PRECAUTIONS

< PRECAUTION > [V9X]

PRECAUTION A
PRECAUTIONS
Precaution for Battery Service (for V9X Models) INFOID:0000000006466962
EM
When disconnect the battery cable, pay attention to the following.
• Always use a 12 volt battery as power source.
• Do not attempt to disconnect battery cables while engine is run- C
ning.
• Before disconnecting battery cables, turn ignition switch OFF
and wait at least 4 minutes. D
• After high-load driving, turn the ignition switch OFF and wait
for at least 15 minutes to remove the battery cable.
NOTE:
• Turbocharger cooling pump may operate in a few minutes after E
the ignition switch is turned OFF.
SEF289H
• Example of high-load driving
- Driving for 30 minutes or more at 140 km/h (86 MPH) or more. F
- Driving for 30 minutes or more on a steep slope.
Precaution for Procedure without Cowl Top Cover INFOID:0000000006466963

G
When performing the procedure after removing cowl top cover, cover
the lower end of windshield with urethane, etc to prevent damage to
windshield. H

J
PIIB3706J

Precaution Necessary for Steering Wheel Rotation After Battery Disconnect

INFOID:0000000006466964
K

CAUTION:
Comply with the following cautions to prevent any error and malfunction. L
• This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-
THEFT SYSTEM).
• Remove and install all control units after disconnecting both battery cables with the ignition switch
in the LOCK position. M
• Always use CONSULT to perform self-diagnosis as a part of each function inspection after finishing
work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results.
For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mech- N
anism is adopted on the key cylinder.
For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and
steering wheel rotation will become impossible.
If steering wheel rotation is required when battery power is interrupted, follow the procedure below before O
starting the repair operation.
OPERATION PROCEDURE
P
1. Connect both battery cables.
NOTE:
Supply power using jumper cables if battery is discharged.
2. Use the Intelligent Key or mechanical key to turn the ignition switch to the ACC position. At this time, the
steering lock will be released.
3. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be
rotated.

EM-281
 PRECAUTIONS
< PRECAUTION > [V9X]
4. Perform the necessary repair operation.
5. When the repair work is completed, return the ignition switch to the LOCK position before connecting the
battery cables. (At this time, the steering lock mechanism will engage.)
6. Perform a self-diagnosis check of all control units using CONSULT.
Precautions For Engine Service INFOID:0000000008180054

DISCONNECTING FUEL PIPING

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

DRAINING ENGINE COOLANT

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

INSPECTION, REPAIR AND REPLACEMENT

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

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.
• Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
• Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
• When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
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.
• 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.

Precaution for Supplemental Restraint System (SRS) "AIR BAG" and "SEAT BELT
PRE-TENSIONER" INFOID:0000000006466965

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along
with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain
types of collision. Information necessary to service the system safely is included in the “SUPPLEMENTAL
RESTRAINT SYSTEM” and “SEAT BELTS” of this Service Manual.
WARNING:
• To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in
the event of a collision which would result in air bag inflation, all maintenance must be performed by
an authorized NISSAN/INFINITI dealer.

EM-282
 PRECAUTIONS
< PRECAUTION > [V9X]
• Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal
injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag A
Module, see the “SUPPLEMENTAL RESTRAINT SYSTEM”.
• Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
EM
ness connectors.
PRECAUTIONS WHEN USING POWER TOOLS (AIR OR ELECTRIC) AND HAMMERS
WARNING: C
• When working near the Air Bag Diagnosis Sensor Unit or other Air Bag System sensors with the
ignition ON or engine running, DO NOT use air or electric power tools or strike near the sensor(s)
with a hammer. Heavy vibration could activate the sensor(s) and deploy the air bag(s), possibly
D
causing serious injury.
• When using air or electric power tools or hammers, always switch the ignition OFF, disconnect the
battery, and wait at least 3 minutes before performing any service.
E
Parts Requiring Angular Tightening INFOID:0000000006466971

• Use an angle wrench for the final tightening of the following engine parts.
- Cylinder head bolts F
- Main bearing cap bolts
- Timing sprocket bolts
- Crankshaft pulley bolt G
- Wear compensation gear bolt
- Camshaft sprocket (for fuel pump) bolt
• Do not use a torque value for final tightening.
• The torque value for these parts are for a preliminary step. H
• Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid Gasket INFOID:0000000006466972
I

REMOVAL OF LIQUID GASKET

• After removing mounting nuts and bolts, separate the mating sur- J
face using the seal cutter [SST:KV10111100 ( — )] (A) and remove
old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces. K
• Tap the seal cutter to insert it (B), and then slide it (C) by tapping
on the side as shown in the figure.
• In areas where the seal cutter is difficult to use, use a plastic ham- L
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
JPBIA0052ZZ
screwdriver is used, be careful not to damage the mating sur- M
faces.
LIQUID GASKET APPLICATION PROCEDURE
N
1. Using a scraper (A), remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
• Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes. O
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials. P

JPBIA0053ZZ

EM-283
 PRECAUTIONS
< PRECAUTION > [V9X]
3. Attach the liquid gasket to the tube presser (commercial service
tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
• If there is a groove for the liquid gasket application, apply the
gasket to the groove.

EMA0622D

• As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes.
Check to read the instruction in this manual.

A : Groove
B : Bolt hole
: Inside

• Within five minutes of gasket application, install the mating

component.
• If the liquid gasket protrudes, wipe it off immediately. JPBIA0010ZZ
• Do not retighten after the installation.
• After 30 minutes or more have passed from the installation, fill the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
Precaution for Diesel Equipment INFOID:0000000006466973

CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM
Risks relating to contamination
The system is very sensitive to contamination. The risks caused by the introduction of contamination are:
• Damage or destruction of the high pressure injection system and the engine
• Seizing or leaking of a component
All After-Sales operations must be performed under very clean conditions. This means that no impurities (par-
ticles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions.
The cleanliness principle must be applied from the fuel filter to the fuel injectors.
WHAT ARE THE SOURCES OF CONTAMINATION?
Contamination is caused by:
• Metal or plastic chips
• Paint
• Fibers:
- Boxes
- Brushes
- Paper
- Clothing
- Cloths
• Foreign bodies such as hair
• Ambient air
• Etc.
WARNING:
It is not possible to clean the engine using a high pressure fuel pump because of the risk of damaging
connections. In addition, moisture may collect in the connectors and create electrical connection mal-
functions
INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS-
TEM
EM-284
 PRECAUTIONS
< PRECAUTION > [V9X]
• Check that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan
part No. 16609 00Q0C, Renault part No. 77 01 479 091). Plugs are to be used once only. After use, they A
must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable).
Unused plugs must be thrown away.
• Check that you have hermetically resealable plastic bags for storing removed parts. Stored parts will there-
EM
fore be less subject to the risk of impurities. The bags must be used only once, and after use they must be
thrown away.
• Lint-free towelettes to be used for fuel pump related service purpose. The use of a normal cloth or paper for
cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system. C
Each lint-free cloth should only be used once.
INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT
• For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle. D
• For each operation, use a clean brush which is in good condition (the brush must not shed its bristles).
• Use a brush and thinners to clean the connections to be opened.
• Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and
injection system zone). Check that no bristles remain adhered. E
• Wash your hands before and during the operation if necessary.
• When wearing leather protective gloves, cover these with latex gloves.
INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION F
• As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system.
The plugs to be used are available from the Parts Stores - Nissan part No. 16609 00Q0C, Renault part No.
77 01 479 091. They must not, under any circumstances, be reused.
• Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries con- G
tamination.
• All components of the injection system that are removed must be stored in a hermetically sealed plastic bag
once the plugs have been inserted. H
• The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been
opened. These items are likely to allow impurities to enter the system.
• A new component replacing an old one must not be removed from its packaging until it is to be fitted to the
vehicle. I
Instructions for Fitting the Plugs
Nissan part No. 16609 00Q0C
J

EM-285
 PRECAUTIONS
< PRECAUTION > [V9X]
(Renault part No. 77 01 479 091)

JPBIA0585ZZ

SPECIAL FEATURES
CAUTION:
• The engine must not operate with:
- Use diesel fuel required by the regulations for cetane number. Refer to GI-4, "Precaution for Fuel".
- Petrol, even in tiny quantities
• Before carrying out any work, check that the fuel rail is not under pressure and that the fuel temper-
ature is not too high. [The system can inject the diesel into the engine at a pressure up to 160,000
kPa (1,600 bar, 1,632 kg/cm2, 23,200 psi)].

EM-286
 PRECAUTIONS
< PRECAUTION > [V9X]
• Respect the cleaning and safety advice specified in this document for any work on the high pressure
injection system. A
• Remove of the interior of the fuel pump and fuel injectors is prohibited.
• For safety reasons, it is strictly forbidden to slacken an injection tube union when the engine is run-
ning.
EM
• It is not possible to remove the fuel pressure sensor from the fuel rail because this may cause circuit
contamination malfunctions. If the fuel pressure sensor fails, the fuel pressure sensor, the fuel rail
and the fuel injection tubes must be replaced.
• It is strictly forbidden to remove the fuel pump pulley. C
• Applying 12 volts directly to any component in the system is prohibited.
• Ultrasonic carbon removal and cleaning are prohibited.
• Never start the engine without the battery being connected correctly. D
CHECKING SEALING AFTER REPAIR
CAUTION:
After any operation, check that there is no diesel leakage.
• Start the engine and check for fuel leak for one minute after starting. E
• Apply tracing fluid around the high pressure connections of the pipe that has been replaced.
• Once the engine coolant temperature is above 50°C (122°F) and provided there are no malfunctions
present, carry out a road test, taking the engine speed up to 4,000 rpm at least once to check that there is no F
leakage.
• Perform a visual inspection after the road test to check that there is no high pressure leakage.
• Clean off the tracing fluid.
G
Definitions of Bank Names INFOID:0000000006466974

• In this manual, each bank name is defined as follows:

H
A : Bank 1 (The conventional right bank)
B : Bank 2 (The conventional left bank)
: Engine front
I

• For cylinder numbers and bank layout, refer to the illustration.

J
Bank 1 : The bank side including cylinder No. 1
(odd-numbered cylinder side)
Bank 2 : The other bank side of the above JPBIA1135ZZ
K
(even-numbered cylinder side)

EM-287
 PREPARATION
< PREPARATION > [V9X]

PREPARATION
PREPARATION
Special Service Tools INFOID:0000000006466975

NISSAN tool number

(RENAULT tool No.) Description
Tool name
EM03470000 Installing piston assembly into cylinder bore
(—)
Piston ring compressor

NT044

KV10111100 Removing oil pan and front cover. etc

(—)
Seal cutter

NT046

KV10112100 Tightening bolts for bearing cap, cylinder

(—) head, etc. in angle
Angle wrench

NT014

KV10117100 Loosening or tightening air fuel ratio sensor

(—)
Heated oxygen sensor wrench

NT379

KV10116400 Installing front oil seal

(—)
Front oil seal fitting tool

JPBIA3552ZZ

KV10116500 To lock drive plate and flywheel

(—)
Ring gear stopper

JPBIA3544ZZ

EM-288
 PREPARATION
< PREPARATION > [V9X]
NISSAN tool number
(RENAULT tool No.) Description A
Tool name
— Removing front oil seal
(Mot. 1577) EM
Lip seal extractor

JPBIA3546ZZ

— To lock crankshaft pulley D

(Mot. 1770)
Crankshaft pulley locking tool
E

JPBIA0630ZZ F
— Connecting compression gauge and glow
(Mot. 1772) plug hole
Compression gauge adapter G

H
JPBIA0626ZZ

— To position the gear and apply for the right

(Mot. 1773) clearance (wear compensation gear) I
Positioning tool

JPBIA0625ZZ
K
— To lock engine at TDC
(Mot. 1874)
TDC set pin
L

M
JPBIA3550ZZ

— To lock camshaft when changing timing chain

(Mot. 1880)
N
Camshaft timing tool

JPBIA3551ZZ

EM-289
 PREPARATION
< PREPARATION > [V9X]
NISSAN tool number
(RENAULT tool No.) Description
Tool name
— Removing front oil seal used with lip seal ex-
(Mot. 1912) tractor (Mot. 1577)
Adapter

JPBIA3554ZZ

— Removing and installing drive plate

(Mot. 1959) Size: T55+
TORX Socket

E1BIA0349ZZ

Commercial Service Tools INFOID:0000000006466976

NISSAN tool number

(RENAULT tool No.) Description
Tool name
KV113B0040 Gauge stand used with KV113B0050 (Mot.
(Mot. 251-01) 252-01)
Dial indicator stand set

MBIB0360E

KV113B0050 Thrust plate for measuring the protrusion of

(Mot. 252-01) piston used with KV113B0040 (Mot. 251-01)
Dial indicator stand set

MBIB0361E

KV113B0090 Tool for removing valve oil seals

(Mot. 1335)
Valve seal remover

MBIB0370E

KV113B0180 Tool for installing valve oil seals

(Mot. 1511-01)
Valve seal drift

MBIB0378E

EM-290
 PREPARATION
< PREPARATION > [V9X]
NISSAN tool number
(RENAULT tool No.) Description A
Tool name
KV113B0200 Cylinder head and cylinder head housing sup-
(Mot. 1573) port EM
Cylinder head stand

MBIB0380E

Tube presser Pressing the tube of liquid gasket D

NT052 F
Valve spring compressor Disassembling valve mechanism

H
JPBIA0770ZZ

Manual lift table caddy Removing and installing engine

I

ZZA1210D
K
Piston ring expander Removing and installing piston ring

M
NT030

EM-291
 COMPRESSION PRESSURE
< BASIC INSPECTION > [V9X]

BASIC INSPECTION
COMPRESSION PRESSURE
Inspection INFOID:0000000006466977

1. Warm up engine thoroughly. Then stop it.

2. Disconnect the battery cable from the negative terminal.
3. Remove glow plugs from all cylinders.
CAUTION:
• Before removal, clean the surrounding area to prevent entry of any foreign materials into engine.
• Carefully remove glow plugs to prevent any damage or breakage.
• Handle with care to avoid applying any shock to glow plugs.
4. Disconnect fuel injector harness connectors to avoid fuel injection during measurement.
5. Install compression gauge (commercial service tool) with compression gauge adapter [SST: — (Mot.
1772)] to the hole for glow plug.
6. Turn ignition switch to START for cranking. When the gauge pointer stabilizes, read the compression
pressure and engine rpm. Perform these steps to check each cylinder.

Compression pressure : Refer to EM-393, "General Specification".

CAUTION:
Always use a fully-charged battery to obtain specified engine speed.
• When engine rpm is out of the specified range, check the specific gravity of battery liquid. Measure
again under corrected conditions.
• If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
• If some cylinder has low compression pressure, pour small amount of engine oil into the glow plug hole
of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check pis-
ton rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal-
functioning. Check valves for damage. Replace valve or valve seat accordingly.
• If two adjacent cylinders have respectively low compression pressure and their compression remain
slow 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-1262, "Diagnosis Description".

EM-292
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [V9X]

SYMPTOM DIAGNOSIS A
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
NVH Troubleshooting - Engine Noise INFOID:0000000006466978
EM

JPBIA3931GB

EM-293
 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
< SYMPTOM DIAGNOSIS > [V9X]
Use the Chart Below to Help You Find the Cause of the Symptom INFOID:0000000006466979

1. Locate the area where noise occurs.

2. Confirm the type of noise.
3. Specify the operating condition of engine.
4. Check specified noise source.
If necessary, repair or replace these parts.

Operating condition of engine

Location Type of Before After When Source of Refer-
When When While Check item
of noise noise warm- warm- start- noise ence page
idling racing driving
up up ing
Hydraulic
Ticking or
Top of en- A C — B B — tappet Out of oil EM-377
clicking
gine noise
Cylinder Camshaft
head Camshaft journal oil
Rattle C A — A B C bearing EM-368
clearance
noise
Piston to piston pin oil
Slap or Piston pin clearance
— A — B B — EM-386
knock noise Connecting rod bushing
Crank- oil clearance
shaft pul- Piston ring side clear-
ley Slap or Piston
A — — B B A ance EM-386
Cylinder rap slap noise
Piston ring end gap
block
(Side of Connect- Connecting rod bushing
engine) ing rod oil clearance
Knock A B C B B B EM-386
Oil pan bearing Connecting rod bearing
noise oil clearance
Main bear- Main bearing oil clear-
Knock A B — A B C EM-386
ing noise ance
Timing
Front of Timing chain cracks
chain and
engine Tapping or and wear
A A — B B B chain ten- EM-322
Front cov- ticking Timing chain tensioner
sioner
er operation
noise
Drive belt
Squeak-
(Sticking
ing or fizz- A B — B — C Drive belt deflection
or slip-
ing EM-295
ping)
Front of
Drive belt Idler pulley bearing op-
engine Creaking A B A B A B
(Slipping) eration
Water
Squall
A B — B A B pump Water pump operation CO-75
Creak
noise
A: Closely related B: Related C: Sometimes related —: Not related

EM-294
 DRIVE BELTS
< PERIODIC MAINTENANCE > [V9X]

PERIODIC MAINTENANCE A
DRIVE BELTS
Exploded View INFOID:0000000006466980
EM

JPBIA3567ZZ

1. Water pump 2. Idler pulley 3. Alternator

G
4. Power steering oil pump pulley 5. Drive belt auto-tensioner 6. Crankshaft pulley
7. Cooling fan pulley 8. A/C compressor 9. Idler pulley
H
10. Drive belt
A. Range when new drive belt is installed B. Possible use range C. Indicator
D. View
I
Refer to GI-9, "Component" for symbols in the figure.
Checking INFOID:0000000006466981
J
WARNING:
Be sure to perform this step when the engine is stopped.
• Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range K
(B).
NOTE:
• Check the drive belt auto-tensioner indication when the engine is cold. L
• When new drive belt is installed, the indicator (notch on fixed side) should be within the range (A) in the fig-
ure.
• Visually check entire drive belt for wear, damage or cracks.
• If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt. M
CAUTION:
Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced. N
Tension Adjustment INFOID:0000000006466982

Refer to EM-393, "Drive Belts". O

Removal and Installation INFOID:0000000006466983

CAUTION: P
• Replace the drive belt that has been removed with a new one.
• Drive belt auto-tensioner and idler pulley must be replaced with new ones when the drive belt is
replaced.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
1. Remove engine front undercover.

EM-295
 DRIVE BELTS
< PERIODIC MAINTENANCE > [V9X]
2. Hold the hexagonal part of drive belt auto-tensioner pulley with a
hexagonal socket (A) securely. Then move the wrench handle in
the direction of arrow (loosening direction of tensioner).
CAUTION:
Never place hand in a location where pinching may occur if
the holding tool accidentally comes off.

JPBIA3628ZZ

3. Insert a stopper pin (A) in diameter such as hexagonale wrench

into the hole of the retaining boss to fix drive belt auto-tensioner
pulley.
• Keep drive belt auto-tensioner pulley arm locked after drive
belt is removed.
NOTE:
Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin.

JPBIA3629ZZ

4. Remove drive belt.

INSTALLATION
1. Install drive belt.
CAUTION:
• Check that drive belt is completely set to pulleys.
• Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Check that the indicator (notch on fixed side) of drive belt auto-tensioner is within the range when new
drive belt is installed. Refer to EM-295, "Checking".

EM-296
 AIR CLEANER FILTER
< PERIODIC MAINTENANCE > [V9X]
AIR CLEANER FILTER
A
Removal and Installation INFOID:0000000006466984

REMOVAL EM
1. Unhook clips and remove air cleaner upper case.
2. Remove air cleaner filter from air cleaner case.
C

E1BIA0314ZZ
F
INSTALLATION
Install in the reverse order of removal.
G

EM-297
 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
< REMOVAL AND INSTALLATION > [V9X]

REMOVAL AND INSTALLATION

DRIVE BELT AUTO TENSIONER AND IDLER PULLEY
Exploded View INFOID:0000000006466985

JPBIA3594GB

1. Idler pulley 2. Drive belt auto-tensioner 3. Cooling fan pulley

4. Idler pulley 5. Idler pulley bracket
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466986

CAUTION:
• Replace the drive belt that has been removed with a new one.
• Never disassemble drive belt auto-tensioner.
• Never run the engine without the drive belt to avoid damaging the crankshaft pulley.
REMOVAL
1. Remove engine undercover.
2. Remove drive belt. Refer to EM-295, "Removal and Installation".
• Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
3. Remove drive belt auto-tensioner.
4. Remove cover and idler pulley.
INSTALLATION
Note the following, and install in the reverse order of removal.
Idler pulley and cover
• When replacing idler pulley, replace the cover as well.

EM-298
 ENGINE COVER
< REMOVAL AND INSTALLATION > [V9X]
ENGINE COVER
A
Exploded View INFOID:0000000006466987

EM

G
E1BIA0304ZZ

1. Engine cover 2. Mounting rubber 3. Pin

Refer to GI-9, "Component" for symbols in the figure.
H

Removal and Installation INFOID:0000000006466988

I
REMOVAL
1. Remove engine cover following arrows.
CAUTION: J
• Never damage or scratch cover when installing or remov-
ing.
K

E1BIA0305ZZ
M
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
When installing, push the engine cover at the position on the pins. N

EM-299
 AIR CLEANER AND AIR DUCT
< REMOVAL AND INSTALLATION > [V9X]
AIR CLEANER AND AIR DUCT
Exploded View INFOID:0000000006466989

E1BIA0312GB

1. Air cleaner case (lower) 2. Air cleaner filter 3. Air cleaner case (upper)
4. clamp 5. clamp 6. Air duct
7. Resonator 8. Air duct 9. Mass air flow sensor (with intake air
temperature sensor)
10. clamp
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466990

REMOVAL
1. Remove battery cable from negative terminal.
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove mass air flow sensor harness clamp from air cleaner case (upper).
4. Disconnect mass air flow sensor harness connector.
5. Remove air cleaner case (upper) and air cleaner filter.
• Add marks as necessary for easier installation.
6. Remove mass air flow sensor from air cleaner case (upper).
CAUTION:
• Never shock mass air flow sensor.
• Never disassemble mass air flow sensor.
7. Remove air cleaner case (lower).
8. Remove air duct and resonator.

EM-300
 AIR CLEANER AND AIR DUCT
< REMOVAL AND INSTALLATION > [V9X]
INSTALLATION
Note the following, and install in the reverse order of removal. A
• Align marks.
• Attach each joint.
• Screw clamps firmly. EM
Inspection INFOID:0000000006466991

INSPECTION AFTER REMOVAL C

Inspect air duct assembly for crack or tear.
• If anything found, replace air duct assembly.
D

EM-301
 VACUUM PUMP
< REMOVAL AND INSTALLATION > [V9X]
VACUUM PUMP
Exploded View INFOID:0000000006466992

E1BIA0347GB

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

4. Vacuum hose 5. Vacuum hose 6. Vacuum tube and bracket
7. Vacuum hose 8. Vacuum hose 9. Turbocharger boost control solenoid
valve bracket
10. Turbocharger boost control solenoid 11. Vacuum hose 12. EGR cooler bypass valve control so-
valve lenoid valve
A. To brake booster B. To engine mount solenoid valve C. To EGR
D. To resonator E. To turbocharger F. To engine mount solenoid valve
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466993

REMOVAL
1. Remove engine cover. Refer to EM-299, "Exploded View".
2. Remove air inlet hose 4, 5 and air inlet tube 6. Refer to EM-307, "Exploded View".
3. Disconnect vacuum hoses from vacuum pump.
4. Remove vacuum pump.

EM-302
 VACUUM PUMP
< REMOVAL AND INSTALLATION > [V9X]
INSTALLATION
Note the following, and install in the reverse order of removal. A
CAUTION:
Be sure to check that the vacuum pump is in contact with the cylinder head before tightening the
mounting bolts. EM

EM-303
 FUEL PUMP
< REMOVAL AND INSTALLATION > [V9X]
FUEL PUMP
Exploded View INFOID:0000000006466994

E1BIA0348GB

1. Fuel pump bracket 2. Fuel pump bracket 3. Fuel pump protector

4. High pressure fuel pump 5. O-ring 6. Fuel pump drive spacer
7. Fuel inlet tube
A To fuel injector B To fuel tank
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006466995

REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-284, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• Never disassemble or adjust the fuel pump body.
1. Disconnect battery cable from negative terminal.
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove air duct assembly and air cleaner case. Refer to EM-300, "Exploded View".
4. Remove air inlet hose 1. Refer to EM-307, "Exploded View".

EM-304
 FUEL PUMP
< REMOVAL AND INSTALLATION > [V9X]
5. Remove mounting bolts (A) and nut (B), and then remove fuel
pump protector (1). A

EM

JPBIA3829ZZ

D
6. Remove mounting bolts (A), and then remove fuel pump
bracket (1).
E

G
JPBIA3830ZZ

7. Remove injection tube mounting bolt (A).

H
8. Disconnect injection tube (1) from fuel high pressure pump.
Refer to EM-315, "Exploded View".
9. Plug all the holes of the injection circuit. I

JPBIA3831ZZ
K
10. Remove mounting bolts (A), and then remove high pressure fuel
pump.
L

N
JPBIA3615ZZ

INSTALLATION O
Install in the reverse order of removal, for the rest of parts.
• Before starting engine, bleed air from fuel piping. Refer to FL-31, "Air Bleeding".
NOTE: P
Fill the fuel of at least 60 m (2.11 Imp fl oz).
Inspection INFOID:0000000006466996

INSPECTION AFTER INSTALLATION

• Start the engine and check for fuel leak for one minute after starting.
CAUTION:

EM-305
 FUEL PUMP
< REMOVAL AND INSTALLATION > [V9X]
After any operation, check that there are no diesel leaks. Refer to EM-284, "Precaution for Diesel
Equipment".

EM-306
 CHARGE AIR COOLER
< REMOVAL AND INSTALLATION > [V9X]
CHARGE AIR COOLER
A
Exploded View INFOID:0000000006466997

EM

L
E1BIA0303GB

1. Charge air cooler 2. Gasket 3. Air inlet tube 3 M

4. Clamp 5. Air inlet hose 2 6. Bracket
7. Air inlet tube 2 8. Air inlet hose 1 9. Bracket
10. Air inlet tube 1 11. Bracket 12. Turbocharger inlet and outlet tube N
13 Gasket 14. Air inlet hose 5 15. Bracket
16. Air inlet tube 6 17. Air inlet hose 4 18. Air inlet tube 5
19. Air inlet hose 3 20. Air inlet tube 4 21. gasket O
A. To electric throttle control actuator
Refer to GI-9, "Component" for symbols in the figure.
P
Removal and Installation INFOID:0000000006466998

REMOVAL
1. Remove front grille. Refer to EI-16, "Removal and Installation".
2. Remove front bumper. Refer to EI-12, "Removal and Installation".
3. Remove charge air cooler with the following procedure:
• Loosen air inlet hose clamp.
EM-307
 CHARGE AIR COOLER
< REMOVAL AND INSTALLATION > [V9X]
• Remove charge air cooler mounting bolts.
• Remove charge air cooler.
INSTALLATION
Note the following, and install in the reverse order of removal.
• Apply a neutral detergent (fluid) to the joint between air inlet hoses and air inlet tubes (oil is not permissible).
• Align marks. Attach each joint. Screw clamps firmly.
Inspection INFOID:0000000006466999

INSPECTION AFTER REMOVAL

1. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it
dry.
2. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace
charge air cooler if necessary.
• Do not deform core fins.
• For cleaning procedure of charge air cooler core, refer to CO-69, "Inspection".

EM-308
 ELECTRIC THROTTLE CONTROL ACTUATOR
< REMOVAL AND INSTALLATION > [V9X]
ELECTRIC THROTTLE CONTROL ACTUATOR
A
Exploded View INFOID:0000000006467000

EM

L
JPBIA3589GB

1. Intake manifold (bank 1) 2. Intake manifold gasket 3. O-ring M

4. Bracket 5. Intake manifold (center) 6. Gasket
7. Electric throttle control actuator 8. Gasket 9. Intake manifold gasket
10. Intake manifold (bank 2) 11. Gasket 12. Adaptor N
13. O-ring
Refer to GI-9, "Component" for symbols in the figure.
O
Removal and Installation INFOID:0000000006467001

REMOVAL
P
1. Disconnect battery cable from negative terminal. Refer to SC-11, "Removal and Installation".
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove air inlet hose 5. Refer to EM-307, "Exploded View".
4. Disconnect electric throttle control actuator harness connector.

EM-309
 ELECTRIC THROTTLE CONTROL ACTUATOR
< REMOVAL AND INSTALLATION > [V9X]
5. Loosen electric throttle control actuator mounting bolts in
reverse order as shown in the figure.
NOTE:
The figure shows the electric throttle control actuator viewed
from the air duct side.
CAUTION:
Handle carefully to avoid any shock to electric throttle con-
trol actuator.
6. Remove electric throttle control actuator.

JPBIA3610ZZ

INSTALLATION
Note the following, and install in the reverse order of removal.
Electric Throttle Control Actuator Gasket
• Install electric throttle control actuator gasket in direction shown in
the figure.

A : Triangle press
: Engine upper

JPBIA3609ZZ

Electric Throttle Control Actuator

• Tighten in numerical order as shown in the figure.
NOTE:
• The figure shows the electric throttle control actuator viewed
from the air duct side.
• Perform the “Throttle Valve Closed Position Learning” when har-
ness connector of electric throttle control actuator is disconnected.
Refer to EC-1321, "Work Procedure".
• Perform the “Throttle Valve Closed Position Learning Value Clear”
when electric throttle control actuator is replaced. Refer to EC-
1320, "Work Procedure" and EC-1319, "Work Procedure".
JPBIA3610ZZ

EM-310
 CATALYST
< REMOVAL AND INSTALLATION > [V9X]
CATALYST
A
Exploded View INFOID:0000000006467002

EM

I
E1BIA0338GB

1. Turbocharger 2. Gasket 3. Air fuel ratio sensor J

4. Oxidation catalytic converter 5. Bracket 6. Bracket
7. Gasket 8. Exhaust front tube
Refer to GI-9, "Component" for symbols in the figure. K

Removal and Installation INFOID:0000000006467003

L
REMOVAL
1. Remove engine cover. Refer to EM-299, "Exploded View".
2. Remove engine undercover. M
3. Remove front right wheel.
4. Remove front right mudguard. Refer to EI-21, "Removal and Installation"
5. Remove front right fender protector. Refer to EI-19, "Removal and Installation of Front Fender Protector" N
6. Remove air fuel ratio sensor (1).
• Using heated oxygen sensor wrench [SST: KV10117100] (A),
remove air fuel ratio sensor. O
CAUTION:
Be careful not to impact or damage air fuel ratio sensor.
P
: Engine front

JPBIA3611ZZ

7. Remove oxidation catalytic converter from turbocharger.

EM-311
 CATALYST
< REMOVAL AND INSTALLATION > [V9X]
INSTALLTION
Note the following, and install in the reverse order of removal.
Air Fuel Ratio Sensor
CAUTION:
• Before installing a air fuel ratio sensor, clean catalyst thread.
• When installing, never use such tools as an air impact wrench.
Inspection INFOID:0000000006467004

INSPECTION AFTER INSTALLATION

Start engine and raise engine speed to check no exhaust emission leaks.

EM-312
 GLOW PLUG
< REMOVAL AND INSTALLATION > [V9X]
GLOW PLUG
A
Exploded View INFOID:0000000006467005

EM

G
JPBIA3584GB

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

Removal and Installation INFOID:0000000006467006

I
REMOVAL
CAUTION:
Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken. J
Bank 1 Side
1. Disconnect the battery cable from the negative terminal. Refer to SC-11, "Removal and Installation"
2. Remove engine cover. Refer to EM-299, "Exploded View". K
3. Remove vacuum tube and bracket. Refer to EM-302, "Exploded View"
4. Move aside main harness.
L
5. Disconnect harness connector from glow plug.
6. Remove glow plug.
CAUTION: M
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal.
Bank 2 Side N
1. Remove engine cover. Refer to EM-299, "Exploded View".
2. Remove air inlet hose 1 and air inlet tube 1. Refer to EM-307, "Exploded View"
3. Remove engine cover pin bracket bank 2 side. O
4. Clamp EGR cooler hose and EGR cooler by pass hose to prevent fluid leakage.
5. Remove EGR cooler hose. Refer to EM-358, "Exploded View"
6. Remove EGR cooler by pass valve hose. Refer to EM-358, "Exploded View" P
7. Remove main harness.
8. Disconnect harness connector from glow plug.
9. Remove glow plug.
CAUTION:
• When removing or installing, never use such tools as an air impact wrench.
• Handle it carefully without giving any impact, even after removal.

EM-313
 GLOW PLUG
< REMOVAL AND INSTALLATION > [V9X]
INSTALLATION
1. Remove adhered carbon from glow plug installation hole with a reamer.
2. Install glow plug.
3. Install in the reverse order of removal, for the rest of parts.

EM-314
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
INJECTION TUBE AND FUEL INJECTOR
A
Exploded View INFOID:0000000006467007

FEED SYSTEM EM

JPBIA3581GB
N

1. Injection transfer tube 2. Tube clamp 3. Tube clamp

4. Insulator 5. Fuel injector rail protector (bank 1) 6. Injection tube No.5 O
7. Injection tube No.3 8. Injection tube No.1 9. Fuel rail seal
10. Fuel rail (bank 1) 11. Fuel rail (bank 2) 12. Injection tube No.2
13. Injection tube No.4 14. Injection tube No.6 15. Fuel injector rail protector (bank 2) P
16. Fuel injector rail protector panel 17. Injection tube 18. Tube clamp
19. Fuel injector 20. Fuel injector support
A. View A
Refer to GI-9, "Component" for symbols in the figure.

RETURN SYSTEM

EM-315
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]

JPBIA3582GB

1. Spill hose 2. fuel return hose

A. To fuel tank B. To fuel pump
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006467008

REMOVAL
CAUTION:
• Be sure to read “Precautions for Diesel Equipment”. Refer to EM-284, "Precaution for Diesel Equip-
ment".
• Wait until the fuel temperature drops before carrying out any work.
• Order the special high pressure injection circuit plug kit.
• It is forbidden to open an fuel injector. If you open an fuel injector by mistake, you will have to
change it.
NOTE:
It is possible to replace a single injection tube.
Bank 1 Side, Injector 1,3 and 5
1. Disconnect battery cable from negative terminal. Refer to SC-11, "Removal and Installation".
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Put aside turbocharger boost control. Refer to EM-302, "Exploded View".
4. Remove engine cover rear pin bracket bank 1.
5. Remove fuel injector rail protector.

EM-316
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
6. Remove spill hose (1).
• Lift the movable sections of the injector unions away from the A
spill hose.

EM

JPBIA0601ZZ

D
7. Remove injection tube (No. 1, 3, 5).
• Put a paint mark or tag on injection tubes to identify each cylinder.
8. Remove fuel injectors with the following procedure: E
a. Remove fuel injector support.
b. Remove fuel injector. While rotating it to left and right, raise it to remove.
• If fuel injector spacer remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out. F
CAUTION:
• Handle fuel injector carefully without giving an impact.
• Never disassemble fuel injector.
G
9. Plug all the holes in the injection circuit.
Bank 2 Side, Injector 2,4 and 6
1. Disconnect battery cable from negative terminal. Refer to SC-11, "Removal and Installation" H
2. Remove engine cover. Refer to EM-299, "Exploded View".
3. Remove air cleaner and air duct. Refer to EM-300, "Exploded View".
4. Remove air inlet hose 1 and tube 1. Refer to EM-307, "Exploded View". I
5. Remove fuel injector rail protector. Refer to EM-315, "Exploded View"
6. Remove fuel return hose (1).
J
: Engine front

JPBIA3639ZZ
M
7. Remove spill hose (1).
• Lift the movable sections of the injector unions away from the
spill hose. N

P
JPBIA0601ZZ

8. Remove injection tube (No. 2, 4, 6).

• Put a paint mark or tag on injection tubes to identify each cylinder.
9. Remove fuel injectors with the following procedure:
a. Remove fuel injector support.

EM-317
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
b. Remove fuel injector. While rotating it to left and right, raise it to remove.
• If fuel injector spacer remains in cylinder head, hook it with tip of a flat-bladed screwdriver and pull it out.
CAUTION:
• Handle fuel injector carefully without giving an impact.
• Never disassemble fuel injector.
10. Plug all the holes in the injection circuit.
Bank 1 and 2 side, fuel rail
1. Remove engine unit. Refer to EM-342, "Exploded View".
2. Remove turbocharger. Refer to EM-348, "Exploded View".
3. Remove EGR cooler. Refer to EM-358, "Exploded View".
4. Remove EGR cooler support bracket. Refer to EM-358, "Exploded View".
5. Remove fuel injector rail protector.
6. Remove fuel pump protector. Refer to EM-304, "Exploded View".
7. Remove fuel return hose (1).

: Engine front

JPBIA3639ZZ

8. Remove spill hose (1).

• Lift the movable sections of the injector unions away from the
spill hose.

JPBIA0601ZZ

9. Remove injection transfer tube. Refer to EM-315, "Exploded View"

10. Remove injection tubes.
11. Remove fuel rail and fuel rail seal.
12. Plug all the holes in the injection circuit.
INSTALLATION
1. Record “INJECTOR ADJUSTMENT VALUE” on the top surface
when replacing fuel injector. Refer to EC-1316, "Description".

Example: Injector adjustment valve (A) = AZSSCAG

JPBIA3640ZZ

2. Install fuel injector, injection tubes and fuel rail with the following procedure:

EM-318
 INJECTION TUBE AND FUEL INJECTOR
< REMOVAL AND INSTALLATION > [V9X]
a. Install new fuel injector spacer (1) to fuel injector, and insert
them into cylinder head. A
CAUTION:
• Completely remove any foreign material among fuel injec-
tor and cylinder head.
EM
• Never mix ring (B) location. Upper location is mandatory.

A :Fuel injector guide

C

JPBIA0984ZZ

D
b. Install fuel rail, fuel rail seal, injection tube (center) and mounting rubber (temporarily).
• Finger tighten until contact the injection tube nuts.
c. Install fuel injector support. Tighten mounting bolt (specified torque).
E
CAUTION:
Be sure to fit fuel injector support without looseness.
d. Install injection tube (No. 1, 2, 3, 4, 5, 6) in the original position (temporarily).
• Finger tighten until contact the injection tube nuts. F
CAUTION:
Never put injection tubes under stress.
e. Tighten fuel rail mounting bolts and all injection tube nuts (specified torque). G
3. Install spill hose onto fuel injectors.
• Align center to insert spill hose straightly into fuel injector.
4. Install in the reverse order of removal, for the rest of parts. H
• Before starting engine, bleed air from fuel piping. Refer to FL-31, "Air Bleeding".
NOTE:
Fill the fuel of at least 60 m (2.11 Imp fl oz). I
Inspection INFOID:0000000006467009

INSPECTION AFTER INSTALLATION J

• Input “INJECTOR ADJUSTMENT VALUE” to ECM after installing
to the vehicle when replacing fuel injector. Refer to EC-1316,
"Description". K

Example: Injector adjustment valve (A) = AZSSCAG

L

M
JPBIA3640ZZ

• Start the engine and check for fuel leak for one minute after starting. N
CAUTION:
After any operation, check that there are no diesel leaks. Refer to EM-284, "Precaution for Diesel
Equipment". O

EM-319
 OIL PAN
< REMOVAL AND INSTALLATION > [V9X]
OIL PAN
Exploded View INFOID:0000000006467010

E1BIA0335GB

1. Oil pan 2. Gasket 3. Oil pressure switch

4. Oil temperature/level sensor 5. Oil level gauge and guide 6. Oil strainer
7. Snap ring 8. Baffle plate 9. Oil pan gasket
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006467011

REMOVAL
1. Remove engine undercover.
2. Remove front final drive assembly. Refer to FFD-16, "Removal and Installation".
3. Remove oil cooler. Refer to LU-39, "Exploded View"
4. Remove transmission assembly. Refer to AT-527, "Exploded View".
5. Remove rear oil seal retainer. Refer to EM-340, "REAR OIL SEAL : Removal and Installation".
6. Remove front cover lower. Refert to EM-322, "Exploded View"
7. Remove oil pan with the following procedure:

EM-320
 OIL PAN
< REMOVAL AND INSTALLATION > [V9X]
• Loosen mounting bolts in reverse order as shown in the figure.
A
: Engine front

EM

E1BIA0334ZZ

D
INSTALLATION
1. Install oil pan with the following procedure:
• Tighten mounting bolts in numerical order as shown in the fig- E
ure.

: Engine front
F

E1BIA0334ZZ
H
2. Install rear oil seal retainer. Refer to EM-340, "REAR OIL SEAL : Removal and Installation".
3. Install in the reverse order of removal, for the rest of parts.
I

EM-321
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
TIMING CHAIN
Exploded View INFOID:0000000006467012

E1BIA0302GB

1. Wear compensation gear (bank 1) 2. Wear compensation spacer 3. Timing sprocket (bank 1)
4. Timing chain sprocket (bank 1) 5. Timing chain sprocket spacer (bank 1) 6. Vacuum pump drive spacer
7. Gasket 8. Front cover upper (bank 1) 9. Front cover upper (bank 2)
10. Gasket 11. Wear compensation spacer 12. Wear compensation gear (bank 2)
13. Timing sprocket (bank 2) 14. Timing chain sprocket (bank 2) 15. Timing chain sprocket spacer (bank 2)
16. Crankshaft sprocket 17. Timing chain tension guide (bank 2) 18. Timing chain
19. Timing chain slack guide (bank 2) 20. Timing chain tensioner 21. Timing chain slack guide (bank 1)

EM-322
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
22. Timing chain 23. Timing chain tension guide (bank 1) 24. Timing chain tensioner
25. Crankshaft spacer 26. Crankshaft pulley 27. Front oil seal A
28. Oil pump drive key 29. Front cover lower 30. Gasket
31. Fuel pump drive gear 32. Fuel pump drive gear shaft
Comply with the installation proce- EM
A. dure when tightening. Refer to EM-
323
Refer to GI-9, "Component" for symbols in the figure. C

Removal and Installation INFOID:0000000006467013

D
REMOVAL
CAUTION:
Never turn the engine in the direction opposite to that of normal operation.
E
1. Drain engine oil. Refer to LU-36, "Draining".
CAUTION:
Perform this step when the engine is cold.
2. Drain engine coolant. Refer to CO-65, "Draining". F
3. Disconnect the battery cable from the negative terminal.
4. Remove the following parts:
• Drive belt: Refer to EM-295, "Removal and Installation". G
• Drive belt auto-tensioner and idler pulley: Refer to EM-298, "Exploded View".
• Power steering oil pump and bracket: Refer to PS-35, "V9X : Removal and Installation".
• Alternator: Refer to SC-25, "Removal and Installation". H
• Water pump: Refer to CO-75, "Exploded View".
• A/C compressor: Refer to ATC-116, "Removal and Installation for Compressor (V9X models)".
• Vacuum pump: Refer to EM-302, "Exploded View".
I
• High pressure fuel pump: EM-304, "Exploded View".
• Air inlet tube and pipe: Refer to EM-307, "Exploded View".
5. Remove crankshaft pulley with the following procedure:
J
a. Set the crankshaft pulley locking tool [SST: — (Mot. 1770)] (A)
and loosen crankshaft pulley bolt.

M
JPBIA3641ZZ

b. Remove crankshaft pulley and spacer.

• Pull crankshaft pulley with both hands to remove it. N
CAUTION:
Be careful not to damage front oil seal lip.
6. Remove oil pump deive key (1). O

JPBIA3642ZZ

EM-323
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
7. Remove front oil seal. Refer to EM-339, "FRONT OIL SEAL : Removal and Installation".
8. Remove engine oil filter. Refer to LU-38, "Removal and Installation".
9. Remove front cover with the following procedure:
a. Loosen mounting bolts in the reverse of the order shown in the
figure.

JPBIA3579ZZ

b. Loosen mounting bolts in the reverse of the order shown in the

figure.

A : Bank 1
B : Bank 2

JPBIA3578ZZ

10. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft groove (A) to set it in the position shown in the
figure.

1 : Crankshaft
B : 45 degrees
: Engine front

E1BIA0306ZZ

EM-324
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
b. Remove TDC pin plug (A).
A
: Engine front

EM

JPBIA3834ZZ

D
c. Screw in the TDC set pin [SST: — (Mot. 1874)] (A). Turn the
engine clockwise until the crankshaft (1) touches the TDC set
pin.
E
: Engine front

G
E1BIA0307ZZ

d. Check that the camshaft are located as shown in the figure.

• Fit the notch (C) of camshaft RH (1) and plug (D) of cylinder H
head.
• Set the camshaft LH (2) with the offset side faced upward.
I
A : Bank 1
B : Bank 2

JPBIA3932ZZ

11. Remove vacuum pump drive spacer (1). O

JPBIA3645ZZ

EM-325
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
12. Remove the timing chain (bank 1) with the following procedure:
a. Set the camshaft timing tool [SST: — (Mot.1880)] (A), and
tighten mounting bolt [M6 × 50 mm (1.97 in)] (B).
b. Loosen timing sprocket mounting bolts (C) and wear compensa-
tion gear mounting bolt (D).
c. Remove the camshaft timing tool.

JPBIA3646ZZ

d. Remove timing sproket spacer (1).

JPBIA3832ZZ

e. Remove the timing chain tensioner.

• Compress the timing chain tensioner (1) with timing chain
slack guide (2), and then insert a stopper pin (A) into hole on
timing chain tensioner.
NOTE:
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin

JPBIA3647ZZ

f. Remove timing chain slack guide (1) and timing chain tension
guide (2).
g. Remove timing sprocket spacer, timing sprocket and timing
chain.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is
removed. It causes interference between valve and piston.

JPBIA3803ZZ

EM-326
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
h. Insert a screwdriver (A) and lift it up to move the gear of wear
compensation gear (1). A
NOTE:
To align two gear teeth of wear compensation gear.
i. Remove timing gear (2) under the condition shown in Step “h”. EM
j. Remove wear compensation gear and spacer.

JPBIA3804ZZ

D
13. Remove the timing chain (bank 2) with the following procedure:
a. Set the camshaft timing tool [SST: — (Mot.1880)] (A), and
tighten mounting bolt [M6 × 50 mm (1.97 in) (B). E
b. Loosen timing sprocket mounting bolts (C) and wear compensa-
tion gear mounting bolt (D).
c. Loosen fuel pump drive gear mounting bolts. F
d. Remove the camshaft timing tool.

JPBIA3805ZZ

H
e. Remove the timing chain tensioner.
• Compress the timing chain tensioner (1) with timing chain
slack guide (2), and then insert a stopper pin (A) into hole on
timing chain tensioner. I
NOTE:
Use approximately 3.0 mm (0.118 in) dia. hard metal pin as a
stopper pin J

JPBIA3806ZZ

f. Remove timing sproket spacer (1). L

O
JPBIA3833ZZ

EM-327
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
g. Remove timing chain slack guide (1) and timing chain tension
guide (2).

JPBIA3807ZZ

h. Remove timing sprocket spacer, timing sprocket, fuel pump drive gear, crankshaft sprocket and timing
chain.
CAUTION:
Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between
valve and piston.
i. Insert a screwdriver (A) and lift it up to move the gear of wear
compensation gear (1).
NOTE:
To align two gear teeth of wear compensation gear.
j. Remove timing gear (2) under the condition shown in Step “h”.
k. Remove wear compensation gear and spacer.

JPBIA3808ZZ

14. Remove fuel pump gear shaft.

INSTALLATION
1. Set No. 1 cylinder at TDC on its compression stroke with the following procedure:
a. Rotate crankshaft groove (A) to set it in the position shown in the
figure.

1 : Crankshaft
B : 45 degrees
: Engine front

E1BIA0306ZZ

b. Remove TDC pin plug (A).

: Engine front

JPBIA3834ZZ

EM-328
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
c. Screw in the TDC set pin [SST: — (Mot. 1874)] (A). Turn the
engine clockwise until the crankshaft (1) touches the TDC set A
pin.

: Engine front
EM

E1BIA0307ZZ

D
d. Check that the camshaft are located as shown in the figure.
• Fit the notch (C) of camshaft RH (1) and plug (D) of cylinder
head.
• Set the camshaft LH (2) with the offset side faced upward. E

A : Bank 1
B : Bank 2 F

JPBIA3932ZZ K
2. Install fuel pump gear shaft.
3. Install wear compensation gear (bank 2) with the following procedure: L
a. Set the wear compensation gear (1) on base plate of positioning
tool [SST: — (Mot. 1773)] (A).
M

O
JPBIA0766ZZ

EM-329
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
b. Set the lever (B) in the lower gear teeth (A). Pivot the lever
counterclockwise until the two gear teeth are aligned.

1 : Wear compensation gear

JPBIA0594ZZ

c. Set a stopper pin (A) in the gear hole.

1 : Wear compensation gear

NOTE:
• Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin

JPBIA0595ZZ

d. Install wear compensation gear and wear compensation gear spacer to the camshaft LH (bank 2).
e. Align matching mark (A) on wear compensation gear and boss
(B) of cylinder head.
f. Temporarily tighten mounting bolt.

JPBIA3836ZZ

4. Install timing gear with the following procedure:

a. Parallelize the groove (A) of camshaft LH to face the offset side
upward.
b. Center the timing gear openings on the camshaft RH hub
mounting holes (B).
c. Set the timing gear fully onto the camshaft RH hub.
d. Remove stopper pin (C).

JPBIA3837ZZ

5. Install timing sprocket (1), crankshaft sprocket (2), timing chain (3) and fuel pump drive gear (4).
• Align matching marks on each sprocket and timing chain.

EM-330
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]

EM

E
JPBIA3838ZZ

A : Matching mark (copper link) B : Matching mark (notched) F

6. Install timing chain slack guide (1) and timing chain tension
guide (2).
G

I
JPBIA3807ZZ

7. Install timing chain tensioner (1). J

• Check that the timing chain tensioner makes contact with the
cylinder block before tightening the bolts.
• Pull out stopper pin (A) after installing, and the release K
plunger.

JPBIA3806ZZ
M

8. Install timing sprocket spacer (1) on the timing gear and tempo-
rarily tighten mounting bolt. N
• Allow the timing sprocket to rotate freely.

JPBIA3833ZZ

9. Tighten mounting bolts (timing sprockets and wear compensation gear) with the following procedure:

EM-331
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
a. Set the tool collet (A) of the timing adjustment tool [SST: —
(Mot. 1880)] (B) in the camshaft RH groove.
b. Pivot the camshaft timing tool to align the axes of the spacer (C)
and the bolt hole.

JPBIA3840ZZ

c. Set tool pins (D) into the wear compensation gear holes.
d. Pivot the camshaft timing tool [SST: — (Mot. 1880)] (B) to align
the axes of the spacer (C) and the bolt hole.
e. Set the tool collet (A), without force, into the camshaft RH
groove.

JPBIA3841ZZ

f. Set the mounting bolt [M6 × 50 mm (1.97 in)] (B) onto spacer of
the timing adjustment tool [SST: — (Mot. 1880)] (A).
g. Tighten timing sprocket mounting bolts (C).

1st step : 10.0 N·m (1.0 kg-m, 7 ft-lb)

2nd step : Turn 40 degrees clockwise (angle
tightening)
h. Tighten wear compensation gear mounting bolt (D).
JPBIA3805ZZ
1st step : 20.0 N·m (2.0 kg-m, 15 ft-lb)
2nd step : Turn 35 degrees clockwise (angle
tightening)
CAUTION:
Check the tightening angle by using an angle wrench [SST: KV10112100 ( — )] or protractor. Never
judge by visual inspection without an angle wrench.
i. Remove timing adjustment tool.

10. Install wear compensation gear (bank 1) with the following procedure:
a. Set the wear compensation gear (1) on base plate of positioning
tool [SST: — (Mot. 1773)] (A).

JPBIA0766ZZ

EM-332
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
b. Set the lever (B) in the lower gear teeth (A). Pivot the lever
counterclockwise until the two gear teeth are aligned. A

1 : Wear compensation gear

EM

JPBIA0594ZZ

D
c. Set a stopper pin (A) in the gear hole.

1 : Wear compensation gear

E
NOTE:
• Use approximately 4.0 mm (0.157 in) dia. hard metal pin as a
stopper pin
F

G
JPBIA0595ZZ

d. Install wear compensation gear and wear compensation gear spacer to the camshaft LH (bank 1).
H
e. Align matching mark (A) on wear compensation gear and boss
(B) of cylinder head.
f. Temporarily tighten mounting bolt.
I

K
JPBIA3842ZZ

11. Install timing gear with the following procedure:

a. Parallelize the groove (A) of camshaft LH to face the offset side L
upward.
b. Center the timing gear openings on the camshaft RH hub
mounting holes (B). M
c. Set the timing gear fully onto the camshaft RH hub.
d. Remove stopper pin (C).
N

O
JPBIA3843ZZ

12. Install timing sprocket (1), crankshaft sprocket (2) and timing chain (3).
• Align matching marks on each sprocket and timing chain. P

EM-333
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]

JPBIA3844ZZ

A : Matching mark (copper link) B : Matching mark (notched)

13. Install timing chain slack guide (1) and timing chain tension
guide (2).

JPBIA3803ZZ

14. Install timing chain tensioner (1).

• Check that the timing chain tensioner makes contact with the
cylinder block before tightening the bolts.
• Pull out stopper pin (A) after installing, and the release
plunger.

JPBIA3845ZZ

15. Install timing sprocket spacer (1) on the timing gear and tempo-
rarily tighten mounting bolt.
• Allow the timing sprocket to rotate freely.

JPBIA3833ZZ

16. Tighten mounting bolts (timing sprockets and wear compensation gear) with the following procedure:

EM-334
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
a. Set the tool collet (A) of the timing adjustment tool [SST: —
(Mot. 1880)] (B) in the camshaft RH groove. A
b. Pivot the camshaft timing tool to align the axes of the spacer (C)
and the bolt hole.
EM

JPBIA3846ZZ

D
c. Set tool pins (D) into the wear compensation gear holes.
d. Pivot the camshaft timing tool [SST: — (Mot. 1880)] (B) to align
the axes of the spacer (C) and the bolt hole. E
e. Set the tool collet (A), without force, into the camshaft RH
groove.
F

G
JPBIA3847ZZ

f. Set the mounting bolt [M6 × 50 mm (1.97 in)] (B) onto spacer of
H
the timing adjustment tool [SST: — (Mot. 1880)] (A).
g. Tighten timing sprocket mounting bolts (C).
I
1st step : 10.0 N·m (1.0 kg-m, 7 ft-lb)
2nd step : Turn 40 degrees clockwise (angle
tightening) J
h. Tighten wear compensation gear mounting bolt (D).
JPBIA3646ZZ
1st step : 20.0 N·m (2.0 kg-m, 15 ft-lb) K
2nd step : Turn 35 degrees clockwise (angle
tightening)
L
CAUTION:
Check the tightening angle by using an angle wrench [SST: KV10112100 ( — )] or protractor. Never
judge by visual inspection without an angle wrench.
M
i. Remove timing adjustment tool.

17. Remove vacuum pump drive spacer (1).

N

JPBIA3645ZZ

18. Remove the TDC set pin [SST: — (Mot.1874)].

19. Apply liquid gasket to TDC pin plug, and tighten it.

EM-335
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]

Tightening torque : 25.0 N·m (2.6 kg-m, 18 ft-lb)

Use Genuine Liquid Gasket or equivalent.
20. Install oil pump drive key.
21. Install front cover lower with the following procedure:
a. Install gasket to front cover lower.
b. Apply liquid gasket to the front cover lower gasket (1), referring
to the application point shown in the figure.

A : Liquid gasket application point

Use Genuine Liquid Gasket or equivalent.
NOTE:
Liquid gasket should be applied to the front cover side because
the workspace is narrow.

JPBIA3644ZZ

c. Temporarily tighten mounting bolts in the following steps in

numerical order as shown in the figure.

JPBIA3564ZZ

d. Tighten mounting bolts in the following steps in numerical order

as shown in the figure.
i. Tighten No. 1 to 17 in numerical order as shown.

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

ii. Tighten No. 18 bolt.

: 10.0 N·m (1.0 kg-m, 89 in-lb)

JPBIA3579ZZ

22. Install front cover uppeer with the following procedure:

a. Install gasket to front cover upper.
b. Apply liquid gasket to the front cover upper gasket (1), referring
to the application point shown in the figure.

A : Liquid gasket application point

Use Genuine Liquid Gasket or equivalent.
NOTE:
Liquid gasket should be applied to the front cover side because
the workspace is narrow.

JPBIA3644ZZ

EM-336
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
c. Tighten mounting bolts in the following steps in numerical order
as shown in the figure. A

A : Bank 1
B : Bank 2 EM

M8 bolt
: 32.0 N·m (3.3 kg-m, 24 ft-lb) C
M10 bolt
: 64.0 N·m (6.5 kg-m, 47 ft-lb) D

G
JPBIA3578ZZ

23. Install engine oil filter. Refer to LU-38, "Removal and Installation".
24. Install front oil seal. Refer to EM-339, "FRONT OIL SEAL : Removal and Installation". H
25. Install crankshaft pulley with the following procedure:
a. Secure crankshaft pulley with a crankshaft pulley locking tool
[SST: — (Mot. 1770)] (A). I
b. Tighten crankshaft pulley bolt.

1st step : 50.0 N·m (5.1 kg-m, 37 ft-lb) J

2nd step : Turn 115 degrees clockwise (angle

tightening)
K
CAUTION:
Check the tightening angle by using an angle wrench [SST:
KV10112100 ( — )] or protractor. Never judge by visual JPBIA0730ZZ
L
inspection without an angle wrench.
c. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns
smoothly.
M
26. Install in the reverse order of removal, for the rest of parts.
Inspection INFOID:0000000006467014

N
INSPECTION AFTER INSTALLATION
Inspection for Leaks
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required O
quantity, fill to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
- Start engine. With engine speed increased, check again for fuel leakage at connection points. P
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.

EM-337
 TIMING CHAIN
< REMOVAL AND INSTALLATION > [V9X]
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 / transaxle fluid
Leakage Level / Leakage Leakage

Other oils and fluid* Level Leakage Level

Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.

EM-338
 OIL SEAL
< REMOVAL AND INSTALLATION > [V9X]
OIL SEAL
A
FRONT OIL SEAL
FRONT OIL SEAL : Removal and Installation INFOID:0000000006467015
EM
REMOVAL
1. Remove the following parts.
• Engine cover. Refer to EM-299, "Exploded View". C
• Undercover.
• Fan shroud. Refer to CO-73, "Exploded View".
• Cooling fan. Refer to CO-73, "Exploded View". D
• Drive belt: Refer to EM-295, "Removal and Installation".
• Crankshaft pulley: Refer to EM-322, "Exploded View".
2. Remove oil pump drive key (1). E

JPBIA3642ZZ H

3. Remove front oil seal with the follwing procedure:

a. Remove end piece (A) of the seal extractor [SST: — (Mot. I
1577)] from the extractor.
b. Remove snap ring (B) from the seal extractor [SST: — (Mot.
1577)] using snap ring pliers.
J

JPBIA3960ZZ
L
c. Remove shaft (A) from the seal extractor [SST: — (Mot. 1577)].
d. Remove adapter (B), and then install adapter [SST: — (Mot.
M
1912)] from the seal extractor [SST: — (Mot. 1577)]
e. Install shaft on the seal extractor [SST: — (Mot. 1577)].
N

O
JPBIA3961ZZ

EM-339
 OIL SEAL
< REMOVAL AND INSTALLATION > [V9X]
f. Install snap ring (A) on the seal extractor [SST: — (Mot. 1577)]
using snap ring pliers.
g. Install end piece (B) onto the seal extractor [SST: — (Mot. 1577)]
from the extractor.

JPBIA3962ZZ

h. Remove front oil seal using the lip seal extractor [SST: — (Mot. 1577)].
i. Press the seal lip extractor (A) pawl toward the inner side of the
front oil seal.
ii. Tighten nut (B) and hold the front oil seal with the seal extractor
pawl.
iii. Rotate shaft (C) clockwise to remove the front oil seal.

JPBIA3643ZZ

INSTALLATION
1. Install front oil seal with the following procedure:
NOTE:
• This type of seal is extremely fragile.
• When handling, it is essential to grip protective piece.
• It is strictly forbidden to touch the seal, in order to prevent any oil leaks once the seal is fitted to theen-
gine.
a. Set the crackshaft seal fitting tool [SST: —] (A).
b. Install crankshaft pulley bolt (B) and tighten it until crackshaft
seal fitting tool touches the front cover lower.

JPBIA3934ZZ

2. Install in the reverse order of removal, for the rest of parts.

REAR OIL SEAL
REAR OIL SEAL : Removal and Installation INFOID:0000000006467016

REMOVAL
1. Remove A/T assembly. Refer to AT-527, "Exploded View".
2. Remove drive plate.
3. Remove rear oil seal retainer.
INSTALLATION
1. Install rear oil seal retainer with the following procedure:

EM-340
 OIL SEAL
< REMOVAL AND INSTALLATION > [V9X]
a. Set guide bolt (A) to rear oil seal retainer (1).
A
: Engine front

b. Move the rear oil seal retainer evenly by hand until it makes con-
EM
tact with the cylinder block.

JPBIA3813ZZ

D
c. Remove guide bolts and protector.
d. Tighten mounting bolts in two steps separately in numerical
order as shown in the figure. E

1st step : 5.0 N·m (0.51 kg-m, 44 in-lb)

2nd step F
: 10.0 N·m (1.0 kg-m, 89 in-lb)

JPBIA3814ZZ

H
2. Install in the reverse order of removal, for the rest of parts.

EM-341
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]

UNIT REMOVAL AND INSTALLATION

ENGINE ASSEMBLY
Exploded View INFOID:0000000006467017

E1BIA0342GB

1. Engine mount insulator (Rear) 2. Transmission cross member 3. Engine mount insulator (LH)
4. Vacuum hose 5. Vacuum hose 6. Vacuum hose
7. Engine mounting bracket (RH) 8. Engine mounting insulator (RH) 9. Engine mounting bracket (LH)
Refer to GI-9, "Component" for symbols in the figure.

Removal and Installation INFOID:0000000006467018

WARNING:
• Situate the vehicle on a flat and solid surface.
• Place chocks at the front and back of rear wheels.
• For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• Always be careful to work safely, and avoid forceful or uninstructed operations.
• Never start working until exhaust system and engine coolant are cool enough.
• If items or work required are not covered by the engine section, refer to the applicable sections.

EM-342
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]
• Always use the support point specified for lifting.
• Use either 2-pole lift type or separate type lift as much as possible. If board-on type is used for A
unavoidable reasons, support at rear axle jacking point with transmission jack or similar tool before
starting work, in preparation for the backward shift of the center of gravity.
• For supporting points for lifting and jacking point at rear axle, refer to GI-42, "Pantograph Jack,
EM
Garage Jack and Safety Stand".
REMOVAL
Outline C
At first, remove the engine, transmission, transfer and front final drive assembly with front suspension member
facing downward. Then separate the engine from transmission.
Preparation D
1. Remove battery. Refer to SC-11, "Removal and Installation".
2. Discharge refrigerant from A/C system. Refer to ATC-111, "HFC-134a (R-134a) Service Procedure" or
E
MTC-100, "HFC-134a (R-134a) Service Procedure".
3. Drain engine coolant from radiator. Refer to CO-65, "Draining".
CAUTION:
Perform this step when engine is cold. F
4. Remove the following parts:
• Engine undercover (power tool)
• Remove Hood assembly. Refer to BL-14, "Removal and Installation of Hood Assembly". G
• Remove front grille. Refer to EI-16, "Removal and Installation".
• Remove front bumper. Refer to EI-12, "Removal and Installation".
• Engine cover. Refer to EM-299, "Exploded View". H
• Air duct inlet. Refer to EM-300, "Exploded View".
• Charge air cooler, inlet tube and hose. Refer to EM-307, "Exploded View".
• Reservoir tank. Refer to CO-70, "Exploded View".
• Front road wheel and tires (power tool). I
• Front mudguard. Refer to EI-21, "Removal and Installation".
• Front fender. Refer to EI-19, "Removal and Installation of Front Fender Protector".
5. Remove radiator hoses (upper and lower). Refer to CO-70, "Exploded View". J
Engine Room
1. Disconnect heater hose at engine side, and fit a plug onto hose end to prevent engine coolant leakage.
K
2. Remove Radiator. Refer to CO-70, "Exploded View".
3. Remove A/C condenser. Refer to ATC-122, "Removal and Installation for Condenser".
4. Remove A/C piping from A/C compressor. L
5. Remove vacuum hose. Refer to EM-302, "Exploded View".
6. Disconnect ground cable.
7. Remove fan shroud (lower and Upper). Refer to CO-73, "Exploded View". M
8. Remove cooling fan. Refer to CO-73, "Exploded View".
9. Remove A/C compressor. Refer to ATC-116, "Removal and Installation for Compressor (V9X models)".
10. Remove alternator. Refer to SC-26, "Disassembly and Assembly". N
11. Remove steering oil pump. Refer to PS-34, "V9X : Exploded View".
12. Remove turbocharger heat shield on the body.
O
13. Disconnect all clips and connectors of the engine room harness.
14. Disconnect engine room harness connectors at unit sides and other locations.
15. Disconnect fuel feed hose from high pressure fuel pump. P
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
16. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them
on engine.
CAUTION:
When temporarily securing, keep the reservoir tank upright to avoid fluid leakage.
17. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.

EM-343
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]
CAUTION:
• When pulling out harnesses, take care not to damage harnesses and connectors.
• After temporarily securing, cover connectors with vinyl or similar material to protect against
adhesion of foreign materials.
Vehicle Underbody
1. Remove oil cooler. Refer to LU-39, "Exploded View".
2. Remove catalyst. Refer to EM-311, "Exploded View".
3. Remove starter. Refer to SC-41, "Removal and Installation".
4. Remove A/T fluid cooler and tube. Refer to AT-524, "Exploded View".
5. Remove exhaust front tube. Refer to EX-15, "WITHOUT DPF (DIESEL PARTICULATE FILTER) MODELS
: Exploded View".
6. Remove oxydation catalytic converter. Refer to EX-15, "WITHOUT DPF (DIESEL PARTICULATE FILTER)
MODELS : Exploded View".
7. Remove front propeller shaft. Refer to PR-3, "Removal and Installation".
8. Remove drive shaft. Refer to FAX-7, "Removal and Installation".
9. Remove front final drive assembly. Refer to FFD-16, "Removal and Installation".
Separation and removal work
1. Install engine slingers into front of cylinder head (bank 1) and
rear of cylinder head (bank 2).

1 : Engine front slinger (bank 1)

2 : Engine rear slinger (bank 2)
: Engine front

Slinger bolts:
Front : 19 N·m (1.9 kg-m, 14 ft-lb)
JPBIA2099ZZ
Rear : 24 N·m (2.4 kg-m, 18 ft-lb)

2. Lift the hoist of a two-point engine lifter (commercial service tool)

(A) from the front and rear engine slingers to support engine.
• CAUTION:
Always lift or support the engine by using a two-point
engine lifter (i.e. hoisting the front and rear slingers from
one point in the air), or the rocker cover and parts around
the engine may be damaged due to the fall of the engine
slinger.

JPBIA2509ZZ

3. Remove A/T bolts. Refer to AT-527, "Exploded View".

4. Remove engine mounting insulators bolts(RH and LH). Refer to EM-342, "Exploded View".
5. Lift with hoist and separate the engine from A/T.
CAUTION:
• Before and during this lifting, always check that any harnesses are left connected.
• Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine
mounting insulator.
INSTALLATION
Note the following item, and install in the reverse order of removal.
• Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
• For a location with a positioning pin, insert it securely into hole of matching part.
• For a part with a specified installation orientation, refer to component figure in EM-342, "Exploded View".
• Check that all engine mounting insulators are seated properly, then tighten mounting nuts and bolts.

EM-344
 ENGINE ASSEMBLY
< UNIT REMOVAL AND INSTALLATION > [V9X]
Inspection INFOID:0000000006467019

A
INSPECTION AFTER INSTALLATION
Inspection for Leaks
EM
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
- Start engine. With engine speed increased, check again for fuel leakage at connection points. C
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant. D
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
E
Summary of the inspection items:
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
F
Engine oil Level Leakage Level
Transmission / AT & CVT Models Leakage Level / Leakage Leakage
transaxle fluid G
MT Models Level / Leakage Leakage Level / Leakage

Other oils and fluids* Level Leakage Level

Fuel Leakage Leakage Leakage H
Exhaust gas — Leakage —
*: Power steering fluid, brake fluid, etc.
I

EM-345
 ENGINE STAND SETTING
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

UNIT DISASSEMBLY AND ASSEMBLY

ENGINE STAND SETTING
Setting INFOID:0000000006467020

NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1. Remove the engine assembly from the vehicle. Refer to EM-342, "Exploded View".
2. Install engine to engine stand with the following procedure:
a. Remove drive plate.
• Secure crankshaft using a ring gear stopper [SST: KV10116500 (—)], and remove mounting bolts.
CAUTION:
Never disassemble them.
b. Lift the engine with a hoist to install it onto widely use engine stand.
CAUTION:
Use the engine stand that has a load capacity [approximately 225 kg (496 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.
- Intake manifold: Refer to EM-351, "Exploded View".
- Exhaust manifold: Refer to EM-355, "Exploded View".
- Oil separator: Refer to EM-361, "Exploded View".
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with drive plate
removed.
CAUTION:
Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.

PBIC3227J

3. Drain engine oil. Refer to LU-36, "Draining".

CAUTION:
Be sure to clean drain plug and install with new gasket.

EM-346
 ENGINE UNIT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
ENGINE UNIT
A
Disassembly INFOID:0000000006467021

1. Remove multifunction support bracket. Refer to EM-298, "Exploded View". EM

2. Remove intake manifold. Refer to EM-351, "Exploded View".
3. Remove exhaust manifold. Refer to EM-355, "Exploded View".
4. Remove oil pan (lower). Refer to EM-320, "Exploded View". C
5. Remove oil cooler. Refer to LU-39, "Exploded View".
6. Remove vacuum pump. Refer to EM-302, "Exploded View".
D
7. Remove fuel pump. Refer to EM-304, "Exploded View".
8. Remove timing chain. Refer to EM-322, "Exploded View".
9. Remove cylinder head housing. Refer to EM-363, "Exploded View". E
10. Remove water suction pipe. Refer to CO-82, "Exploded View".
11. Remove water outlet and thermostat assembly. Refer to CO-80, "Exploded View".
Assembly INFOID:0000000006467022
F

Assembly is the reverse order of disassembly.

G

EM-347
 TURBOCHARGER
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
TURBOCHARGER
Exploded View INFOID:0000000006467023

JPBIA3565GB

1. Exhaust gas pressure sensor 1 2. Exhaust gas temperature sensor 1 3. Turbocharger insulator
4. Turbocharger 5. Gasket 6. Oil tube
7. Gasket 8. Oil tube 9. Gasket
10. Oil tube 11. Gasket 12. Water tube
13. Water tube 14. Bracket
A. To turbocharger cooling water pump B. To exhaust fuel injector cooler C. To cylinder block
D. to cylinder block
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467024

DISASSEMBLY
1. Remove oil feed tube from turbocharger. Refer to EM-348, "Exploded View".
2. Remove exhaust manifold. Refer to EM-355, "Exploded View".

EM-348
 TURBOCHARGER
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
3. Remove mounting bolt (A), and then remove EGR tube (1).
A
: Engine front

EM

JPBIA3606ZZ

D
4. Remove turbocharger.
CAUTION:
Never disassemble or adjust the turbocharger body.
E
5. Remove exhaust gas pressure sensor 1and exhaust gas temperature sensor 1.
CAUTION:
Be careful not to impact or damage exhaust gas pressure sensor 1 and exhaust gas temperature
sensor 1. F
ASSEMBLY
Note the following, and install in the reverse order of disassembly.
G
Exhaust Gas Temperature Sensor 1
CAUTION:
• Before installing a new exhaust gas temperature sensor, clean turbocharger thread.
• Be careful not to impact or damage exhaust gas temperature sensor 1. H
• When installing, never use such tools as an air impact wrench.
Inspection INFOID:0000000006467025
I

INSPECTION AFTER DISASSEMBLY

Turbocharger J

O
JPBIA3612GB

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

Suction side: Between turbocharger and air cleaner

Between turbocharger and charge air cooler
Exhaust side: Between turbocharger and catalyst
Between turbocharger and exhaust manifold

EM-349
 TURBOCHARGER
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Turbocharger Boost Control
• Connect the handy vacuum pump (A) to the actuator, and check
that the rod strokes smoothly in compliance with the following
pressure.

Standard (value of vacuum/value of rod moving):

Refer to SDS.

JPBIA3828ZZ

INSPECTION AFTER INSTALLATION

Start engine and raise engine speed to check no exhaust emission leaks.

EM-350
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
INTAKE MANIFOLD
A
Exploded View INFOID:0000000006467026

EM

L
JPBIA3589GB

1. Intake manifold (bank 1) 2. Intake manifold gasket 3. O-ring M

4. Bracket 5. Intake manifold (center) 6. Gasket
7. Electric throttle control actuator 8. Gasket 9. Intake manifold gasket
10. Intake manifold (bank 2) 11. Gasket 12. Adaptor N
13. O-ring
Refer to GI-9, "Component" for symbols in the figure.
O
Disassembly and Assembly INFOID:0000000006467027

DISASSEMBLY
P
1. Remove tubocharger. Refer to EM-348, "Exploded View".
2. Remove EGR assembly. Refer to EM-358, "Exploded View".

EM-351
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
3. Remove injection tube No.1 (1) and injection transfer tube (2).

: Engine front

JPBIA3616ZZ

4. Disconnect glow plug harness connector.

5. Disconnect oil separator tube.
6. Remove mounting bolts (A), and then remove intake manifold
(center) and electric throttle control actuator (1).

: Engine front

JPBIA3633ZZ

7. Remove mounting bolts (A) between intake manifold (bank 1)

and intake manifold (bank 2).

: Engine front

JPBIA3634ZZ

8. Remove intake manifold (bank 2).

• Loosen mounting bolts in reverse order as shown in the figure.

: Engine front

JPBIA3635ZZ

9. Remove intake manifold (bank 1).

EM-352
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Loosen mounting bolts in reverse order as shown in the figure.
A
: Engine front

EM

JPBIA3636ZZ

D
ASSEMBLY
Note the following, and install in the reverse order of disassembly.
CAUTION: E
Clean each joint surface before installation.
Intake Manifold
F
Bank 1
• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front G

I
JPBIA3636ZZ

Bank 2 J
• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front K

M
JPBIA3635ZZ

Intake Manifold Gasket

• Install intake manifold gasket to cylinder head in direction shown in N
the figure.

A : Triangle press O
: Engine upper

JPBIA3630ZZ

EM-353
 INTAKE MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Install intake manifold adaptor gasket to intake manifold (bank 2) in
direction shown in the figure.

: Engine upper

JPBIA3632ZZ

• Install intake manifold (center) gasket to intake manifold (bank 2) in

direction shown in the figure.

: Engine upper

JPBIA3631ZZ

Electric Throttle Control Actuator

• Tighten mounting bolts of electric throttle control actuator equally and diagonally in several steps.
• Perform “Throttle Valve Closed Position Learning” after repair when removing or replacing electric throttle
control actuator. Refer to EC-1321, "Work Procedure".
Inspection INFOID:0000000006467028

INSPECTION AFTER DISASSEMBLY

Surface Distortion
• Check the surface distortion of the intake manifold mating surface with a straightedge and a feeler gauge.

Standard : Refer to SDS.

• If it exceeds the standard, replace intake manifold.

EM-354
 EXHAUST MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
EXHAUST MANIFOLD
A
Exploded View INFOID:0000000006467029

EM

I
JPBIA3562GB

1. Gasket 2. Exhaust manifold (bank 2) 3. Front exhaust manifold cover (bank 2) J

4. Rear exhaust manifold cover (bank 2) 5. Clamp 6. Gasket
7. Gasket 8. Clamp 9. Front exhaust manifold cover (bank 1)
10. Rear exhaust manifold cover (bank 1) 11. Exhaust manifold (bank 1) 12. Gasket K
A. To turbocharger B. Comply with the assembly procedure
when tightening. Refer to EM-355,
"Disassembly and Assembly".
L
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467030

M
DISASSEMBLY
1. Remove oil feed tube for turbocharger.
N
2. Remove EGR cooler tube insulator cover. Refer to EM-348, "Exploded View".
3. Remove exhaust manifold cover.
4. Remove exhaust manifold. O

EM-355
 EXHAUST MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Loosen mounting nuts in the reverse order as shown in the fig-
ure.

A : Bank 2
B : Bank 1
: Engine front

JPBIA3613ZZ

5. Remove gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
ASSEMBLY
1. Install gasket to cylinder head as shown in the figure.

A : Triangle press
: Engine upper

JPBIA3614ZZ

2. Install exhaust manifold.

EM-356
 EXHAUST MANIFOLD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Tighten the mounting nuts in two steps separately in numerical
order as shown in the figure. A

A : Bank 2
B : Bank 1 EM
: Engine front

1st step C
: 18.0 N·m (1.8 kg-m, 13 ft-lb)
2st step : 30.0 N·m (3.1 kg-m, 22 ft-lb)
D

G
JPBIA3613ZZ

3. Install in the reverse order of disassembly, for the rest of parts.

H
Inspection INFOID:0000000006467031

INSPECTION AFTER DISASSEMBLY

I
Surface Distortion
• Check the surface distortion of the exhaust manifold mating surface with a straightedge and a feeler gauge.
J
Standard : Refer to SDS.
• If it exceeds the standard, replace exhaust manifold.
K
INSPECTION AFTER INSTALLATION
Start engine and raise engine speed to check no exhaust emission leaks.
L

EM-357
 EGR SYSTEM
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
EGR SYSTEM
Exploded View INFOID:0000000006467032

JPBIA3590GB

1. EGR cooler 2. Turbocharger 3. EGR cooler tube insulator

4. Gasket 5. EGR cooler tube 6. Intake manifold assembly
7. EGR cooler support bracket 8. EGR volume control valve 9. Gasket
10. EGR tube 11. Gasket 12. Gasket
13. Water hose 14. Clamp
A. To EGR water pump B. To radiator
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467033

DISASSEMBLY
1. Remove turbocharger. Refer to EM-348, "Exploded View".
2. Remove fuel injector rail protector. Refer to EM-315, "Exploded View"

EM-358
 EGR SYSTEM
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
3. Remove mounting bolts (A) and remove EGR tube (1).
A
: Engine front

EM

JPBIA3606ZZ

D
4. Remove EGR cooler and EGR volume control valve.
• Loosen mounting bolts in reverse order as shown in the figure.

: Engine front
E

JPBIA3607ZZ

H
• Remove EGR cooler (1) with the EGR cooler bypass valve (A)
pressed in the direction shown by the arrow.

K
JPBIA3992ZZ

5. Remove EGR support bracket.

• Loosen mounting bolts in reverse order as shown in the figure. L

: Engine front
M

JPBIA3608ZZ O

6. Separate EGR cooler and EGR volume control valve, if necessary.

ASSEMBLY P
Note the following, and install in the reverse order of removal.
CAUTION:
Clean each joint surface before installation.
EGR Support Bracket

EM-359
 EGR SYSTEM
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front

JPBIA3608ZZ

EGR Cooler Tube

• Tighten mounting bolts in numerical order as shown in the figure.

: Engine front

JPBIA3607ZZ

Inspection INFOID:0000000006467034

INSPECTION AFTER DISASSEMBLY

Perform “EGR Volume Control Valve Closed Position Learning Value Clear” and “EGR Volume Control Valve
Closed Position Learning” after installing to the vehicle when replacing EGR volume control valve.
• EGR volume control valve closed position learning value clear: Refer to EC-1318, "Work Procedure".
• EGR volume control valve closed position learning: Refer to EC-1319, "Work Procedure".

EM-360
 OIL SEPARATOR
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
OIL SEPARATOR
A
Exploded View INFOID:0000000006467035

EM

J
JPBIA3591GB

1. Oil separator 2. Gasket 3. Clamp K

4. PCV hose 5. PCV tube 6. PCV hose
7. PCV valve 8. Turbocharger inlet & outlet tube
Refer to GI-9, "Component" for symbols in the figure. L

Disassembly and Assembly INFOID:0000000006467036

M
DISASSEMBLY
1. Remove intake manifold. Refer to EM-351, "Exploded View".
2. Remove water outlet. Refer to CO-80, "Exploded View". N
3. Remove oil separator.
• Loosen mounting bolts in the reverse order as shown in the
figure. O

: Engine front
P

JPBIA3638ZZ

EM-361
 OIL SEPARATOR
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
ASSEMBLY
1. Install gasket to oil separator.
CAUTION:
Check the gasket is not dropped.
2. Install oil separator.
• Tighten mounting bolts in numerical order as shown in the fig-
ure.

: Engine front

JPBIA3638ZZ

3. Install water outlet. Refer to CO-80, "Exploded View".

NOTE:
• There are three types of mounting bolts.

Tightening torque
A, B : 12 N·m (1.2 kg-m, 9 ft-lb)
C : 10 N·m (1.0 kg-m, 89 in-lb)

JPBIA3637ZZ

4. Install in the reverse order of disassembly, for the rest of parts.

EM-362
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
CAMSHAFT
A
Exploded View INFOID:0000000006467037

EM

J
JPBIA3571GB

1. Cylinder head housing (bank 1) 2. Camshaft RH (bank 1) 3. Camshaft bracket K

4. Camshaft bracket 5. Wear compensation gear (bank 1) 6. Wear compensation gear spacer
7. Timing chain sprocket spacer 8. Timing chain sprocket (bank 1) 9. Timing gear (bank 1)
10. Camshaft LH (bank 1) 11. Wear compensation gear (bank 2) 12. Camshaft RH (bank 2) L
13. Timing chain sprocket spacer (bank 2) 14. Timing chain sprocket (bank 2) 15. Timing gear (bank 2)
16. Camshaft LH (bank 2) 17. Cylinder head housing (bank 2) 18. Camshaft position sensor
Comply with the installation procedure Comply with the installation procedure M
A. when tightening. Refer to EM-363, B. when tightening. Refer to EM-363,
"Disassembly and Assembly" "Disassembly and Assembly"
Refer to GI-9, "Component" for symbols shown in the figure. N
Disassembly and Assembly INFOID:0000000006467038

CAUTION: O
• This engine has a different valve arrangement from normal DOHC 4-valve type engines. As both
camshafts on this engine have intake and exhaust camshafts.
P

EM-363
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Refer to the figure for intake and exhaust valve arrangement.
(The camshafts have, alternately, either intake valve or an
exhaust valve.)

1. Camshaft (right side)

2. Camshaft (left side)
A. Intake cam
B. Exhaust cam
C. Bank 1
D. Bank 2
: Engine front

JPBIA3809ZZ

DISASSEMBLY
1. Remove turbocharger. Refer to EM-348, "Exploded View"
2. Remove timing chain. Refer to EM-323, "Removal and Installation".
3. Remove camshaft position sensor.
CAUTION:
• Handle camshaft position sensor carefully and avoid impacts.
• Never disassemble camshaft position sensor.
• Never place sensor where it is exposed to magnetism.
4. Remove cylinder head housing with the following procedure:
a. Loosen mounting bolts in reverse order as shown in the figure.

A : Bank 1
B : Bank 2
: Engine front

JPBIA3577ZZ

b. Remove the cylinder head housing (1) using a screwdriver (A).

EM-364
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

EM

JPBIA3810ZZ F

B : Screwdriver insertion point

CAUTION: G
Be careful not to damage the mating surface.

5. Remove camshafts with the following procedure: H

a. Install cylinder head housing (1) to cylinder head stand [com-
mercial service tool: KV113B0200 (Mot.1573)] (A).
b. Loosen mounting bolts, and remove camshaft brackets and I
camshafts.
• Mark camshafts and camshaft brackets so they are placed in
the same position and direction for installation. J

K
JPBIA3849ZZ

ASSEMBLY L
1. Install camshaft to cylinder head housing with the following procedure:
a. Clean camshaft journal to remove any foreign material.
M
b. Install camshafts.

EM-365
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Refer to the figure to install camshaft bracket in its original.

A : Part marking ADM2

B : Part marking ADM1
C : Part marking ECH2
D : Part marking ECH1
E : Bank 1
F : Bank 2
: Engine front

JPBIA3811ZZ

d. Tighten camshaft bracket mounting bolts.

• Finger tighten the camshaft bracket mounting bolts, until they just make contact.
2. Install cylinder head housing with the following procedure:
a. Rotate crankshaft groove (A) to set it in the position shown in the
figure.

1 : Crankshaft
b : 45 degrees
: Engine front

E1BIA0306ZZ

b. Remove foreign material completely from cylinder head housing backside and cylinder head installation
face.

EM-366
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Apply liquid gasket to cylinder head as shown in the figure.
A
B : Bank 1
C : Bank 2
a : 0.5 - 2.5 mm (0.020 - 0.098 in) EM
: Engine front

Use Genuine Liquid Gasket or equivalent.

C

G
JPBIA3812ZZ

d. Install so that camshafts are positioned in the directions shown

in the figure. H
• Set the camshaft RH (1) notch (C) at angle of 45 degrees.
• Set the camshaft LH (2) with the offset side faced upward.
I
A : Bank 1
B : Bank 2

N
JPBIA3848ZZ

EM-367
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
e. Tighten mounting bolts of cylinder head housing in numerical
order as shown in the figure.

A : Bank 1
B : Bank 2
: Engine front

1st step : 5.0 N·m (0.51 kg-m, 4 ft-lb)

2nd step : 12.0 N·m (1.2 kg-m, 9 ft-lb)
CAUTION:
After tightening mounting bolts of cylinder head housing,
be sure to wipe off excessive liquid gasket from the mating
surface of cylinder head.
3. Install timing chain and related parts. Refer to EM-323,
"Removal and Installation".

JPBIA3577ZZ

4. Install crankshaft position sensor. Refer to EM-363, "Exploded View".

5. Install in the reverse order of disassembly, for the rest of parts
Inspection INFOID:0000000006467039

INSPECTION AFTER DISASSEMBLY

CAMSHAFT JOURNAL DIAMETER
• Measure the camshaft journal with a micrometer (A).

Standard : Refer to SDS.

JPBIA0122ZZ

CYLINDER HEAD HOUSING AND CAMSHAFT BRACKET INNER DIAMETER

• Measure the inner diameter (A) of cylinder head housing and cam-
shaft bracket with a bore gauge.

Standard : Refer to SDS.

JPBIA3850ZZ

CAMSHAFT JOURNAL OIL CLEARANCE

• (Oil clearance) = (Bracket inner diameter) – (Camshaft journal diameter)

EM-368
 CAMSHAFT
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

Standard : Refer to SDS. A

• If it exceeds the standard, replace camshaft or/and cylinder head housing and cylinder head assembly.
HYDRORICK ADJUSTER
EM
• Check that the adjuster clip (1) are in place.

E
JPBIA3851ZZ

INSPECTION AFTER INSTALLATION

Inspection for Leaks F
• Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-25, "Fluids and Lubricants".
• Use procedure below to check for fuel leakage. G
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including
H
engine oil and engine coolant.
• Bleed air from lines and hoses of applicable lines, such as in cooling system.
• After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary. I
Summary of the inspection items:
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
J

Engine oil Level Leakage Level

Transmission / transaxle fluid
Leakage Level / Leakage Leakage K

Other oils and fluid* Level Leakage Level

Fuel Leakage Leakage Leakage L
Exhaust gases — Leakage —
*: Power steering fluid, brake fluid, etc.
M

EM-369
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
CYLINDER HEAD
Exploded View INFOID:0000000006467040

JPBIA3583GB

1. Rocker arm 2. Hydraulic tappet 3. Valve cotter

4. Valve spring retainer 5. Valve spring 6. Valve oil seal
7. Cylinder head (bank 1) 8. Cylinder head gasket (bank 1) 9. Exhaust valve
10. Intake valve 11. Cylinder head gasket (bank 2) 12. Valve oil seal
13. Cylinder head (bank 2)
Comply with the assembly procedure when
A. tightening. Refer to EM-370, "Disassembly and
Assembly".
Refer to GI-9, "Component" for symbols in the figure.

Disassembly and Assembly INFOID:0000000006467041

DISASSEMBLY
1. Remove the following components and related parts.
• Turbocharger: Refer to EM-348, "Exploded View" .
• Intake manifold: Refer to EM-351, "Exploded View".
• Exhaust manifold: Refer to EM-355, "Exploded View".
• Water inlet and thermostat assembly: Refer to CO-80, "Exploded View".
• Front cover, timing chain: Refer to EM-322, "Exploded View".
• Cylinder head housing: Refer to EM-363, "Exploded View".

EM-370
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
2. Remove mounting bolts (A).
A
: Engine front

EM

JPBIA3818ZZ

D
3. Remove cylinder head.
• Loosen mounting bolts in reverse order as shown in the figure.
E
A : Bank 1
B : Bank 2
: Engine front
F

JPBIA3819ZZ K

4. Remove cylinder head gasket.

5. Set the cylinder head assembly to the cylinder head support [commercial service tool: KV113B0200 L
(Mot.1573)].
6. Remove hydraulic tappet.
CAUTION: M
Be sure to immerse the hydraulic tappets in a bath of engine oil to ensure no air enters.
7. Remove valve collet (1).
• Compress valve spring with valve spring compressor (com- N
mercial service too) (A).

JPBIA0643ZZ

8. Remove valve spring retainer and valve spring.

9. Check dimension of valve oil seal mounting position before removing valve and valve oil seal with the fol-
lowing procedure:

EM-371
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
a. Install the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve oil seal.
NOTE:
The inner diameter of the push rod must be identical to that of
the valve. In addition, the bottom of the push rod must come into
contact with the metal upper section of the valve oil seal.

JPBIA3936ZZ

b. Install the guide tube (B) over the push rod (A) until the guide
tube comes into contact with the cylinder head, locking the push
rod with the knurled wheel.
• Remove the guide tube assembly plus push rod, being careful
not to loosen the knurled wheel.

JPBIA3937ZZ

10. Push valve stem to combustion chamber side, and remove valve.
• Identify installation positions, and store them without mixing them up.
11. Remove valve oil seal (1) with a valve oil seal puller [commercial
service tool: KV113B0090 (Mot.1335)] (A).

JPBIA0663ZZ

ASSEMBLY
1. Install valve.
NOTE:
Install larger diameter to intake side.
2. Install valve oil seal with the following procedure:
a. Position the protector (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot.1511-01)] on the valve.

JPBIA3938ZZ

EM-372
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
b. Position a valve oil seal (1) on the protector (A). Move the valve
oil seal past the protector. A
CAUTION:
Never lubricate valve oil seal.
EM

JPBIA3939ZZ

D
c. Remove the protector.
d. Push in the push rod (A) of valve seal drift [commercial service
tool: KV113B0180 (Mot. 1511-01)] with palm of the hand until the E
guide tube (B) makes contact with the cylinder head.

JPBIA3937ZZ

H
3. Install valve spring.
NOTE:
The intake and exhaust valve springs are identical.
I
4. Install valve spring retainer.
5. Install valve collet (1).
• Compress valve spring with a valve spring compressor (com-
mercial service tool) (A). J
• Tap valve stem edge lightly with a plastic hammer after instal-
lation to check its installed condition.
K

JPBIA0643ZZ
M
6. Install hydraulic tappet.
• Check that the tappets are filled with oil before refitting them.
7. Install cylinder head gasket with the following procedure: N
CAUTION:
Before installing cylinder head, inspect piston protrusion.
O

EM-373
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
a. Apply liquid gasket to cylinder head as shown in the figure.

B : Bank 1
C : Bank 2
a : 5.0 mm (0.20 in)
: Engine front

Use Genuine Liquid Gasket or equivalent.

JPBIA3852ZZ

b. Install cylinder head gasket (1), and apply liquid gasket to cylin-
der head gasket as shown in the figure.

B : Bank 1
C : Bank 2
a : 5.0 mm (0.20 in)
: Engine front

Use Genuine Liquid Gasket or equivalent.

JPBIA3926ZZ

EM-374
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
8. Install cylinder head, and tighten mounting bolts in numerical
order as shown in figure with the following procedure: A

A : Bank 1
B : Bank 2 EM
: Engine front

a. Tighten all cylinder head bolts.

C
: 30.0 N·m (3.1 kg-m, 22 ft-lb)

G
JPBIA3819ZZ

b. Tighten all cylinder head bolts (clockwise).

H
Angle tightening: 300 degrees
CAUTION:
Check and confirm the tightening angle by using an angle I
wrench [SST: KV10112100] (A) or protractor. Never judge by
visual inspection without the tool.
J
: Engine front

JPBIA3927ZZ
K

9. Assemble in the reverse order of disassembly, for the rest of parts.

Inspection INFOID:0000000006467042 L

INSPECTION AFTER DISASSEMBLY

M
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked.
N
1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.
CAUTION:
Never allow gasket debris to enter passages for engine oil or water.
2. At each of several locations on bottom surface of cylinder head, O
measure the distortion in six directions (A - F).

Standard: Refer to EM-393, "Cylinder Head". P

• If it exceeds the standard, replace cylinder head and cylinder
head housing.
NOTE:
Cylinder head cannot be replaced as a single part, because it is
machined together with cylinder head housing. Replace whole
cylinder head housing and cylinder head assembly.
JPBIA0176ZZ

EM-375
 CYLINDER HEAD
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

VALVE DIMENSIONS
• Check the dimensions of each valve. For the dimensions, refer to EM-393, "Cylinder Head".
• If dimensions are out of the standard, replace valve and check valve seat contact.
VALVE GUIDE CLEARANCE

Valve Stem Diameter

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

Standard : Refer to EM-393, "Cylinder Head".

Valve Guide Inner Diameter

• Measure the inner diameter of valve guide with bore gauge.

Standard : Refer to EM-393, "Cylinder Head".

Valve Guide Clearance

• (Valve guide clearance) = (Valve guide inner diameter) – (Valve
stem diameter) JPBIA0183ZZ

Standard : Refer to EM-393, "Cylinder Head".

• If it exceeds the standard, replace valve and/or cylinder head and cylinder head housing.
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
B : NG
• If not, grind to adjust valve fitting and check again. If the contacting
surface still has “NG” conditions even after the re-check, replace
cylinder head and cylinder head housing.

JPBIA0187ZZ

VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD

• Check valve spring pressure with valve spring seat installed at the
specified spring height.

Standard : Refer to EM-393, "Cylinder Head".

• If the pressure height is out of the standard, replace valve spring.

SEM113

EM-376
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
CYLINDER BLOCK
A
Exploded View INFOID:0000000006467043

EM

JPBIA3580GB

1. Cylinder block closure panel 2. Rear oil seal retainer 3. Cylinder block
4. Oil jet 5. Side bolt 6. Thrust bearing
7. Main bearing (upper) 8. Crankshaft 9. Main bearing (lower)

EM-377
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
10. Main bearing cap 11. Main bearing cap bolt 12. Pilot converter
13. Connecting rod cap bolt 14. Connecting rod cap 15. Connecting rod bearing
16. Connecting rod 17. Snap ring 18. Piston pin
19. Piston 20. Oil ring 21. Second ring
22. Top ring 23. A/T assembly 24. Crankshaft position sensor
25. Drive plate 26. Rear oil seal retainer
A. Comply with the installation procedure B. Comply with the assembly procedure C. Chamfered
when tightening. Refer to EM-342, "Re- when tightening. Refer to EM-378,
moval and Installation". "Disassembly and Assembly".
D. Comply with the assembly procedure
when tightening. Refer to EM-378, "Dis-
assembly and Assembly".
Refer to GI-9, "Component" for symbols shown in the figure.

Disassembly and Assembly INFOID:0000000006467044

DISASSEMBLY
1. Remove engine oil temperature/level sensor.
CAUTION:
Handle it carefully and avoid impacts.
2. Remove rear oil seal retainer.
3. Remove oil pan. Refer to EM-320, "Exploded View".
4. 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-386, "Inspection".
a. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center.
b. Remove mounting bolts (A), and then remove connecting rod
cap.
• Put a paint mark on cap to identify each cylinder.

: Engine front

JPBIA3816ZZ

c. Using a hammer handle (A) or similar tool, push piston and con-
necting rod assembly out to the cylinder head side.

: Engine front

JPBIA3817ZZ

CAUTION:

EM-378
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Be careful not to damage oil jets (1), cylinder wall and
crankshaft pin, resulting from an interference of the con- A
necting rod big end.
• Never disassemble oil jets.
EM
: Engine front

JPBIA3928ZZ

D
5. Remove connecting rod bearings.
CAUTION:
When removing them, note the installation position. Keep them in the correct.
E
6. Remove piston rings from piston.
• Before removing piston rings, check the piston ring side clearance. Refer to EM-386, "Inspection".
• Use a piston ring expander (commercial service tool) (A).
CAUTION: F
• When removing piston rings, be careful not to damage
the piston.
• Be careful not to damage piston rings by expanding
G
them excessively.

JPBIA3929ZZ
I
7. Remove the snap rings (1) using a screwdriver (A), and then
release the piston pin by hand.
J
B : Channel

L
JPBIA3930ZZ

8. Remove main bearing cap mounting bolts with the following procedure:
• Measure crankshaft end play before loosening main bearing cap mounting bolts. Refer to EM-386, M
"Inspection".
a. Loosen mounting bolts in reverse order as shown in the figure.
N
: Engine front

JPBIA3821ZZ

b. Loosen side bolt (A).

EM-379
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

JPBIA3820ZZ

: Engine front

c. Remove main bearing caps using a screwdriver (A).

• Put a paint mark on main bearing caps to identify each cylin-
der.

: Engine front

CAUTION:
• Be careful not to damage the mounting surface.
• Identify installation positions, and store them without
mixing them up.
JPBIA3822ZZ

9. Remove crankshaft.
10. Remove main bearings and thrust bearings from cylinder block and main bearing caps.
CAUTION:
Identify installation positions, and store them without mixing them up.
11. Remove oil jet, if necessary.
ASSEMBLY
1. Fully air-blow engine coolant and engine oil passages in the cylinder block, cylinder bore and crankcase
to remove any foreign matter.
CAUTION:
Use a goggles to protect your eye.

EM-380
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
2. Install water drain plug (1) to cylinder block as shown in the fig-
ure. A

: Engine front
EM
Water drain plug
: 25.0 N·m (2.6 kg-m, 18ft-ib)
C

G
JPBIA4015ZZ

3. Install main bearings and thrust bearings with the following procedure:
CAUTION: H
Be careful not to drop main bearing, and to scratch the surface.
a. Remove dust, dirt, and engine oil from the bearing mating surfaces of the cylinder block and main bearing
cap. I
b. Install the main bearings paying attention to the direction.
• Ensure the oil hole on cylinder block and oil hole (A) on the
main bearings (upper) (1) are aligned. J
• Before installing main bearings, apply engine oil to the bearing
surface (inside). Do not apply engine oil to the back surface,
but thoroughly clean it.
K

JPBIA3940ZZ

M
• Adjust the position of the main bearings (upper) using a fleer
gauge.
N
a : 0.490 mm (0.019 in)
b : 0.580 mm (0.023 in)
c : 0.015 mm (0.001 in) O

: Engine front
P
JPBIA3942ZZ

EM-381
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Adjust the position of the main bearings (lower) (1) using a
fleer gauge (A).

Main bearing caps No.1, 2 and 3

b : 0.889 mm (0.035 in)
Main bearing caps No.4
b : 1.480 mm (0.058 in)

JPBIA3943ZZ

c. Install thrust bearings (1) to both sides of the No. 4 journal hous-
ing on the cylinder block.
• Install thrust bearings with the oil groove facing crankshaft arm
(outside).

JPBIA3941ZZ

4. Install crankshaft to cylinder block.

• While turning crankshaft by hand, check that it turns smoothly.
5. Install main bearing caps with the following procedure:
a. Tighten new main bearing cap bolts in numerical order as shown
in the figure with the following procedure:

: Engine front

i. Tighten main bearing cap bolts.

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

CAUTION:
Be sure to check that the main bearing cap is in contact
with the cylinder block before tightening the bolts. JPBIA3821ZZ

ii. Tighten main bearing cap bolts (clockwise).

Tightening angle: 100 degrees

CAUTION:
Confirm the tightening angle by using an angle wrench
[SST: KV10112100] (A) or protractor. Never judge by visual
inspection without the tool.

JPBIA3944ZZ

iii. Tighten side bolt (A).

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

EM-382
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]

EM

JPBIA3820ZZ

D
: Engine front

• After installing mounting bolts, check that crankshaft can be rotated smoothly by hand.
E
• Check crankshaft end play. Refer to EM-386, "Inspection".
6. Install piston to connecting rod with the following procedure:
a. Install snap ring to the groove of the piston rear side.
F
• Insert it fully into the groove.
b. Assemble piston to connecting rod.
• Point the mark engraved (A) on the piston head facing as
shown in the figure. G

B : Bank 1
C : Bank 2 H
: Engine front

• Piston pin can be pushed in by hand without excessive force.

I
From the front to the rear, insert piston pin into piston and con-
necting rod.

M
JPBIA3945ZZ

c. Install snap ring to the groove of the piston front side. N

• Insert it fully into the groove.
• After installing, check that connecting rod moves smoothly.
7. Using a piston ring expander (commercial service tool), install piston rings.
CAUTION: O
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
P

EM-383
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Position each ring with the gap as shown in the figure referring
to the piston front mark.

: Engine front

JPBIA3946ZZ

8. Install connecting rod bearing (upper) and connecting rod bearing (lower) to connecting rod and connect-
ing rod cap.
• When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Never
apply new engine oil to the back surface, but thoroughly clean the back surface.
• Adjust the position of the connecting rod bearing (1) using a
fleer gauge [1.4 mm (0.055 in)] (A).
NOTE:
Locate the bearing for the connecting rod cap side.

b : 1.4 mm (0.055 in)

JPBIA3947ZZ

9. Install piston and connecting rod assembly to crankshaft with the following procedure:
• Install removed parts in the same locations as before.
a. 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.
b. Install piston with the mark engraved (A) on the piston head fac-
ing the rear of the engine as shown in the figure.

B : Bank 1
C : Bank 2
: Engine front

JPBIA3945ZZ

EM-384
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Using a piston ring compressor [SST: EM03470000 (—)] (A) or
suitable tool. A
CAUTION:
Be careful not to damage oil jets, cylinder wall and crank-
shaft pin, resulting from an interference of the connecting
EM
rod big end.

JPBIA3948ZZ

D
10. Install connecting rod cap with the following procedure:
CAUTION:
Check that there is no gap in the thrust surface (A) of the
E
joint between connecting rod (1) and connecting rod cap (2)
and that these parts are in the correct position. And then,
tighten the new bolts.
a. Tighten new connecting rod cap bolts. F

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

G
JPBIA3949ZZ

b. Tighten connecting rod cap bolts (clockwise).

H
Tightening angle: 55 degrees
CAUTION:
Confirm the tightening angle by using an angle wrench I
[SST: KV10112100 (—)] (A) or protractor. Never judge by
visual inspection without the tool.
J

JPBIA0846ZZ
K
• After tightening connecting rod cap bolt, check that crankshaft rotates smoothly.
• Check the connecting rod side clearance. Refer to EM-386, "Inspection".
• Check the piston protrusion. Refer to EM-386, "Inspection". L
11. Install oil pan. Refer to EM-320, "Exploded View".
12. Install rear oil seal retainer with the following procedure:
M
a. Set guide bolt (A) to rear oil seal retainer (1).

: Engine front
N
b. Move the rear oil seal retainer evenly by hand until it makes con-
tact with the cylinder block.
O

P
JPBIA3813ZZ

EM-385
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
c. Tighten mounting bolts in numerical order as shown in the fig-
ure.
i. Tighten all mounting bolts.

: 5.0 N·m (0.51 kg-m, 44 in-lb)

ii. Tighten all mounting bolts.

: 10.0 N·m (1.0 kg-m, 89 in-lb)

JPBIA3814ZZ

13. Install drive plate.

a. Fix crankshaft using ring gear stopper [SST: KV10116500 (—].
b. Tighten bolts by using Torx wrench (size 55+) [SST: (Mot.1959)]
in numerical order as shown in the figure with the following pro-
cedure:
i. Tighten all mounting bolts.

: 25.0 N·m (2.6 kg-m, 18 ft-lb)

ii. Tighten all mounting bolts (clockwise).

Tightening angle: 55 degrees

JPBIA3951ZZ

14. Install crankshaft position sensor.

CAUTION:
• Handle crankshaft position sensor carefully and avoid impacts.
• Never place crankshaft position sensor in a location where it is exposed to magnetism.
15. Install engine oil temperature/level sensor.
CAUTION:
Handle it carefully and avoid impacts.
16. Assemble in the reverse order of disassembly.
Inspection INFOID:0000000006467045

CRANKSHAFT END PLAY

• Measure the clearance between thrust bearings and crankshaft
arm when crankshaft is moved fully forward or backward with a dial
indicator (A).

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace thrust bearings, and measure
again. If it still exceeds the standard, also replace crankshaft.

JPBIA3823ZZ

CRANKSHAFT PIN JOURNAL DIAMETER

EM-386
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Measure the outer diameter of crankshaft pin journal with a
micrometer (A). A

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, measure the connecting rod bearing oil EM
clearance. Refer to “CONNECTING ROD BEARING OIL CLEAR-
ANCE”.
C

JPBIA0228ZZ

D
CRANKSHAFT MAIN JOURNAL DIAMETER
• Measure the outer diameter of crankshaft main journals with a micrometer.

Standard : Refer to EM-393, "General Specification". E

• If it exceeds the standard, measure the main bearing oil clearance. Refer to “MAIN BEARING OIL CLEAR-
ANCE”.
F
CONNECTING ROD SIDE CLEARANCE
• Measure the side clearance between connecting rod and crank-
shaft arm with a feeler gauge (A). G

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace connecting rod, and measure H
again. If it still exceeds the standard, also replace crankshaft.

JPBIA3953ZZ

CONNECTING ROD BIG END DIAMETER J

• Install connecting rod cap without connecting rod bearing installed,
and tightening connecting rod cap bolts to the specified torque.
Refer to EM-378, "Disassembly and Assembly". K

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

Standard : Refer to EM-393, "General Specifica- M

tion".
JPBIA3954ZZ
• If it exceeds the standard, replace connecting rod assembly.
CONNECTING ROD BUSHING OIL CLEARANCE N

Connecting Rod Bushing Inner Diameter

Measure the inner diameter of connecting rod bushing with an inside O
micrometer (A).

Standard : Refer to EM-393, "General Specifica-

tion". P

JPBIA0223ZZ

EM-387
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to EM-393, "General Specifica-

tion".

JPBIA0218ZZ

Connecting Rod Bushing Oil Clearance

(Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diame-
ter)

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace connecting rod assembly and/or piston and piston pin assembly.
• If replacing piston and piston pin assembly. Refer to “PISTON PROTRUSION”.

PISTON PROTRUSION
Measure the protrusion of piston with the following procedure:
1. Set piston at a point close to the TDC. Refer to EM-323, "Removal and Installation".
2. Set the dial indicator stand set [commercial service tool:
KV113B0040 (Mot.251-01)] (B) and [commercial service tool:
KV113B0050 (Mot.252-01)] (A) at the location as shown in the
figure.
3. Set the indicator scale to “0” where the piston protrusion is max-
imized.
4. Move the dial indicator stand so that the tip of dial indicator can
contact the cylinder block. Read the difference.

Standard : Refer to EM-393, "General Specification".

JPBIA1803ZZ

5. If measured value is out of the standard, replace piston. Select a

piston in “Piston Protrusion Grade”.

A : Date of manufacture
B : Piston grade
C : Modification in production suffix
D : Mark engraved
: Engine front

Piston Protrusion Grade: JPBIA0589ZZ

Refer to EM-393, "General Specification".

PISTON TO PISTON PIN OIL CLEARANCE

Piston Pin Hole Diameter

EM-388
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Measure the inner diameter of piston pin hole with an inside
micrometer (A). A

Standard : Refer to EM-393, "General Specification".

EM

JPBIA0217ZZ

D
Piston Pin Outer Diameter
Measure the outer diameter of piston pin with a micrometer (A).

Standard : Refer to EM-393, "General Specification". E

G
JPBIA0218ZZ

Piston to Piston Pin Oil Clearance H

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

Standard : Refer to EM-393, "General Specification". I

• If it exceeds the standard, replace piston and piston pin an assembly.
NOTE:
Piston is available together with piston pin as assembly. J
PISTON RING SIDE CLEARANCE
• Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C). K

A : OK
B : NG L

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace piston ring, and measure again. M
If it still exceeds the standard, also replace piston.
JPBIA0219ZZ

N
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 O
then insert (A) piston ring until middle of cylinder with piston, and
measure piston ring end gap with a feeler gauge (B).
P
C : Measuring point

Standard : Refer to EM-393, "General Specification".

• If it exceeds the standard, replace piston ring, and measure again.
If it still exceeds the standard, replace cylinder block and piston
rings.
JPBIA0220ZZ

EM-389
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
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.
• Measure the distortion on the cylinder block upper face at different
points in six directions (C, D, E, F, G and H) with a straight edge
(A) and feeler gauge (B).

Standard : Refer to EM-393, "General Specifica-

tion".
• If it exceeds the standard, replace cylinder block.

JPBIA0224ZZ

MAIN BEARING HOUSING INNER DIAMETER

• Install main bearing cap without main bearings installed, and tighten main bearing cap mounting bolts to the
specified torque. Refer to EM-378, "Disassembly and Assembly".
• Measure the inner diameter of main bearing housing with a bore
gauge.

1 : Cylinder block
2 : Main bearing cap

Standard : Refer to EM-393, "General Specifica-

tion".
• If it exceeds the standard, replace cylinder block and main bearing
caps assembly. JPBIA3955ZZ
NOTE:
Main bearing caps cannot be replaced individually, because it is machined together with the cylinder block.
PISTON TO CYLINDER BORE CLEARANCE
Cylinder Bore Inner Diameter
• Using a bore gauge, measure the cylinder bore for wear, out-of-round and taper at six different points on
each cylinder.

Standard:
Cylinder bore inner diameter
: Refer to EM-393, "General Specifica-
tion".
• If it exceeds the standard, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder
block.
Piston Skirt Diameter
Measure the outer diameter of piston skirt with a micrometer (A).

Standard : Refer to EM-393, "General Specification".

Measure point : Refer to EM-393, "General Specifica-

tion".

JPBIA0227ZZ

EM-390
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
Piston to Cylinder Bore Clearance
Calculate by piston skirt diameter and cylinder bore inner diameter. A
(Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter)

Standard : Refer to EM-393, "General Specifica- EM

tion".
• If it exceeds the standard, replace piston and piston pin assembly and/or cylinder block.
CONNECTING ROD BEARING OIL CLEARANCE C

Method by Calculation
• Install connecting rod bearings (1) to connecting rod (2) and con- D
necting rod bearing cap, and tighten connecting rod cap bolts to
the specified torque. Refer to EM-378, "Disassembly and Assem-
bly".
• Measure the inner diameter of connecting rod bearing with an E
inside micrometer.
(Bearing oil clearance) = (Connecting rod bearing inner diameter)
– (Crankshaft pin journal diameter) F

Standard : Refer to SDS.

• If it exceeds the standard. Replace connecting rod bearing or/and JPBIA3956ZZ
G
connecting rod.
Method of Using Plastigage
• Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. H
• 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-
I
fied torque. Refer to EM-378, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove connecting rod cap and bearing, and using the scale on J
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the standard is K
the same as that described in “Method by Calculation”.

JPBIA0231ZZ
M

MAIN BEARING OIL CLEARANCE

Method by Calculation N
• Install main bearings (3) to cylinder block (1) and main bearing cap
(2), and tighten main bearing cap mounting bolts to the specified
torque. Refer to EM-378, "Disassembly and Assembly".
O
• Measure the inner diameter of main bearing with a bore gauge.
(Bearing oil clearance) = (Main bearing inner diameter) – (Crank-
shaft main journal diameter)
P
Standard : Refer to SDS.
• If it exceeds the standard, select proper main bearing according to
main bearing inner diameter and crankshaft main journal diameter
to obtain specified bearing oil clearance. Refer to SDS. JPBIA3957ZZ

Method of Using Plastigage

• Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely.

EM-391
 CYLINDER BLOCK
< UNIT DISASSEMBLY AND ASSEMBLY > [V9X]
• Cut a plastigage slightly shorter than the bearing width, and place it in the crankshaft axial direction, avoiding
oil holes.
• Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap mounting bolts to
the specified torque. Refer to EM-378, "Disassembly and Assembly".
CAUTION:
Never rotate crankshaft.
• Remove main bearing cap and bearings, and using the scale on
the plastigage bag, measure the plastigage width.
NOTE:
The procedure when the measured value exceeds the standard is
the same as that described in “Method by Calculation”.

JPBIA0231ZZ

EM-392
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [V9X]

SERVICE DATA AND SPECIFICATIONS (SDS) A

SERVICE DATA AND SPECIFICATIONS (SDS)
General Specification INFOID:0000000006467046
EM

GENERAL SPECIFICATIONS
C
Engine type V9X
Cylinder arrangement V-6
Displacement cm3 (cu in) 2,998 (182.93) D
Bore and stroke mm (in) 84.0 x 90.0 (3.307 x 3.543)
Valve arrangement DOHC
E
Firing order 1-2-3-4-5-6
Compression 2
Number of piston rings
Oil 1 F
Compression ratio 15.5

Drive Belts INFOID:0000000006467047 G

DRIVE BELT
H
Tension of drive belt Belt tensioning is not necessary, as it is automatically adjusted by drive belt auto-tensioner.

Cylinder Head INFOID:0000000006467048

I

CYLINDER HEAD
Unit: mm (in)
J
Items Standard
Head surface distortion 0.05 (0.0020)
K

JPBIA3958ZZ N

Normal cylinder head height “a” 132.5 (5.22)

O
VALVE DIMENSIONS

EM-393
 SERVICE DATA AND SPECIFICATIONS (SDS)
< SERVICE DATA AND SPECIFICATIONS (SDS) [V9X]
Unit: mm (in)

E1BIA0064ZZ

Item Standard
Intake 27.58 - 27.82 (1.0858 - 1.0953)
Valve head diameter “D”
Exhaust 25.88 - 26.12 (1.0189 - 1.0283)
Intake 103.865 - 103.899 (4.089 - 4.091)
Valve length “L”
Exhaust 103.56 - 104.00 (4.077 - 4.094)
Intake 5.970 - 5.985 (0.2350 - 0.2356)
Valve stem diameter “d”
Exhaust 5.955 - 5.970 (0.2344 - 0.2350)
Measuring point "X1" 35.0 (1.378)
Intake 1.1 (0.043)
Valve margin “T”
Exhaust 0.94 (0.037)
Valve lift amount 8.0 (0.315)

VALVE SPRING

Free height 46.90 mm (1.8465 in)

200 - 220 N (20.4 - 22.4 kg, 45 - 49 lb) 34.90 mm (1.3740 in)
Pressure height
353 - 387 N (36.0 - 39.5 kg, 79 - 87 lb) 26.90 mm (1.0591 in)
Diameter of the wire 2.78 - 2.82 mm (0.1094 - 0.1110 in)
Inner diameter 13.90 - 14.30 mm (0.5472 - 0.5630 in)
Outer diameter 19.50 - 19.90 mm (0.7677 - 0.7835 in)
Valve spring squareness 1.2 mm (0.047 in)

EM-394