excessive liquid gasket from the
mating surface of cylinder head. N
4. Install the camshaft sprocket to the camshaft with the following procedure.
a. When the camshaft sprocket (INT) (2) and camshaft sprocket
(EXH) (3) is installed, refer to the paint matching marks (A) O
made during removal. Securely align the knock pin and the pin
hole, and then install them.
P
(1) : Camshaft bracket
JPBIA4404ZZ

CAMSHAFT
b. Tighten bolts in the following steps.
• Secure the hexagonal part (A) of camshaft using suitable tool
to tighten bolt.
CAUTION:
Check the tightening angle using Tool (B). Do not judge by
visual inspection.
Step 1 : 35.0 N·m (3.6 kg-m, 26 ft-lb)

Step 2 : 30.5 degrees rotation
Tool number (B) : KV10112100 (BT-8653-A)

JPBIA4412ZZ
(1) : Camshaft sprocket
5. Install timing chain. Refer to EM-48, "Exploded View".

6. Inspect and adjust valve clearance. Refer to EM-20, "Inspection and Adjustment".

Camshaft Runout
1. Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
2. Set suitable tool (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the
camshaft runout on dial indicator. (Total indicator reading)
Standard and Limit : Refer to EM-119, "Camshaft".

4. If it exceeds the limit, replace camshaft.
AWBIA1415ZZ
Camshaft Cam Height

1. Measure the camshaft cam height using suitable tool (A).
AWBIA1416ZZ
2. If it exceeds the limit, replace camshaft.

Camshaft Journal Oil Clearance
CAMSHAFT JOURNAL OUTER DIAMETER

CAMSHAFT
Measure the outer diameter of camshaft journal using suitable tool
(A). A
Standard : Refer to EM-119, "Camshaft".

If it exceeds the limit, replace camshaft. EM
AWBIA1417ZZ
D
CAMSHAFT BRACKET INNER DIAMETER
• Tighten camshaft bracket bolts with specified torque. Refer to EM-60, "Removal and Installation".
• Measure the inner diameter of camshaft bracket using suitable tool E
(A).
(B) : Measuring direction of inner diameter

F

• If it exceeds limit, replace camshaft bracket. G
AWBIA1418ZZ H
CAMSHAFT JOURNAL OIL CLEARANCE

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

• If it exceeds the limit, replace camshaft or cylinder head, or both. J
NOTE:
Camshaft bracket cannot be replaced as a single part, because it is machined together with cylinder head.
Replace cylinder head assembly. K
Camshaft End Play
1. Install camshaft in cylinder head. Refer to EM-60, "Removal and Installation".
2. Install suitable tool in thrust direction on front end of camshaft. L
Read the end play on suitable tool (A) when camshaft is moved
forward/backward (in direction to axis).
M
AWBIA1419ZZ
O
• Measure the following parts if out of the standard.

P

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

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

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

1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft.
CAUTION:
Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter
from the other four locations.
2. Measure the camshaft sprocket runout using suitable tool (A).
(Total indicator reading)
Limit : Refer to EM-119, "Camshaft".

• If it exceeds the limit, replace camshaft sprocket.
JPBIA4413ZZ
Valve Lifter
Check if surface of valve lifter has any wear or cracks.
• If anything above is found, replace valve lifter. Refer to EM-119,
"Camshaft".
KBIA0182E
Valve Lifter Clearance

VALVE LIFTER OUTER DIAMETER
• Measure the outer diameter of valve lifter using suitable tool (A).
AWBIA1420ZZ
VALVE LIFTER HOLE DIAMETER

CAMSHAFT
Measure the inner diameter of valve lifter hole of cylinder head using
suitable tool (A). A

VALVE LIFTER CLEARANCE EM
• (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter
outer diameter)
C
• If out of the standard, referring to the each standard of valve lifter AWBIA1421ZZ
outer diameter and valve lifter hole diameter, replace either or both D
valve lifter and cylinder head.
E
Inspection of Camshaft Sprocket (INT), (EXH) Oil Groove
WARNING:
Check when engine is cold so as to prevent burns by the splashing engine oil.
CAUTION: F
Perform this inspection only when DTC P0011 or P0014 is detected in self-diagnostic results of CON-
SULT and it is directed according to inspection procedure of EC section. Refer to EC-175, "Diagnosis
Procedure" (P0011) or EC-178, "Diagnosis Procedure" (P0014). G
1. Check engine oil level. Refer to LU-7, "Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking. H
a. Release the fuel pressure. Refer to EC-147, "Work Procedure".
b. Remove intake manifold. Refer to EM-27, "Exploded View".
c. Disconnect ignition coil and injector harness connectors. I
d. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting
bracket (RH) and engine mounting insulator (RH). Refer to EM-82, "M/T : Exploded View".
J
3. Remove intake or exhaust valve timing control solenoid valve. Refer to EM-48, "Exploded View".
• Lift the front side of the engine with a jack base to remove intake or exhaust valve timing control sole-
noid valve.
4. Clean the mounting area of intake or exhaust valve timing control solenoid valve, and then insert a clean K
shop cloth with no oil adhesion into the oil hole of the cylinder head.
5. Install engine mounting insulator (RH) and engine mounting bracket (RH). (After the removal of intake or
exhaust valve timing control solenoid valve and insertion of a shop cloth into the oil hole.) L
6. Perform cranking to check that engine oil comes out from the oil hole (mounting hole of intake or exhaust
valve timing control solenoid valve) of cylinder head.
• Regarding the engine oil check, judge it by the amount of oil adhered to the shop cloth inserted into the M
oil hole.
WARNING:
• Do not insert fingers into the oil hole. N
• Be careful not to touch rotating parts (drive belt, idler pulleys and crankshaft pulley, etc.).
CAUTION:
• Do not perform cranking without installing the engine mounting insulator (RH) and engine
mounting bracket (RH). O
• Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil
and so as to prevent engine oil contamination.
• Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to P
engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. Perform the following inspection if engine oil does not come out from intake or exhaust valve timing con-
trol solenoid valve oil hole of the cylinder head.
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-6,
"Engine Lubrication System Schematic".

CAMSHAFT
8. Remove components between intake or exhaust valve timing control solenoid valve and camshaft
sprocket (INT) or (EXH), and then check each oil groove for clogging.
• Clean oil groove if necessary. Refer to LU-6, "Engine Lubrication System Schematic".

OIL SEAL
OIL SEAL
A
VALVE OIL SEAL
VALVE OIL SEAL : Removal and Installation INFOID:0000000012787764
EM
REMOVAL
1. Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve
from dropping into cylinder. C
CAUTION:
When rotating crankshaft, be careful to avoid scarring front cover with timing chain.
2. Remove camshafts. Refer to EM-60, "Exploded View". D
3. Remove valve lifters. Refer to EM-60, "Exploded View".
4. Remove valve collet, valve spring retainer, and valve spring
using Tools. E
Tool number (A) : KV10116200 (J-26336-B)

Tool number (B) : KV10109220 (J-26336-20) F
Tool number (C) : KV10115900 ( — )
JPBIA1365ZZ
H
CAUTION:
• Do not damage valve lifter holes.
• Install Tool (A) in the center of valve spring retainer to I
press it.
(1) : Valve spring retainer

J
Tool number (A) : KV10115900 ( — )

K
AWBIA1422ZZ L
5. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Do not remove valve spring seat from valve spring. M
6. Remove valve oil seal using Tool (A).
Tool number (A) : KV10107902 (J-38959) N
P
AWBIA1423ZZ
INSTALLATION
1. Apply new engine oil to valve oil seal joint surface and seal lip.

OIL SEAL
2. Press in valve oil seal to the height (H) shown using Tool (A).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in)
Tool number (A) : KV10115600 (J-38958)
AWBIA1424ZZ

FRONT OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000012787765
REMOVAL
1. Remove front fender protector (RH). Refer to EXT-27, "FENDER PROTECTOR : Exploded View".
2. Remove drive belt. Refer to EM-15, "Removal and Installation".
3. Remove crankshaft pulley. Refer to EM-48, "Exploded View".
4. Remove front oil seal using suitable tool.
CAUTION:
Do not damage front cover and crankshaft.
INSTALLATION
1. Apply new engine oil to new front oil seal joint surface and seal lip.
CAUTION:
Do not reuse front oil seal.
2. Install front oil seal so that each seal lip is oriented as shown.
(A) : Dust seal lip

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

REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000012787766
REMOVAL

OIL SEAL
1. Remove engine and transaxle assembly. Refer to EM-86, "CVT : Exploded View" (CVT models) or EM-82,
"M/T : Exploded View" (M/T models). A
2. Remove clutch cover and clutch disc (M/T models). Refer to CL-17, "Exploded View".
3. Remove drive plate (CVT models) or flywheel (M/T models). Refer to EM-90, "Exploded View".
4. Remove rear oil seal using suitable tool. EM
CAUTION:
Do not damage crankshaft and cylinder block.
INSTALLATION C
1. Apply the liquid gasket lightly to entire outside area of new rear oil seal.
CAUTION:
• Do not reuse rear oil seal. D
• Use Genuine Silicone RTV Sealant, or equivalent. Refer to GI-22, "Recommended Chemical
Products and Sealants".
2. Install rear oil seal so that each seal lip is oriented as shown. E
(A) : Dust seal lip

(B) : Oil seal lip F
: Engine outside
: Engine inside
G
PBIC3485J
H
• Press-fit rear oil seal using suitable tool (A) with outer diameter
115 mm (4.53 in) and inner diameter 90 mm (3.54 in). I
CAUTION:
• Do not damage crankshaft and cylinder block.
• Press-fit oil seal straight to avoid causing burrs or tilt- J
ing.
• Do not touch grease applied onto oil seal lip.
K
JPBIA4414ZZ
L
• Press in rear oil seal (1) to the position as shown.
(A) : Rear end surface of cylinder block M
O
PBIC3952E
3. Installation of the remaining components is in the reverse order of removal. P

CYLINDER HEAD
CYLINDER HEAD
AWBIA1445ZZ
1. Cylinder head assembly 2. Cylinder head bolt 3. Cylinder head gasket

REMOVAL
2. Drain engine coolant and engine oil. Refer to CO-13, "Changing Engine Coolant" (for Coolant) and LU-8,
"Draining" (for Oil).
3. Remove fan motor and shroud assembly. Refer to CO-17, "Component".
4. Remove the exhaust manifold. Refer to EM-30, "Exploded View"
5. Remove the intake manifold. Refer to EM-27, "Exploded View".
6. Remove the fuel injector and fuel tube assembly. Refer to EM-40, "Exploded View".
7. Remove the water outlet. Refer to CO-24, "Exploded View".
8. Remove the rocker cover. Refer to EM-46, "Exploded View".
9. Remove the front cover and timing chain. Refer to EM-48, "Exploded View".
10. Remove the camshaft. Refer to EM-60, "Exploded View".
11. Remove cylinder head.
• Loosen cylinder head bolts in the reverse order as shown.
: Engine front
AWBIA1425ZZ
12. Remove cylinder head gasket.

INSTALLATION

CYLINDER HEAD
1. Install cylinder head gasket.
CAUTION: A
Do not reuse cylinder head gasket.
2. Install cylinder head, and tighten cylinder head bolts in order as shown using Tool (A).
• Clean threads and seating surfaces of bolts. EM
• Apply new engine oil to threads and seating surface of bolts.
CAUTION:
• If cylinder head bolts are reused, check their outer diameters before installation. Refer to EM-79,
"Inspection". C
• Check and confirm the tightening angle by using Tool (A).
Do not judge by visual inspection without the tool.
D
Tool number (A) : KV10112100 (BT-8653-A)
F
AWBIA1426ZZ
G
Step 1 : 40.0 N·m (4.1 kg-m, 30 ft-lb)
Step 2 : 100° clockwise in order
Step 3 : 0 N·m (0 kg-m, 0 ft-lb) H
Step 4 : 40.0 N·m (4.1 kg-m, 30 ft-lb)
I
: Engine front AWBIA1425ZZ J

K

CYLINDER HEAD
AWBIA1446ZZ
1. Valve collet 2. Valve spring retainer 3. Valve spring (EXH)

(with valve spring seat)
4. Valve oil seal 5. Valve guide (EXH) 6. Valve lifter (EXH)
7. Valve seat (EXH) 8. Valve (EXH) 9. Valve (INT)
10. Valve seat (INT) 11. Cylinder head 12. Valve lifter (INT)
13. Valve guide (INT) 14. Spark plug tube 15. Valve spring (INT)
(with valve spring seat)
Disassembly and Assembly INFOID:0000000012787770
DISASSEMBLY
1. Remove spark plug using suitable tool.
2. Remove valve lifter.

CYLINDER HEAD
3. Remove valve collet, valve spring retainer, and valve spring
using Tools. A

Tool number (B) : KV10109220 (J-26336-20) EM
Tool number (C) : KV10115900 ( — )
JPBIA1365ZZ
D
CAUTION:
• Do not damage valve lifter holes.
• Install Tool (A) in the center of valve spring retainer (1) to E
install it.
Tool number (A) : KV10115900 ( — )

F
AWBIA1422ZZ H
4. Remove valve spring retainer and valve spring (with valve spring seat).
CAUTION:
Do not remove valve spring seat from valve spring. I
5. Push valve stem to combustion chamber side, and remove valve.
6. Remove valve oil seal using Tool (A). J
Tool number (A) : KV10107902 (J-38959)

K
AWBIA1447ZZ M
7. Remove valve seat (if necessary).

• 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-121, "Cylinder Head". N
CAUTION:
Do not bore excessively to prevent damage to cylinder head.
8. Remove valve guide (if necessary). O

CYLINDER HEAD
a. To remove valve guide, heat cylinder head to 110 to 130°C (230
to 266°F) by soaking in heated oil (A).
WARNING:
Cylinder head contains heat. When working, wear protec-
tive equipment to avoid getting burned.
PBIC3214J
b. Drive out valve guide using suitable tool.
SEM931C
ASSEMBLY
1. Install valve guide (if removed).
CAUTION:
Replace with oversize [0.2 mm (0.008 in)] valve guide. Refer to EM-121, "Cylinder Head".
a. Ream cylinder head valve guide hole using suitable tool (A).
AWBIA1449ZZ
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in

heated oil (A).
WARNING:
PBIC3214J

CYLINDER HEAD
c. Press valve guide (1) from camshaft side to dimension as
shown. A
(2) : Cylinder head
EM
Projection (H) : Refer to EM-121, "Cylinder Head".
PBIC3217J
D
d. Apply reamer finish to valve guide using suitable tool (A).
Standard : Refer to EM-121, "Cylinder Head".

E
G
AWBIA1449ZZ
2. Install valve seat, if removed.

CAUTION: H
Replace with oversize [0.5 mm (0.020 in)] valve seat. Refer to EM-121, "Cylinder Head".
a. Ream cylinder head (1) recess diameter for service valve seat
(2). I
• Be sure to ream in circles concentric to the valve guide center.
This will enable valve seat to fit correctly.
J
PBIC3218J
L
b. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in
heated oil (A).
WARNING: M
O
PBIC3214J
c. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head.
CAUTION: P
Do not touch cold valve seats directly.

CYLINDER HEAD
d. Finish valve seat to the specified dimension using suitable tool.
Refer to EM-121, "Cylinder Head".
CAUTION:
When using 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 the cutter or cutting many different times may
result in stage valve seat.
SEM934C
e. Using compound, grind to adjust valve.

f. Check again for normal contact. Refer to EM-121, "Cylinder
Head".
JPBIA0187ZZ
3. Install valve oil seal using Tool (A).

NOTE:
Dimension is height measured before installing valve spring
(with valve spring seat).
Height (H) : 15.1 - 15.7 mm (0.594 - 0.618 in)
Tool number (A) : KV10115600 (J-38958)
AWBIA1448ZZ
4. Install valve.
• Install larger diameter to intake side.
5. Install valve spring with valve spring seat (1) (do not remove from valve spring).
• Install smaller pitch (valve spring seat side) to cylinder head
side (B).
• Confirm identification color (A) of valve spring.
Intake : White
Exhaust : Orange
PBIC3462J
6. Install valve spring retainer.

7. Install valve collet.

CYLINDER HEAD
• Compress valve spring using Tool. Install valve collet with a
magnet hand. A

Tool number (B) : KV10109220 (J-26336-20) EM
Tool number (C) : KV10115900 ( — )
CAUTION:
When working do not damage valve lifter holes. C
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition. JPBIA1365ZZ
D
8. Install valve lifter.
• Install it in the original position.
9. Install spark plug. Refer to EM-12, "Exploded View". E
INSPECTION AFTER REMOVAL F
Cylinder Head Bolts Outer Diameter

• Cylinder head bolts are tightened by plastic zone tightening
G
method. Whenever the size difference between (d1) and (d2)
exceeds the limit, replace them with a new one.
Limit [(d1) – (d2)]: 0.15 mm (0.0059 in) H
• If reduction of outer diameter appears in a position other than (d2),

use it as (d2) point.
I
PBIC3994E
J
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should also be checked. Refer to EM-121, "Cylinder K
Head".
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
L
Do not allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head,
measure the distortion in six directions using suitable tools (A,
B). M
Limit: Refer to EM-121, "Cylinder Head".

N
• If it exceeds the limit, replace cylinder head.
PBIC3207J
P
INSPECTION AFTER DISASSEMBLY
Valve Dimensions
• Check the dimensions of each valve. Refer to EM-121, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact. Refer to “VALVE SEAT
CONTACT”.
Valve Guide Clearance

CYLINDER HEAD
Valve Stem Diameter
• Measure the diameter of valve stem using suitable tool (A).
Standard: Refer to EM-121, "Cylinder Head".
Valve Guide Inner Diameter

• Measure the inner diameter of valve guide using suitable tool.
Standard: Refer to EM-121, "Cylinder Head".
Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) PBIC3213J
Standard and Limit: Refer to EM-121, "Cylinder Head".

• If the calculated value exceeds the limit, replace valve and/or valve guide, when valve guide must be
replaced. Refer to EM-74, "Disassembly and Assembly".
Valve Seat Contact
• After confirming that the dimensions of valve guides and valves are within the specifications, perform this
procedure.
• Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve
contact on the surface.
• Check if the contact area band is continuous all around the circum-
ference.
(A) : OK
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions (B) even after the recheck,
replace valve seat. Refer to EM-74, "Disassembly and Assembly".
JPBIA0187ZZ
VALVE SPRING SQUARENESS

• Set a try square (A) along the side of valve spring and rotate
spring. Measure the maximum clearance between the top of spring
and try square.
(B) : Contact
Limit : Refer to EM-121, "Cylinder Head".

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

• Check valve spring pressure with valve spring seat installed at the
specified spring height.
CAUTION:
Do not remove valve spring seat from valve spring.
Standard : Refer to EM-121, "Cylinder Head".

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

CYLINDER HEAD
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required A
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak- EM
NOTE: C
after hydraulic pressure rises. D
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to spec- E
F
Engine oil Level Leakage Level G
H
Exhaust gas — Leakage — I
*Power steering fluid, brake fluid, etc.

ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [MRA8DE]
UNIT REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
M/T
M/T : Exploded View INFOID:0000000012787772
AWBIA1455ZZ
1. Washer 2. Upper torque rod (RH) (if equipped) 3. Engine mounting insulator (RH)
4. Rear torque rod bracket 5. Rear torque rod 6. Engine mounting bracket (LH)
7. Engine mounting frame support (LH) 8. Engine mounting insulator (LH)
CAUTION:
Check that the stud bolt (*2) is tight at the specified torque before tightening the nut (*1) shown. [Stud
bolt (*2) may be loosened after loosening the nut (*1)]
M/T : Removal and Installation INFOID:0000000012787773
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations.
ENGINE ASSEMBLY
• Do not start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections. A
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
EM
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-33, "Garage Jack and
Safety Stand and 2-Pole Lift".
NOTE: C
ing.
REMOVAL D
Outline
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle. E
1. Remove hood assembly. Refer to DLK-144, "HOOD ASSEMBLY : Removal and Installation".
F
3. Remove battery and battery tray. Refer to PG-74, "Exploded View".
5. Remove cowl top. Refer to EXT-26, "Removal and Installation". G
6. Remove air cleaner body. Refer to EM-25, "Exploded View".
8. Drain engine coolant from radiator. Refer to CO-13, "Changing Engine Coolant". H
CAUTION:
• Perform this step when the engine is cold.
• Do not spill engine coolant on drive belts. I
9. Remove front wheels and tires (RH/LH) using power tool. Refer to WT-47, "Adjustment".
10. Remove front fender protector side covers (RH/LH). Refer to EXT-27, "FENDER PROTECTOR :
Exploded View". J
12. Disconnect vacuum hose from intake manifold. Refer to EM-27, "Exploded View".
13. Remove radiator hoses (upper and lower). Refer to CO-15, "Exploded View". K
14. Remove radiator and fan motor and shroud assembly. Refer to CO-15, "Exploded View".
15. Remove ECM bracket, and then temporarily secure the engine harness on the engine side.
CAUTION: L
Protect harness connectors using a resin bag against foreign materials during the operation.
16. Disconnect fuel feed hose quick connector. Refer to EM-40, "Exploded View".
17. Disconnect heater hoses. Refer to CO-24, "Exploded View". M
18. Disconnect control linkage from transaxle. Refer to TM-22, "Exploded View".
19. Remove EVAP hoses. Refer to FL-16, "Exploded View".
N
20. Disconnect clutch tube on transaxle side from concentric slave cylinder (CSC). Refer to CL-14, "Exploded
View".
21. Remove A/C compressor bolts and position A/C compressor aside. Refer to HA-30, "Exploded View".
O
22. Remove ground cable at engine side.
23. Remove ground cable at transaxle side.
24. Remove drive shafts (RH/LH). Refer to FAX-18, "6M/T : Exploded View (LH)". P
25. Remove exhaust front tube. Refer to EX-5, "Exploded View".

ENGINE ASSEMBLY
26. Remove rear torque rod (1) and torque rod bracket (2).
ALBIA0970ZZ
27. Remove stabilizer connecting rod. Refer to FSU-12, "Exploded View".

28. Remove front suspension member. Refer to FSU-16, "Exploded View".
29. Preparation for the separation work of transaxle is as follows:
• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-33, "Exploded
View".
30. Install engine slinger to front cover front (LH) side (A) and cylin-
der head rear (RH) side (B).
: Engine front
Slinger bolts
Front cover front (LH)
: 32.9 N·m (3.4 kg-m, 24 ft-lb)
side:
Cylinder head rear
: 25.0 N·m (2.6 kg-m, 18 ft-lb)
(RH) side: JPBIA4422ZZ
31. Support engine and transaxle assembly with engine lifting equipment from the top with the vehicle raised
on a hoist.
32. Use a manual lift table caddy (A) or equivalent rigid tool such as
a transmission jack. Securely support bottom of the engine and
the transaxle assembly.
CAUTION:
Put a piece of wood or equivalent as the supporting sur-
face, secure a completely stable condition.
PBIC3223J
33. Remove upper torque rod (RH) (if equipped) (1) and engine
mounting insulator (RH) (2).
: Front
JPBIA4419ZZ

ENGINE ASSEMBLY
34. Remove engine mounting bracket (LH) through bolt nut (B).
A
(1) : Engine mounting insulator (LH)
(2) : Engine mounting bracket support (LH)
(A) : Through bolt EM
: Front
JPBIA4421ZZ
D
35. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work,
observe the following caution.
CAUTION:
• Check that no part interferes with the vehicle side. E
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to
changes in the center of gravity. F
• If necessary, support the vehicle by setting jack or suitable tool at the rear.
36. Remove starter motor. Refer to STR-30, "Exploded View".
37. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-28, "Exploded View". G
INSTALLATION
CAUTION: H
• Do not allow engine oil to get on engine insulator. Be careful not to damage engine mounting insula-
tor.
• Check that each mounting insulator is seated properly, and tighten nuts and bolts. I
• When installation directions are specified, install parts according to the direction marks on them
referring to the illustration of components. Refer to EM-82, "M/T : Exploded View".
NOTE:
Tighten all mounts to specification. J
M/T : Inspection INFOID:0000000012787774
K
• Use procedure below to check for fuel leakage. L
• Start engine. With engine speed increased, check again for fuel leakage at connection points. M
NOTE:
N
engine oil and engine coolant. O
P


ENGINE ASSEMBLY

CVT
CVT : Exploded View INFOID:0000000012787775
AWBIA1491ZZ
1. Washer 2. Upper torque rod (RH) (if equipped) 3. Engine mounting insulator (RH)
4. Engine mounting insulator (LH) 5. Rear torque rod bracket 6. Rear torque rod
CVT : Removal and Installation INFOID:0000000012787776
WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at front and back of rear wheels.
• Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped.

ENGINE ASSEMBLY
CAUTION:
• Always be careful to work safely, avoid forceful or uninstructed operations. A
• Do not start working until exhaust system and coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.
• Always use the support point specified for lifting.
EM
• Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoid-
able reasons, support at the rear axle jacking point with a transmission jack or similar tool before
starting work, in preparation for the backward shift of center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-33, "Garage Jack and C
Safety Stand and 2-Pole Lift".
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spill- D
ing.
REMOVAL
Outline E
Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the tran-
saxle.
1. Remove hood assembly. Refer to DLK-144, "HOOD ASSEMBLY : Removal and Installation". F
3. Remove battery and battery tray. Refer to PG-74, "Exploded View".
G
5. Remove cowl top. Refer to EXT-26, "Removal and Installation".
6. Remove air cleaner body. Refer to EM-25, "Exploded View". H
8. Drain engine coolant from radiator. Refer to CO-13, "Changing Engine Coolant".
CAUTION: I
• Perform this step when the engine is cold.
• Do not spill engine coolant on drive belts.
9. Remove front wheels and tires (RH/LH) using power tool. Refer to WT-47, "Adjustment".
J
10. Remove front fender protector side covers (RH). Refer to EXT-27, "FENDER PROTECTOR : Exploded
View".
K
12. Disconnect vacuum hose from intake manifold. Refer to EM-27, "Exploded View".
13. Remove radiator hose (upper and lower). Refer to CO-15, "Exploded View".
14. Remove radiator and fan shroud and motor assembly. Refer to CO-15, "Exploded View". L
15. Remove TCM and bracket. Refer to TM-266, "Exploded View".
16. Remove ECM bracket, and then temporarily secure the engine harness on the engine side.
CAUTION: M
Protect harness connectors using a resin bag against foreign materials during the operation.
17. Disconnect fuel feed hose quick connector. Refer to EM-40, "Exploded View".
18. Disconnect heater hoses. Refer to CO-24, "Exploded View". N
19. Disconnect control cable from transaxle. Refer to TM-259, "Exploded View".
20. Disconnect lines from CVT oil warmer. Refer to TM-282, "Exploded View".
21. Remove EVAP hoses. Refer to FL-16, "Exploded View". O
22. Remove A/C compressor bolts and position A/C compressor aside. Refer to HA-30, "Exploded View".
23. Remove ground cable at engine side.
P
24. Remove ground cable at transaxle side.
25. Remove drive shafts (RH/LH). Refer to FAX-25, "EXCEPT 6M/T : Exploded View".
26. Remove exhaust front tube. Refer to EX-5, "Exploded View".
27. Remove rear cover plate.
28. Remove torque converter nuts.

ENGINE ASSEMBLY
29. Remove rear torque rod (1) and torque rod bracket (2).
ALBIA0970ZZ
30. Remove stabilizer connecting rod. Refer to FSU-12, "Exploded View".

31. Remove front suspension member. Refer to FSU-16, "Exploded View".
32. Preparation for the separation work of transaxle is as follows:
• Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to EM-33, "Exploded
View".
33. Install engine slinger to front cover front (LH) side (A) and cylin-
der head rear (RH) side (B).
: Engine front
Slinger bolts
Front cover front (LH)
: 32.9 N·m (3.4 kg-m, 24 ft-lb)
side:
Cylinder head rear
: 25.0 N·m (2.6 kg-m, 18 ft-lb)
(RH) side: JPBIA4422ZZ
34. Support engine and transaxle assembly with engine lifting equipment from the top with the vehicle raised
on a hoist.
35. Use a manual lift table caddy (A) or equivalent rigid tool such as
a transmission jack. Securely support bottom of the engine and
the transaxle assembly.
CAUTION:
Put a piece of wood or equivalent as the supporting sur-
face, secure a completely stable condition.
PBIC3223J
36. Remove upper torque rod (RH) (if equipped) (1) and engine
mounting insulator (RH) (2).
: Front
JPBIA4419ZZ
37. Remove engine mounting insulator (LH).

38. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work,
observe the following caution.

ENGINE ASSEMBLY
CAUTION:
• Check that no part interferes with the vehicle side. A
• Before and during this lifting, always check if any harnesses are left connected.
• During the removal, always be careful to prevent the vehicle from falling off the lift due to
changes in the center of gravity.
EM
• If necessary, support the vehicle by setting jack or suitable tool at the rear.
39. Remove starter motor. Refer to STR-30, "Exploded View".
40. Lift with a hoist and separate the engine from the transaxle assembly. Refer to TM-28, "Exploded View".
C
INSTALLATION
CAUTION: D
• Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mount-
ing insulator.
• Check that each mounting insulator is seated properly, and tighten nuts and bolts.
• When installation directions are specified, install parts according to the direction marks on them E
referring to the illustration of components. Refer to EM-86, "CVT : Exploded View".
NOTE:
Tighten all mounts to specification. F
CVT : Inspection INFOID:0000000012787777
INSPECTION AFTER INSTALLATION G

• Use procedure below to check for fuel leakage. H
• Start engine. With engine speed increased, check again for fuel leakage at connection points. I
NOTE:
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop J
engine oil and engine coolant. K
• Summary of the inspection items: L

Engine coolant Level Leakage Level M

N
Fuel Leakage Leakage Leakage O
P

FLYWHEEL
< UNIT DISASSEMBLY AND ASSEMBLY > [MRA8DE]
UNIT DISASSEMBLY AND ASSEMBLY

FLYWHEEL
JSBIA1437GB
1. Flywheel
REMOVAL
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to TM-28, "Exploded View".
2. Remove flywheel.
• Secure flywheel using Tool and remove bolts using suitable tool.
Tool number : KV11105210 (J-44716)
CAUTION:
• Do not disassemble flywheel.
• Do not place flywheel with signal plate facing down.
• When handling signal plate, take care not to damage or scratch.
• Handle signal plate, do so in a manner that prevents it from becoming magnetized.
INSTALLATION
1. Install flywheel.
• Secure flywheel using Tool and install bolts.
Tool number : KV11105210 (J-44716)

CAUTION:
Be careful not to damage or scratch the contact surface of flywheel.
FLYWHEEL DEFLECTION

FLYWHEEL
• Measure the deflection of flywheel contact surface to torque with a
dial indicator (A). A
• Measure the deflection at 210 mm (8.27 in) diameter.
Limit : 0.45 mm (0.0177 in) or less. EM

• If measured value is out of the standard, replace flywheel.
• If a trace of burn or discoloration is found on the surface, repair it
with sandpaper. C
JSBIA1439ZZ
D
MOVEMENT AMOUNT OF FLYWHEEL
CAUTION:
Do not disassemble double mass flywheel.
E
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.
F
Standard : 1.8 mm (0.071 in) or less
G
Movement Amount in Radial (Rotation) Direction
Check the movement amount of radial (rotation) direction with the following procedure:
1. Install clutch cover bolt (1) to clutch cover hole, and place a H
torque wrench (A) on the extended line of the flywheel (2) center
line.
• Tighten bolt at a force of 9.8 N·m (1.0 kg-m, 87 in-lb) to keep it
I
from loosening.
2. Put a mating mark on circumferences of the two flywheel
masses without applying any load (Measurement standard
points). J
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. PBIC4007E K
4. Measure the dimensions of movement amounts (A) and (B) on
circumference of the flywheel on the transaxle side.
L
Limit : 33.2 mm (1.307 in) or less.
M

DRIVE PLATE
DRIVE PLATE
JSBIA1440GB
1. Pilot converter 2. Drive plate 3. Reinforcement plate

A. Chamfered
REMOVAL
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-86, "CVT : Exploded View".
2. Remove drive plate.
• Secure drive plate using Tool, and remove bolts using suitable tool.
Tool number : KV11105210 (J-44716)
3. Remove pilot converter (1) from the rear end of the crankshaft.
Use Tool (A) (if necessary).
Tool number (A) : ST16610001 (J-23907)
AWBIA1461ZZ
INSTALLATION

DRIVE PLATE
1. Install pilot converter (1) drive plate (2) and reinforcement plate
(3) as shown. A
(A) : Crankshaft rear end

(B) : Rounded EM
• Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot con-
verter into the end of crankshaft until it stops.
C
PBIC4075E
D
2. Install drive plate.
• Secure drive plate using Tool and install bolts using suitable tool.
E
Tool number : KV11105210 (J-44716)
CAUTION:
Be careful not to damage or scratch contact surface. F
G
DRIVE PLATE DEFLECTION

• Measure the deflection of drive plate contact surface to torque con- H
verter with a dial indicator (A).
• Measure the deflection at the area limited between 12.4 mm
(0.488 in) dia and 20.0 mm (0.787 in) dia around hole (B).
I
Limit : 0.35 mm (0.0138 in) or less.
• If measured value is out of the standard, replace drive plate.
J
JSBIA1441ZZ
K

CYLINDER BLOCK
CYLINDER BLOCK
AWBIA1452ZZ
1. Cylinder block 2. Block heater (for Canada) 3. Top ring

4. Second ring 5. Oil ring 6. Piston
7. Piston pin 8. Snap ring 9. Connecting rod

CYLINDER BLOCK
10. Connecting rod bearing (upper) 11. Connecting rod bearing (lower) 12. Crankshaft key
13. Connecting rod cap 14. Connecting rod cap bolt 15. Main bearing cap bolt A
16. Main bearing cap 17. Main bearing (lower) 18. Crankshaft
19. Signal plate 20. Rear oil seal 21. Main bearing (upper)
22. Thrust bearing 23. Oil temperature sensor 24. Oil pressure sensor EM
25. Knock sensor A. Refer to INSTALLATION
Disassembly and Assembly INFOID:0000000012787785 C
DISASSEMBLY
1. Remove engine and transaxle assembly from the vehicle. Refer to EM-82, "M/T : Exploded View" (M/T) or D
EM-86, "CVT : Exploded View" (CVT).
2. Remove the clutch cover and clutch (M/T models). Refer to CL-17, "Exploded View".
3. Remove the flywheel or drive plate. Refer to EM-90, "Exploded View" (M/T) or EM-92, "Exploded View" E
(CVT).
4. Remove pilot converter using Tool.
F
Tool Number : ST16610001 (J-23907)
WBIA0483E
I
5. Remove the rear oil seal. Refer to EM-70, "REAR OIL SEAL : Removal and Installation".
CAUTION:
Do not damage the crankshaft or cylinder block when removing the rear oil seal.
J
6. Install engine to engine stand with the following procedure:
a. Remove flywheel or drive plate. Refer to EM-90, "Exploded View" (M/T models) or EM-92, "Exploded
View" (CVT models).
K
b. Remove pilot converter. Refer to EM-92, "Exploded View" (CVT models).
c. Lift the engine with a hoist to install it onto widely use engine stand (A).
CAUTION:
L
• Use the engine stand (A) that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand. M
- Intake manifold: Refer to EM-27, "Exploded View".
- Rocker cover: Refer to EM-46, "Exploded View".
NOTE: N
The illustration shows an example of widely used engine stand
(A) that can support mating surface of transaxle with flywheel
(M/T models) or drive plate (CVT models) removed.
CAUTION: O
Before removing the hanging chains, check the engine
stand (A) is stable and there is no risk of overturning.
P
PBIC3227J
7. Drain engine oil. Refer to LU-8, "Draining".

CAUTION:

CYLINDER BLOCK
Be sure to clean drain plug and install with new drain plug washer.
8. Drain fluids and lubricants by removing drain plugs (1, 3 and 4)
the cylinder block.
: Engine front
Tightening torque : Refer to EM-95, "Disassembly and

Assembly".
9. Remove the engine harness. PBIC3999E
10. Remove the oil pan (upper). Refer to EM-33, "Exploded View".
11. Remove the water pump. Refer to CO-19, "Exploded View".
12. Remove thermostat housing. Refer to CO-21, "Exploded View".
13. Remove the water outlet. Refer to CO-24, "Exploded View".
14. Remove the cylinder head. Refer to EM-72, "Exploded View".
15. Remove knock sensor (2).
CAUTION:
Carefully handle sensor avoiding shocks.
16. Remove the oil pressure sensor (3) and oil temp sensor (4).
(1) : Engine block
CAUTION:
Do not reuse O-ring.
ALBIA0989ZZ
17. 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-103, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove connecting rod cap. Number connecting rod caps so they can be assembled in the same position
and direction.
c. Using a hammer handle or similar tool, push piston and connect-
ing rod assembly out to the cylinder head side.
CAUTION:
• Do not damage matching surface with connecting rod
cap.
• Do not damage the cylinder wall and crankshaft pin,
resulting from an interference of the connecting rod big
end.
PBIC0259E
18. Remove connecting rod bearings.

CAUTION:
When removing them, note the installation position. Keep them in the correct order.
19. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-103, "Inspection".

CYLINDER BLOCK
• Remove piston rings using suitable tool (A).
CAUTION: A
• When removing piston rings, be careful not to damage
the piston.
• Do not damage piston rings by expanding them exces-
EM
sively.
AWBIA1428ZZ
D
20. Remove piston from connecting rod with the following procedure:
a. Using snap ring pliers (A), remove snap rings.
E
AWBIA1429ZZ
H
b. Heat piston to 60 to 70°C (140 to 158°F) with a heat gun (A).
K
AWBIA1430ZZ
c. Push out piston pin using a punch of outer diameter approxi- L

mately 18 mm (0.71 in).
PBIC0262E O
21. Remove main bearing cap bolts.

• Measure crankshaft end play before loosening main bearing cap bolts. Refer to EM-103, "Inspection". P

CYLINDER BLOCK
• Loosen and remove main bearing cap bolts in reverse order
as shown.
: Engine front
AWBIA1901ZZ
22. Remove main bearing caps.

• Tap main bearing caps lightly with a plastic hammer for removal. Number main bearing caps so they can
be assembled in the same position and direction.
CAUTION:
Do not damage the mounting surface.
23. Remove crankshaft.
CAUTION:
• Do not damage or deform signal plate (1) mounted on rear
end of crankshaft (A).
• When setting crankshaft on a flat floor surface, use a
block of wood to avoid interference between signal plate
and the floor surface.
• Do not remove signal plate unless it is necessary to do
so.
PBIC3234J
24. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
When removing them, note the installation position. Keep them in the correct order.
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 goggles to protect your eyes.
2. Install each plug to cylinder block as shown.
CAUTION:
Do not reuse washers.
(2) : Washer
: Engine front
• Apply liquid gasket to the thread of water drain plug (4).

• Apply sealant to the thread of plug (1).
NOTE: PBIC3999E
Do not apply liquid gasket or high strength thread locking sealant to the plug (3).
• Tighten each plug as specified below.

CYLINDER BLOCK
Part Washer Tightening torque A

(1) Yes 54.0 N·m (5.5 kg-m, 40 ft-lb)
(3) No 19.6 N·m (2.0 kg-m, 14 ft-lb)
EM
(4) No 9.8 N·m (1.0 kg-m, 87 in-lb)
3. Install main bearings and thrust bearings with the following procedure: C
a. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap.
b. Install thrust bearings to both sides of the No. 3 journal housing
(B) on cylinder block. D
: Engine front
• Install thrust bearings with the oil groove (A) facing crankshaft E
arm (outside).
PBIC3258J
G
c. Install the main bearings paying attention to the direction.
• Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply new
engine oil to the back surface, but thoroughly clean it.
• When installing, align main bearing to the center position of cylinder block and main bearing cap. H
• The difference (A) between main bearing (upper) (1) and main
bearing (lower) (3) should be 0.85 mm (0.0335 in) or less
when installing. I
(2) : Cylinder block

(4) : Main bearing cap
J
K
PBIC3237J
• Ensure the oil holes on cylinder block and oil holes (A) on the L
main bearings (1) are aligned.
PBIC3236J O
4. Install signal plate to crankshaft (if removed).

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

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

NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
d. Remove dowel pin.
CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block.
PBIC3238J
• While turning crankshaft by hand, check that it turns smoothly.

6. Install main bearing caps with the following procedure:
a. Install main bearing caps referring to the journal No. stamp (A)
and front mark (B) as shown.
: Engine front
NOTE:
Main bearing cap cannot be replaced as a single part, because it
is machined together with cylinder block.
JPBIA4432ZZ
b. Tighten main bearing cap bolts in numerical order as shown.

• Apply new engine oil to threads and seat surfaces of bolts.
: Engine front
AWBIA1901ZZ
CAUTION:
Confirm the tightening angle by using Tool (A). Do not
judge by visual inspection without the tool.
Step 1 : 34.3 N·m (3.5 kg-m, 25 ft-lb)

Step 2 : 60° clockwise in numerical order
Tool number (A) : KV10112100 (BT-8653-A)
JPBIA4433ZZ
• After installing bolts, check that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-103, "Inspection".
7. 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.

CYLINDER BLOCK
• Using a heat gun, heat the piston until the piston pin can be pushed in by hand without excess force
[approximately 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and A
connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (D) on connecting rod
EM
are positioned as shown.
(C) : Engine type

C
(E) : Large end hole diameter grade
(F) : Front mark (connecting rod)
c. Install new snap ring to the groove of the piston front side. D
• Insert it fully into groove to install.
• After installing, check that connecting rod moves smoothly. JPBIA4434ZZ
CAUTION:
Do not reuse snap rings. E
8. Using a suitable tool, install piston rings.
CAUTION:
• Do not damage piston. F
• Do not damage piston rings by expanding them excessively.
• Position each ring with the gap as shown referring to the pis-
ton front mark.
G
(A) : Oil ring upper or lower rail gap
(B) : Front mark
H
(C) : Second ring and oil ring spacer gap
(D) : Top ring gap
(E) : Stamped mark
I
CAUTION:
Do not contact the rail end gap under the oil ring with the PBIC3242J
oil drain cast groove of piston.
• Install second ring with the stamped surface facing upward. J
9. Install connecting rod bearing upper (2) and lower (3) to con-
necting rod (4) and connecting rod cap (4).
K
(C) : Oil hole (connecting rod)
(D) : View D
(E) : OK L
(F) : NG
(g) : 2.55 - 2.95 mm (0.1004 - 0.1161 in)
: Engine front M
• Install the connecting rod in the direction shown.

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

• 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.
CYLINDER BLOCK
• Match the cylinder position with the cylinder number (D) on
connecting rod to install.
(A) : Front mark (piston)

(B) : Oil hole
(C) : Engine type
• Install so that front mark (A) on the piston head faces the front
of engine. JPBIA4434ZZ
• Install piston with the front mark on the piston head facing the
front of the engine using Tool (A).
CAUTION:
Be careful not to damage the crankshaft pin, resulting
from an interference of the connecting rod big end.
Tool number (A) : EM03470000 (J-8037)
AWBIA1431ZZ
11. Install connecting rod cap.

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

(B) : Oil hole
(C) : Engine type
JPBIA4434ZZ
12. Tighten connecting rod cap bolt using Tool as follows: Apply new engine oil to the threads and seats of
connecting rod cap bolts.
CAUTION:
• Check that there is no gap in the thrust surface (A) of the
joint between connecting rod (1) and connecting rod cap
(2) and that these parts are in the correct position. And
then, tighten the connecting rod cap bolts.
• If the connecting rod cap bolts are reused, measure the
outer diameter. Refer to EM-103, "Inspection".
PBIC3510J
• Check and confirm the tightening angle by using Tool (A). Do not judge by visual inspection
without the tool.

CYLINDER BLOCK
Step 1 : 19.6 N·m (2.0 kg-m, 14 ft-lb) A

Step 2 : 65° clockwise
Tool number (A) : KV10112100 (BT-8653-A) EM
• After tightening connecting rod cap bolt, check that crankshaft

rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-103, C
"Inspection".
JPBIA0688ZZ
D
13. Install oil pan (upper). Refer to EM-33, "Exploded View".
14. Install rear oil seal. Refer to EM-70, "REAR OIL SEAL : Removal and Installation".
E
15. Install flywheel or drive plate. Refer to EM-90, "Removal and Installation" (M/T) or EM-92, "Removal and
Installation" (CVT).
16. Install knock sensor.
• Install knock sensor (1) with harness connector facing toward F
the rear of engine.
(A) : Cylinder block left side G

: Engine front
CAUTION:
• Do not tighten bolts while holding the harness connector. H
• If any impact by dropping is applied to knock sensor,
replace it with a new one.
NOTE: I
• Check that there is no foreign material on the cylinder block PBIC3246J
mating surface and the back surface of knock sensor.

• Check that knock sensor does not interfere with other parts.
J
17. Assembly of remaining components is in the reverse order of disassembly.
K
CRANKSHAFT END PLAY
• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward using L
suitable tool (A).
Standard and Limit : Refer to EM-123, "Cylinder

M
Block".
• If the measured value exceeds the limit, replace thrust bearings,
and measure again. If it still exceeds the limit, replace crankshaft N
also.
JPBIA4436ZZ
O
CONNECTING ROD SIDE CLEARANCE

CYLINDER BLOCK
• Measure the side clearance between connecting rod and crank-
shaft arm using suitable tool (A).

Block".
• If the measured value exceeds the limit, replace connecting rod,
and measure again. If it still exceeds the limit, replace crankshaft
also.
JPBIA4437ZZ
PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter
Measure the inner diameter of piston pin hole using suitable tool (A).
Standard : Refer to EM-123, "Cylinder Block".
AWBIA1432ZZ
Piston Pin Outer Diameter

Measure the outer diameter of piston pin using suitable tool (A).
AWBIA1433ZZ
Piston to Piston Pin Oil Clearance

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

• If oil clearance is out of the standard, replace piston and piston pin assembly.
• When replacing piston and piston pin assembly. Refer to EM-112, "Description".
NOTE:
• Piston is available together with piston pin as assembly.
• Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
grades can be selected. (Only grade “0” is available.)
PISTON RING SIDE CLEARANCE

CYLINDER BLOCK
• Measure the side clearance of piston ring and piston ring groove
using suitable tool (A). A

Block". EM
• If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
C
AWBIA1434ZZ
D
PISTON RING END GAP
• Check that cylinder bore inner diameter is within specification. Refer to “PISTON TO CYLINDER BORE
CLEARANCE”.
• Lubricate with new engine oil to piston (1) and piston ring (2), and E
then insert (A) piston ring until middle of cylinder (B) with piston,
and measure piston ring end gap using suitable tool (C).
F
Block".
• If the measured value exceeds the limit, replace piston ring, and G
measure again. If it still exceeds the limit, rebore cylinder and use
oversized piston and piston rings.
AWBIA1435ZZ
H
CONNECTING ROD BEND AND TORSION

• Check with a connecting rod aligner.
I
(A) : Bend
(B) : Torsion
J
(C) : Feeler gauge
Limit : Refer to EM-123, "Cylinder Block".

K
• If it exceeds the limit, replace connecting rod assembly.
O
AWBIA1437ZZ
CONNECTING ROD BIG END DIAMETER

P

CYLINDER BLOCK
• Install connecting rod cap (1) without connecting rod bearing
installed, and tightening connecting rod cap bolts to the specified
torque. Refer to EM-95, "Disassembly and Assembly".
(2) : Connecting rod

(A) : Example
(B) : Measuring direction of inner diameter
• Measure the inner diameter of connecting rod big end using suit-
able tool.

PBIC3269J
• If out of the standard, replace connecting rod assembly.

CONNECTING ROD BUSHING OIL CLEARANCE
Connecting Rod Bushing Inner Diameter
Measure the inner diameter of connecting rod bushing using suitable
tool (A).
AWBIA1438ZZ
Piston Pin Outer Diameter

Measure the outer diameter of piston pin using suitable tool (A).
AWBIA1433ZZ
Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)
Standard and Limit : Refer to EM-123, "Cylinder Block".

• If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin
assembly.
• If replacing piston and piston pin assembly. Refer to EM-112, "Piston".
• If replacing connecting rod assembly. Refer to EM-113, "Connecting Rod Bearing".
CYLINDER BLOCK TOP SURFACE DISTORTION

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

CYLINDER BLOCK
• Measure the distortion on the cylinder block upper face at some
different points in six directions using suitable tools (A,B). A
Limit : Refer to EM-123, "Cylinder Block".

• If it exceeds the limit, replace cylinder block. EM
AWBIA1439ZZ
D
MAIN BEARING HOUSING INNER DIAMETER
• Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified
torque. Refer to EM-95, "Disassembly and Assembly".
• Measure the inner diameter of main bearing housing using suitable tool. E
• Measure the position shown [5 mm (0.20 in)] backward from main
bearing housing front side in the 2 directions as shown. The
smaller one is the measured value. F
(1) : Cylinder block

(2) : Main bearing cap
G
: Engine front
Standard : Refer to EM-123, "Cylinder Block". H

• If out of the standard, replace cylinder block and main bearing PBIC4005E
caps assembly.
NOTE: I
Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
J
Cylinder Bore Inner Diameter
• Measure the cylinder bore for wear, out-of-round and taper at six
different points on each cylinder using suitable tool. [(A) and (B)
directions at (C), (D), and (E)] [(A) is in longitudinal direction of K
engine]
(f) : 10 mm (0.39 in) L

(g) : 60 mm (2.36 in)
(h) : 130 mm (5.12 in)
NOTE: M
When determining cylinder bore grade, measure the cylinder bore
(B) direction at (D) position. JPBIA2059ZZ
N
Standard:
Cylinder bore inner diameter
: Refer to EM-123, "Cylinder Block". O
Limit:
P
Out-of-round [Difference between (A) and (B)]
Taper [Difference between (C) and (D)]
: Refer to EM-123, "Cylinder Block".
• If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall,
replace cylinder block.
NOTE:
Oversize piston is not provided.
CYLINDER BLOCK
Piston Skirt Diameter
Measure the outer diameter of piston skirt using suitable tool (A).
AWBIA1440ZZ
Piston to Cylinder Bore Clearance

Calculate by piston skirt diameter and cylinder bore inner diameter
[direction (B), position (D)].
(A) : Direction A
(C) : Position C
(E) : Position E
(f) : 10 mm (0.39 in)
(g) : 60 mm (2.36 in)
(h) : 130 mm (5.12 in)
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diame- JPBIA2059ZZ
ter)
Standard and Limit : Refer to EM-123, "Cylinder Block".

• If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. Refer to EM-112, "Pis-
ton".
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals using suit-
able tool (A).

• If out of the standard, measure the main bearing oil clearance.
Then use undersize bearing. Refer to EM-127, "Main Bearing".
AWBIA1441ZZ
CRANKSHAFT PIN JOURNAL DIAMETER

• Measure the outer diameter of crankshaft pin journal using suitable tool.

• If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer
to EM-127, "Connecting Rod Bearing".
OUT-OF-ROUND AND TAPER OF CRANKSHAFT

CYLINDER BLOCK
• Measure the dimensions at four different points as shown on each
main journal and pin journal using suitable tool. A
• Out-of-round is indicated by the difference in dimensions between
(X) and (Y) at (A) and (B).
• Taper is indicated by the difference in dimension between (A) and
EM
(B) at (X) and (Y).
Limit:
C
Out-of-round [Difference between (X) and (Y)]
Taper [Difference between (A) and (B)]
PBIC3459J
: Refer to EM-123, "Cylinder Block". D
• If the measured value exceeds the limit, correct or replace crankshaft.
• If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select
main bearing and/or connecting rod bearing. Refer to EM-113, "Connecting Rod Bearing" and/or EM-115, E
"Main Bearing".
CRANKSHAFT RUNOUT
• Place a V-block on a precise flat table to support the journals on both ends of the crankshaft. F
• Place a suitable tool (A) straight up on the No. 3 journal.
• While rotating crankshaft, read the movement of the pointer on the
suitable tool (A). (Total indicator reading)
G
Block".
H
• If it exceeds the limit, replace crankshaft.
I
AWBIA1442ZZ
CONNECTING ROD BEARING OIL CLEARANCE

J
Method by Calculation
• Install connecting rod bearings (2) to connecting rod (3) and con-
necting rod bearing cap (1), and tighten connecting rod cap bolts to
K
the specified torque. Refer to EM-95, "Disassembly and Assem-
bly".
(A) : Example L
(B) : Inner diameter measuring direction
• Measure the inner diameter of connecting rod bearing using suit-
able tool. M
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter) PBIC3275J
N
Standard and Limit : Refer to EM-127, "Connecting Rod Bearing".
• If clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end
diameter and crankshaft pin journal diameter to obtain specified bearing oil clearance. Refer to EM-113, O
"Connecting Rod Bearing".
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. P
• Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
• Install connecting rod bearings to connecting rod and cap, and tighten connecting rod cap bolts to the speci-
fied torque. Refer to EM-95, "Disassembly and Assembly".
CAUTION:
Do not rotate crankshaft.

CYLINDER BLOCK
• Remove connecting rod cap and bearing, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is
same as that described in the “Method by Calculation”.
JPBIA4438ZZ
MAIN BEARING OIL CLEARANCE

Method by Calculation
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap bolts to the specified torque.
Refer to EM-95, "Disassembly and Assembly".
(A) : Example
(B) : Inner diameter measuring direction
• Measure the inner diameter of main bearing using suitable tool.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
Standard and Limit : Refer to EM-127, "Main Bearing". PBIC3277J
• If clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and
crankshaft main journal diameter to obtain specified bearing oil clearance. Refer to EM-115, "Main 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 main bearing cap, and tighten main bearing cap bolts to the spec-
ified torque. Refer to EM-95, "Disassembly and Assembly".
CAUTION:
Do not rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale (A)
on the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the limit is the
same as that described in the “Method by Calculation”.
AWBIA1443ZZ
MAIN BEARING CRUSH HEIGHT

CYLINDER BLOCK
• When main bearing cap is removed after being tightened to the
specified torque with main bearings (1) installed, the tip end of A
bearing must protrude (B). Refer to EM-95, "Disassembly and
Assembly".
EM
(A) : Example
Standard : There must be crush height.

C
• If the standard is not met, replace main bearings.
PBIC3279J
D
CONNECTING ROD BEARING CRUSH HEIGHT
• When connecting rod cap is removed after being tightened to the
specified torque with connecting rod bearings (1) installed, the tip
end of bearing must protrude (B). Refer to EM-95, "Disassembly E
and Assembly".
(A) : Example F
Standard : There must be crush height.

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

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

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

HOW TO SELECT PISTON AND BEARING
Description INFOID:0000000012787787
Selection points Selection parts Selection items Selection methods

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
grade (outer diameter of jour-
nal)
Combining service grades for
connecting rod big end diame-
Between crankshaft and con- Connecting rod bearing grade
Connecting rod bearing ter and crankshaft pin outer di-
necting rod (bearing thickness)
ameter determine connecting
rod bearing selection.
Piston and piston pin assembly
Between cylinder block and pis- Piston grade (piston outer diam- Piston grade = cylinder bore
(piston is available together with
ton eter) grade (inner diameter of bore)
piston pin as an assembly.)
• The identification grade stamped on each part is the grade for the dimension measured in new condition.
This grade cannot apply to reused parts.
• For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the
measurement with the values of each selection table.
• For details of the measurement method of each part, the reuse standards and the selection method of the
selective fitting parts, refer to the text.
Piston INFOID:0000000012787788
WHEN NEW CYLINDER BLOCK IS USED

• Check the cylinder bore grade on rear (LH) side of cylinder block
(L), and select piston of the same grade.
(A) : Correction stamp

(B) : Standard stamp
(C) : Cylinder No. 1 bore grade
(D) : Cylinder No. 2 bore grade
(E) : Cylinder No. 3 bore grade
(F) : Cylinder No. 4 bore grade
(G) : No. 1 main bearing housing grade
(H) : No. 2 main bearing housing grade
(I) : No. 3 main bearing housing grade
(J) : No. 4 main bearing housing grade
(K) : No. 5 main bearing housing grade
: Engine front
• If there is a correction stamp mark on the cylinder block, use it as a

correct reference.
PBIC3264J
WHEN CYLINDER BLOCK IS REUSED

1. Measure the cylinder bore inner diameter. Refer to EM-123, "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
(A) : Piston grade number
(B) : Front mark
(C) : Identification code EM
ALBIA0961ZZ
D
PISTON SELECTION TABLE
Unit: mm (in)
Grade number (Mark) 1 2 [or no mark (piston only)]
E
Cylinder bore Inner diameter 79.700 - 79.710 (3.1378 - 3.1382) 79.710 - 79.720 (3.1382 - 3.1386)
Piston skirt diameter 79.660 - 79.670 (3.1362 - 3.1366) 79.670 - 79.680 (3.1362 - 3.1370)
NOTE: F
Piston is available together with piston pin as an assembly.
Connecting Rod Bearing INFOID:0000000012787789
G
WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED

1. Apply connecting rod big end diameter grade stamped on con- H
necting rod side face to the row in the “Connecting Rod Bearing
Selection Table”.
I
(A) : Oil hole
(B) : Engine type
(C) : Cylinder number
J
(D) : Big end diameter grade
(E) : Front mark
JPBIA4442ZZ K
2. Apply crankshaft pin journal diameter grade stamped on crank-

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

M
(B) : No. 2 pin journal diameter grade
(C) : No. 3 pin journal diameter grade
(D) : No. 4 pin journal diameter grade
N
(E) : No. 1 main journal diameter grade
(F) : No. 2 main journal diameter grade PBIC3261J
(G) : No. 3 main journal diameter grade
O
(H) : No. 4 main journal diameter grade
(I) : No. 5 main journal diameter grade
P
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter indi-
vidually. Refer to EM-103, "Inspection".

2. Apply the measured dimension to the “Connecting Rod Bearing Selection Table”.
3. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection
Table”.
4. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing.
CONNECTING ROD BEARING SELECTION TABLE
PBIC4077E
CONNECTING ROD BEARING GRADE TABLE
Connecting rod bearing grade table : Refer to EM-127, "Connecting Rod Bearing".
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)] (A). A
Bearing undersize table

: Refer to EM-127, "Connecting Rod Bearing". EM
PBIC3263J
D
Main Bearing INFOID:0000000012787790
WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED E

1. “Main Bearing Selection Table” rows correspond to main bearing
housing grade on rear (LH) side of cylinder block (L).
F
(A) : Correction stamp
(B) : Standard stamp
(C) : Cylinder No. 1 bore grade
G
(D) : Cylinder No. 2 bore grade
(E) : Cylinder No. 3 bore grade
(F) : Cylinder No. 4 bore grade
H
(G) : No. 1 main bearing housing grade
(H) : No. 2 main bearing housing grade
(I) : No. 3 main bearing housing grade
I
(J) : No. 4 main bearing housing grade
(K) : No. 5 main bearing housing grade
: Engine front J
• If there is a correction stamp mark on cylinder block, use it as
a correct reference.
K
PBIC3264J
L
2. Apply main journal diameter grade stamped on crankshaft front

side to column in the “Main Bearing Selection Table”.
M
(A) : No. 1 pin journal diameter grade
(B) : No. 2 pin journal diameter grade
N
(C) : No. 3 pin journal diameter grade
(D) : No. 4 pin journal diameter grade
(E) : No. 1 main journal diameter grade
O
(F) : No. 2 main journal diameter grade
(G) : No. 3 main journal diameter grade PBIC3261J
(H) : No. 4 main journal diameter grade

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

4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED
1. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main
journal diameter individually. Refer to EM-103, "Inspection".
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 No. 1, 4, and 5 journals and the other is for
No. 2 and 3 journals. Make certain to use the appropriate table. This is due to differences in the
specified clearances.
4. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing.
NOTE:
Service part is available as a set of both upper and lower.
MAIN BEARING SELECTION TABLE (No. 1, 4, AND 5 JOURNAL)
PBIC4078E

MAIN BEARING SELECTION TABLE (No. 2 AND 3 JOURNAL)
A
EM
K
AWBIA1895ZZ
MAIN BEARING GRADE TABLE (ALL JOURNALS)

L
Main bearing grade table (All journals) : Refer to EM-127, "Main Bearing".
UNDERSIZE BEARING USAGE GUIDE

• When the specified main bearing oil clearance is not obtained with standard size main bearings, use under- M
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. N
CAUTION:
In grinding crankshaft main journal to use undersize bearings,
keep the fillet R [1.5 - 1.7 mm (0.059 - 0.067 in)] (A).
O
Bearing undersize table:
Refer to EM-127, "Main Bearing".
P
PBIC3263J

SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [MRA8DE]

General Specification INFOID:0000000012787791
GENERAL SPECIFICATIONS
Engine type MRA8DE

Cylinder arrangement In-line 4
Displacement cm3 (cu. in) 1,798 (109.7)

Bore and stroke mm (in) 79.7x90.1 (3.138x3.547)
Valve arrangement DOHC
Firing order 1-3-4-2
Compression 2
Number of piston rings
Oil 1
Compression ratio 9.9
Standard 1,380 (13.8, 14.1, 200.2)
Compression pressure
Minimum 1,220 (12.2, 12.4, 176.9)
kPa (bar, kg/cm2, psi)/250 rpm
Differential limit between cylinders 100 (1.0, 1.0, 14.5)
Unit: degree
Valve timing
Intake valve
Exhaust valve
JPBIA4228ZZ
a b c d e f
−4 (35) 52 (13) 4 (64) 36 (-24)
220 228
ATDC ABDC ATDC BBDC
( ): Valve timing control “ON”
Drive Belt INFOID:0000000012787792
DRIVE BELT
Tension of drive belt Belt tension is not necessary, as it is automatically adjusted by drive belt auto-tensioner.
Spark Plug INFOID:0000000012787793
SPARK PLUG
Unit: mm (in)
Make NGK
Standard type* DILKAR6A-11 (California) or PLZKAR6A-11 (except California)
Standard 0.9 (0.035)
Gap (Nominal)
Limit 1.1 (0.043)

*:Always check with the Parts Department for the latest parts information.
A
Exhaust Manifold INFOID:0000000012787794
EXHAUST MANIFOLD
EM
Unit: mm (in)
Items Limit
Each exhaust port 0.1 (0.004) C
Surface distortion
Entire part 0.3 (0.012)
Camshaft INFOID:0000000012787795
D
CAMSHAFT
Unit: mm (in)
E
Items Standard Limit
No. 1 0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal oil clearance 0.15 (0.0059)
No. 2, 3, 4, 5 0.030 - 0.071 (0.0012 - 0.0028) F
No. 1 28.000 - 28.021 (1.1024 - 1.1032) —
Camshaft bracket inner diameter
No. 2, 3, 4, 5 25.000 - 25.021 (0.9843 - 0.9851) —
G
No. 1 27.935 - 27.955 (1.0998 - 1.1006) —
Camshaft journal diameter
No. 2, 3, 4, 5 24.950 - 24.970 (0.9823 - 0.9831) —
Camshaft end play 0.075 - 0.153 (0.0030 - 0.0060) 0.24 (0.0094) H
Intake 44.605 - 44.795 (1.7561 - 1.7636) 44.66 (1.75827)
Camshaft cam height “A”
Exhaust 43.175 - 43.365 (1.6998 - 1.7073) 44.20 (1.74016)
I
Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020)
Camshaft sprocket runout [TIR*] — 0.15 (0.0059)
J
M
SEM671
*: Total indicator reading
VALVE LIFTER N
Unit: mm (in)
Items Standard
O
Intake 33.977 - 33.987 (1.3377 - 1.3381)
Valve lifter outer diameter
Exhaust 29.977 - 29.987 (1.1802 - 1.1806)
Intake 34.000 - 34.021 (1.3386 - 1.3394) P
Valve lifter hole diameter
Exhaust 30.000 - 30.021 (1.1811 - 1.1819)
Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017)
VALVE CLEARANCE

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

Intake 0.25 - 0.33 (0.01 - 0.013) 0.304 - 0.416 (0.012 - 0.016)
Exhaust 0.28 - 0.36 (0.011 - 0.014) 0.308 - 0.432 (0.012 - 0.017)
*: Approximately 80°C (176°F)
AVAILABLE VALVE LIFTER

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

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

Cylinder Head INFOID:0000000012787796
A
CYLINDER HEAD
Unit: mm (in)
EM
Head surface distortion — 0.1 (0.004)
Normal cylinder head height “H” 130.9 (5.15) — C
PBIC0924E
VALVE DIMENSIONS G
Unit: mm (in)
SEM188A K
Intake 31.2 - 31.5 (1.228 - 1.240)
Valve head diameter “D”
Exhaust 25.6 - 25.9 (1.008 - 1.020)
L
Intake 107.08 (4.22)
Valve length “L”
Exhaust 106.06 (4.18)
Intake 5.465 - 5.480 (0.2152 - 0.2157) M
Valve stem diameter “d”
Exhaust 5.455 - 5.470 (0.2148 - 0.2154)
Valve seat angle “α” 45°15′ - 45°45′
N
Intake 1.4 (0.055)
Valve margin “T”
Exhaust 1.4 (0.055)
VALVE GUIDE O

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

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

Intake 31.900 - 31.927 (1.2559 - 1.2570) 35.200 - 35.227 (1.3858 - 1.3869)
Cylinder head seat recess diameter “D”
Exhaust 26.300 - 26.327 (1.0354 - 1.0365) 29.200 - 29.227 (1.1496 - 1.1507)
Intake 31.997 - 32.013 (1.2597 - 1.2604) 32.497 - 32.513 (1.2794 - 1.2800)
Valve seat outer diameter “d”
Exhaust 26.408 - 26.424 (1.0397 - 1.0403)
Valve seat interference fit 0.07 - 0.113 (0.0028 - 0.0044)
Intake 29.2 (1.150)
Diameter “d1”*1
Exhaust 23.3 (0.917)
Intake 30.5 - 31.0 (1.201 - 1.220)
Diameter “d2”*2
Exhaust 24.9 - 25.4 (0.980 - 1.0)
Intake 70°
Angle “α1”
Exhaust 45°
Angle “α2” 88°45′ - 90°15′
Angle “α3” 120°

Intake 1.0 - 1.4 (0.039 - 0.055)
Contacting width “W”*3 A
Exhaust 1.2 - 1.6 (0.047 - 0.063)
Intake
Height “h” 5.9 - 6.0 (0.232 - 0.236) 5.09 - 5.10 (0.2004 - 0.2008)
Exhaust EM
Intake 6.01 (0.2366)
Depth “H”
Exhaust 6.07 (0.2390)
C
*1: Diameter made by intersection point of conic angles “α1” and “α2”
*2: Diameter made by intersection point of conic angles “α2” and “α3”
*3: Machining data D
VALVE SPRING
Standard E
Items
Intake Exhaust
Free height 49.4 - 49.6 mm (1.945 - 1.953 in) 54.5 - 54.7 mm (2.146 - 2.154 in)
F
Installation height 38.46 mm (1.514 in) 38.46 mm (1.514 in)
Installation load 151 - 175 N (15.4 - 17.9 kg, 34 - 39 lb) 257 - 289 N (26.2 - 29.5 kg, 57.8 - 65.0 lb)
Height during valve open 28.86 mm (1.1362 in) 30.03 mm (1.1823 in) G
Load with valve open 344 - 392 N (35.0 - 40.0 kg, 77.3 - 88.1 lb) 450 - 502 N (45.9 - 51.2 kg, 101.2 - 112.9 lb)
Identification color White Yellow green
H
Unit: mm (in)
Items Limit
Valve spring squareness 1.0 (0.039) I
Cylinder Block INFOID:0000000012787797
J
CYLINDER BLOCK
Unit: mm (in)
N
PBIC4017E
Cylinder block top surface distortion Limit 0.1 (0.004)

Grade No. 1 79.700 - 79.710 (3.1378 - 3.1382) O
Cylinder bore inner diameter Standard
Grade No. 2 79.710 - 79.720 (3.1382 - 3.1386)
Out-of-round 0.015 (0.0006)
Limit P
Taper 0.010 (0.0004)

Grade No. A 55.997 - 55.998 (2.2046 - 2.2046)
Grade No. B 55.998 - 55.999 (2.2046 - 2.2047)
Grade No. C 55.999 - 56.000 (2.2047 - 2.2047)
Grade No. D 56.000 - 56.001 (2.2047 - 2.2048)
Grade No. E 56.001 - 56.002 (2.2048 - 2.2048)
Grade No. F 56.002 - 56.003 (2.2048 - 2.2048)
Grade No. G 56.003 - 56.004 (2.2048 - 2.2049)
Grade No. H 56.004 - 56.005 (2.2049 - 2.2049)
Grade No. J 56.005 - 56.006 (2.2049 - 2.2050)
Grade No. K 56.006 - 56.007 (2.2050 - 2.2050)
Main bearing housing inner diameter grade
Grade No. L 56.007 - 56.008 (2.2050 - 2.2050)
Grade No. M 56.008 - 56.009 (2.2050 - 2.2051)
Grade No. N 56.009 - 56.010 (2.2051 - 2.2051)
Grade No. P 56.010 - 56.011 (2.2051 - 2.2052)
Grade No. R 56.011 - 56.012 (2.2052 - 2.2052)
Grade No. S 56.012 - 56.013 (2.2052 - 2.2052)
Grade No. T 56.013 - 56.014 (2.2052 - 2.2053)
Grade No. U 56.014 - 56.015 (2.2053 - 2.2053)
Grade No. V 56.015 - 56.016 (2.2053 - 2.2053)
Grade No. W 56.016 - 56.017 (2.2053 - 2.2054)
AVAILABLE PISTON
Unit: mm (in)
PBIC0188E
Grade No. 1 79.660 - 79.670 (3.1362 - 3.1366)

Piston skirt diameter “A” Standard*
Grade No. 2 79.670 - 79.680 (3.1362 - 3.1370)
Measure point “H” 43.4 (1.7087)
Piston pin hole diameter 21.993 - 21.999 (0.8658 - 0.8661)
Standard 0.020 - 0.040 (0.0008 - 0.0016)
Piston to cylinder bore clearance
Limit 0.08 (0.0031)
PISTON RING
Unit: mm (in)
Top 0.04 - 0.08 (0.0016 - 0.0031) 0.11 (0.0043)
Piston ring side clearance 2nd 0.03 - 0.07 (0.0012 - 0.0028) 0.10 (0.0039)
Oil ring 0.055 - 0.145 (0.0022 - 0.0057) —

Top 0.19 - 0.29 (0.0075 - 0.0114) 0.48 (0.0189)
A
Piston ring end gap 2nd 0.29 - 0.44 (0.0114 - 0.0173) 0.60 (0.0236)
Oil (rail ring) 0.15 - 0.45 (0.0059 - 0.0177) 0.76 (0.0299)
PISTON PIN EM
Unit: mm (in)

C
Piston pin outer diameter 19.991 - 19.995 (0.7870- 0.7872) —
Piston to piston pin oil clearance 0.002 - 0.006 (0.0001 - 0.0002) —
CONNECTING ROD D
Unit: mm (in)
Center distance 138.97 - 139.07 (5.47 - 5.48)

E
Bend [per 100 (3.94)] Limit 0.15 (0.0059)
Torsion [per 100 (3.94)] Limit 0.30 (0.0118)
Connecting rod bushing inner diameter* Standard 22.000 - 22.012 (0.8661 - 0.8666) F
Standard 0.037 - 0.047 (0.00015 - 0.0019)
Connecting rod bushing oil clearance
Limit 0.07 (0.0028)
G
Standard 0.20 - 0.35 (0.0079 - 0.0138)
Connecting rod side clearance
Limit 0.4 (0.016)
Grade No. A 47.000 - 47.001 (1.8504 - 1.8504) H
Grade No. B 47.001 - 47.002 (1.8504 - 1.8505)
Grade No. C 47.002 - 47.003 (1.8505 - 1.8505)
Grade No. D 47.003 - 47.004 (1.8505 - 1.8505)
I
Grade No. E 47.004 - 47.005 (1.8505 - 1.8506)

Grade No. F 47.005 - 47.006 (1.8506 - 1.8506) J
Connecting rod big end diameter grade Grade No. G 47.006 - 47.007 (1.8506 - 1.8507)
Grade No. H 47.007 - 47.008 (1.8507 - 1.8507)
Grade No. J 47.008 - 47.009 (1.8507 - 1.8507) K
Grade No. K 47.009 - 47.010 (1.8507 - 1.8508)
Grade No. L 47.010 - 47.011 (1.8508 - 1.8508)
L
Grade No. M 47.011 - 47.012 (1.8508 - 1.8509)
Grade No. N 47.012 - 47.013 (1.8509 - 1.8509)
*: After installing in connecting rod M
CRANKSHAFT
Unit: mm (in)
N
SEM645 PBIC3459J
Center distance “r” 40.41 - 40.49 (1.5909 - 1.5940)

Out-of-round Limit
0.0035 (0.0001)
Taper Limit
Standard 0.05 (0.0020)
Runout [TIR*]
Limit 0.10 (0.0039)
Standard 0.10 - 0.26 (0.0039 - 0.0102)
Crankshaft end play
Limit 0.30 (0.0118)
Grade No. A 43.970 - 43.971 (1.7311 - 1.7311)
Grade No. B 43.969 - 43.970 (1.7311 - 1.7311)
Grade No. C 43.968 - 43.969 (1.7310 - 1.7311)
Grade No. D 43.967 - 43.968 (1.7310 - 1.7310)
Grade No. E 43.966 - 43.967 (1.7309 - 1.7310)
Grade No. F 43.965 - 43.966 (1.7309 - 1.7309)
Grade No. G 43.964 - 43.965 (1.7309 - 1.7309)
Grade No. H 43.963 - 43.964 (1.7308 - 1.7309)
Grade No. J 43.962 - 43.963 (1.7308 - 1.7308)
Crankshaft pin journal diameter “Dp” grade.
Grade No. K 43.961 - 43.962 (1.7307 - 1.7308)
Grade No. L 43.960 - 43.961 (1.7307 - 1.7307)
Grade No. M 43.959 - 43.960 (1.7307 - 1.7307)
Grade No. N 43.958 - 43.959 (1.7306 - 1.7307)
Grade No. P 43.957 - 43.958 (1.7306 - 1.7306)
Grade No. R 43.956 - 43.957 (1.7305 - 1.7306)
Grade No. S 43.955 - 43.956 (1.7305 - 1.7305)
Grade No. T 43.954 - 43.955 (1.7305 - 1.7305)
Grade No. U 43.953 - 43.954 (1.7304 - 1.7305)
Grade No. A 51.978 - 51.979 (2.0464 - 2.0464)
Grade No. B 51.977 - 51.978 (2.0463 - 2.0464)
Grade No. C 51.976 - 51.977 (2.0463 - 2.0463)
Grade No. D 51.975 - 51.976 (2.0463 - 2.0463)
Grade No. E 51.974 - 51.975 (2.0462 - 2.0463)
Grade No. F 51.973 - 51.974 (2.0462 - 2.0462)
Grade No. G 51.972 - 51.973 (2.0461 - 2.0462)
Grade No. H 51.971 - 51.972 (2.0461 - 2.0461)
Grade No. J 51.970 - 51.971 (2.0461 - 2.0461)
Grade No. K 51.969 - 51.970 (2.0460 - 2.0461)
Crankshaft main journal diameter “Dm” grade.
Grade No. L 51.968 - 51.969 (2.0460 - 2.0460)
Grade No. M 51.967 - 51.968 (2.0459 - 2.0460)
Grade No. N 51.966 - 51.967 (2.0459 - 2.0459)
Grade No. P 51.965 - 51.966 (2.0459 - 2.0459)
Grade No. R 51.964 - 51.965 (2.0458 - 2.0459)
Grade No. S 51.963 - 51.964 (2.0458 - 2.0458)
Grade No. T 51.962 - 51.963 (2.0457 - 2.0458)
Grade No. U 51.961 - 51.962 (2.0457 - 2.0457)
Grade No. V 51.960 - 51.961 (2.0457 - 2.0457)
Grade No. W 51.959 - 51.960 (2.0456 - 2.0457)
*: Total indicator reading

Connecting Rod Bearing INFOID:0000000012787798
A
CONNECTING ROD BEARING GRADE TABLE
Unit: mm (in)
EM
Grade number* Thickness Identification color Remarks
0 1.494 - 1.497 (0.0588 - 0.0589) Black
1 1.497 - 1.500 (0.0589 - 0.0591) Brown C
Grade and color are the same
2 1.500 - 1.503 (0.0591 - 0.0592) Green
for upper and lower bearings.
3 1.503 - 1.506 (0.0592 - 0.0593) Yellow
4 1.506 - 1.509 (0.0593 - 0.0594) Blue D
UPR 1.494 - 1.497 (0.0588 - 0.0589) Black
01
LWR 1.497 - 1.500 (0.0589 - 0.0591) Brown
E
UPR 1.497 - 1.500 (0.0589 - 0.0591) Brown
12
LWR 1.500 - 1.503 (0.0591 - 0.0592) Green Grade and color are different
between upper and lower bear-
UPR 1.500 - 1.503 (0.0591 - 0.0592) Green ings. F
23
LWR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
UPR 1.503 - 1.506 (0.0592 - 0.0593) Yellow
34 G
LWR 1.506 - 1.509 (0.0593 - 0.0594) Blue
UNDERSIZE TABLE H
Unit: mm (in)
Items Thickness Crank pin journal diameter

I
US 0.25 (0.0098) 1.623 - 1.631 (0.0639 - 0.0642) Grind so that bearing clearance is the specified value.
CONNECTING ROD BEARING OIL CLEARANCE

Unit: mm (in) J
Standard 0.037 - 0.047 (0.0015 - 0.0019)
Connecting rod bearing oil clearance
Limit 0.07 (0.0028)
K
Main Bearing INFOID:0000000012787799
MAIN BEARING GRADE TABLE (ALL JOURNALS) L

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

M
0 1.996 - 1.999 (0.0786 - 0.0787) Black
1 1.999 - 2.002 (0.0787 - 0.0788) Brown
2 2.002 - 2.005 (0.0788 - 0.0789) Green N
3 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are the same
4 2.008 - 2.011 (0.0791 - 0.0792) Blue for upper and lower bearings.
5 2.011 - 2.014 (0.0792 - 0.0793) Pink

O
6 2.014 - 2.017 (0.0793 - 0.0794) Purple
7 2.017 - 2.020 (0.0794 - 0.0795) White
P

UPR 1.996 - 1.999 (0.0786 - 0.0787) Black
01
LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown
UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown
12
LWR 2.002 - 2.005 (0.0788 - 0.0789) Green
UPR 2.002 - 2.005 (0.0788 - 0.0789) Green
23
LWR 2.005 - 2.008 (0.0789 - 0.0791) Yellow
UPR 2.005 - 2.008 (0.0789 - 0.0791) Yellow Grade and color are different
34 between upper and lower bear-
LWR 2.008 - 2.011 (0.0791 - 0.0792) Blue ings.
UPR 2.008 - 2.011 (0.0791 - 0.0792) Blue
45
LWR 2.011 - 2.014 (0.0792 - 0.0793) Pink
UPR 2.011 - 2.014 (0.0792 - 0.0793) Pink
56
LWR 2.014 - 2.017 (0.0793 - 0.0794) Purple
UPR 2.014 - 2.017 (0.0793 - 0.0794) Purple
67
LWR 2.017 - 2.020 (0.0794 - 0.0795) White
UNDERSIZE TABLE
Unit: mm (in)
Items Thickness Main journal diameter

US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value.
MAIN BEARING OIL CLEARANCE

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

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

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ENGINE

Revision: December 2015 EM-1 2016 Sentra NAM

Revision: December 2015 EM-2 2016 Sentra NAM

Precautions For Engine Service INFOID:0000000012787716

DISCONNECTING FUEL PIPING

INSPECTION, REPAIR AND REPLACEMENT

Revision: December 2015 EM-3 2016 Sentra NAM

ASSEMBLY AND INSTALLATION

Parts Requiring Angle Tightening INFOID:0000000012787717

Tool number : KV10112100 (BT-8653-A)

REMOVAL OF LIQUID GASKET SEALING

Tool Number (A) : KV10111100 (J-37228)

Revision: December 2015 EM-4 2016 Sentra NAM

3. Attach liquid gasket tube to the suitable tool.

engine oil and engine coolant.

Revision: December 2015 EM-5 2016 Sentra NAM

16441 6N210 Removing fuel tube quick connectors in en-

KV10116200 Disassembling and assembling valve mecha-

KV10112100 Tightening bolts for main bearing cap, cylinder

KV10117100 Loosening or tightening heated air fuel ratio

KV10107902 Removing valve oil seal

Revision: December 2015 EM-6 2016 Sentra NAM

EM03470000 Installing piston assembly into cylinder bore D

KV11103000 Removing crankshaft pulley

Commercial Service Tools INFOID:0000000012787720

Revision: December 2015 EM-7 2016 Sentra NAM

( — ) Crankshaft pulley removing and installing

( — ) Finishing valve seat dimensions

( — ) Removing and installing piston ring

( — ) Removing and installing valve guide

( — ) 1: Reaming valve guide inner hole

(J-43897-18) Reconditioning the exhaust system threads

Revision: December 2015 EM-8 2016 Sentra NAM

( — ) Removing and installing engine

( — ) Loosening nuts, screws and bolts

(J-45816) Removing and installing CVT drive plate bolts K

Revision: December 2015 EM-9 2016 Sentra NAM

1. Locate the area where noise occurs.

Revision: December 2015 EM-10 2016 Sentra NAM

Operating condition of engine

Piston to piston pin oil

Revision: December 2015 EM-11 2016 Sentra NAM

1. Ignition coil 2. Spark plug 3. Rocker cover

Removal and Installation INFOID:0000000012787723

(a) : 14 mm (0.55 in)

Revision: December 2015 EM-12 2016 Sentra NAM

INSPECTION AFTER REMOVAL

Spark plug (Standard type) : Refer to EM-118, "Spark Plug".

Cleaner air pressure : Less than 588 kPa (6 kg/cm2, N

Revision: December 2015 EM-13 2016 Sentra NAM

Revision: December 2015 EM-14 2016 Sentra NAM

Removal and Installation INFOID:0000000012787726 G

Revision: December 2015 EM-15 2016 Sentra NAM

1. Generator 2. Drive belt auto-tensioner 3. Crankshaft pulley

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

1. Front cover 2. Drive belt auto-tensioner

Removal and Installation INFOID:0000000012787730

Revision: December 2015 EM-17 2016 Sentra NAM