EM-140
[VQ]
EXHAUST MANIFOLD AND THREE WAY CATALYST
EXHAUST MANIFOLD AND THREE WAY CATALYSTPFP:14004
Removal and InstallationBBS004VT
REMOVAL
WARNING:
Perform the work when the exhaust and cooling system have completely cooled down.
1. Drain engine coolant. Refer to CO-34, "
Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
2. Remove the following:
Engine cover; Refer to EM-133, "INTAKE MANIFOLD COLLECTOR" .
Air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly;
Refer to EM-131, "
AIR CLEANER AND AIR DUCT" .
Undercover
Radiator and radiator cooling fan assembly; Refer to CO-37, "RADIATOR" .
1. Heated oxygen sensor 1 (bank 1) 2. Exhaust manifold cover (right bank) 3. Exhaust manifold (right bank)
4. Ring gasket 5. Three way catalyst (right bank) 6.Three way catalyst support (right
bank)
7. Heated oxygen sensor 2 (bank 1) 8. Gasket 9. Gasket
10. Heated oxygen sensor 1 (bank 2) 11. Three way catalyst (left bank) 12. Three way catalyst cover
13. Three way catalyst cover 14. Three way catalyst cover 15.Three way catalyst support (left
bank)
16. Heated oxygen sensor 2 (bank 2) 17. Exhaust manifold cover (left bank) 18. Exhaust manifold (left bank)
PBIC2461E
OIL PAN AND OIL STRAINER
EM-145
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OIL PAN AND OIL STRAINERP F P : 1111 0
Removal and InstallationBBS004VU
Refer to GI-10, "Components" for symbol marks in the figure.
REMOVAL
WARNING:
To avoid the danger of being scalded, do not drain engine oil when engine is hot.
NOTE:
When removing oil pan (lower) or oil strainer only, take step 1 then step 10 and 11.
1. Drain engine oil. Refer to LU-21, "
Changing Engine Oil" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine oil on drive belts.
2. Drain engine coolant. Refer to CO-34, "
Changing Engine Coolant" .
1. Oil pan (upper) 2. O-ring 3. Oil pan gasket (front)
4. Oil pressure switch 5.Plug (VQ23DE)
Relief valve (VQ35DE)6. O-ring
7. Oil cooler 8. Connector bolt 9. Oil filter
10. Oil strainer 11. Drain plug 12. Drain plug washer
13. Oil pan (lower) 14. Rear plate cover 15. Harness bracket
16. Crankshaft position sensor (POS) 17. Seal rubber 18. Oil pan gasket (rear)
A. Refer to LU-22
B. To oil pump C. Oil pan side
D. VQ23DE E. VQ35DE
PBIC4533J
EM-146
[VQ]
OIL PAN AND OIL STRAINER
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
3. Remove the following:
Engine cover; Refer to EM-133, "INTAKE MANIFOLD COLLECTOR" .
Splash guard (RH)
Exhaust front tube; Refer to EX-2, "EXHAUST SYSTEM" .
Drive belts; Refer to EM-128, "DRIVE BELTS" .
4. Remove A/C compressor with piping connected, and temporarily secure it to aside. Refer to ATC-133,
"Components" .
5. Remove three way catalysts (right and left banks) from exhaust manifolds (right and left banks). Refer to
EM-140, "
EXHAUST MANIFOLD AND THREE WAY CATALYST" .
6. Remove oil pressure switch. Refer to LU-20, "
OIL PRESSURE CHECK" .
7. Remove crankshaft position sensor (POS).
CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble.
Do not allow metal powder to adhere to magnetic part at sensor tip.
Do not place sensor in a location where it is exposed to magnetism.
8. Remove oil filter. Refer to LU-22, "
OIL FILTER" .
9. Remove oil cooler and water pipes (VQ35DE). Refer to LU-23, "
OIL COOLER (VQ35DE)" .
10. Remove oil pan (lower) as follows:
a. Loosen mounting bolts in the reverse order as shown in the fig-
ure.
b. Insert seal cutter (SST) between oil pan (lower) and oil pan
(upper).
CAUTION:
Be careful not to damage the mating surfaces.
Do not insert screwdriver, this will damage the mating
surfaces.
c. Slide seal cutter by tapping on the side of the tool with hammer.
Remove oil pan (lower).
PBIC0782E
SEM365ED
FUEL INJECTOR AND FUEL TUBE
EM-155
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FUEL INJECTOR AND FUEL TUBEPFP:16600
Removal and InstallationBBS004VX
Refer to GI-10, "Components" for symbol marks in the figure.
CAUTION:
Do not remove or disassemble parts unless instructed as shown in the figure.
REMOVAL
WARNING:
Put a “CAUTION FLAMMABLE” sign in the workshop.
Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
To avoid the danger of being scalded, do not drain engine coolant when engine is hot.
1. Remove engine cover. Refer to EM-133, "
INTAKE MANIFOLD COLLECTOR" .
2. Release the fuel pressure. Refer to EC-392, "
FUEL PRESSURE RELEASE" .
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-34, "
Changing Engine Coolant" and EM-133, "INTAKE MANIFOLD COLLECTOR" .
CAUTION:
Perform this step when engine is cold.
1. Fuel feed hose (with damper) 2. Quick connector cap 3. Centralized under-floor piping
4. Fuel tube 5. Spacer 6. Clip
7.O-ring (black) (VQ23DE)
O-ring (blue) (VQ35DE)8. Fuel injector 9.O-ring (green) (VQ23DE)
O-ring (brown) (VQ35DE)
10. O-ring 11. Fuel damper
A. Refer to EM-157
PBIC4686E
FRONT TIMING CHAIN CASE
EM-163
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FRONT TIMING CHAIN CASEPFP:13599
Removal and InstallationBBS004VZ
NOTE:
This section describes removal/installation procedure of front timing chain case and timing chain related
parts without removing oil pan (upper) on vehicle.
When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or
installed, remove oil pans (lower and upper) first. Then remove front timing chain case, timing chain
related parts, and rear timing chain case in this order, and install in the reverse order of removal. Refer to
EM-173, "
TIMING CHAIN" .
Refer to EM-173, "TIMING CHAIN" for component parts location.
REMOVAL
1. Remove engine cover. Refer to EM-133, "INTAKE MANIFOLD COLLECTOR" .
2. Remove air duct (inlet), air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to
EM-131, "
AIR CLEANER AND AIR DUCT" .
3. Remove undercover and splash guard (RH).
4. Remove right side front road wheel and tire.
5. Drain engine oil. Refer to LU-21, "
Changing Engine Oil" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine oil on drive belts.
6. Drain engine coolant from radiator. Refer to CO-34, "
Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
7. Remove intake manifold collectors (upper and lower). Refer to EM-133, "
INTAKE MANIFOLD COLLEC-
TOR" .
8. Remove drive belts. Refer to EM-128, "
DRIVE BELTS" .
9. Remove alternator. Refer to SC-27, "
CHARGING SYSTEM" .
10. Remove power steering oil pump from bracket with piping connected, and temporarily secure it to aside.
Refer to PS-29, "
POWER STEERING OIL PUMP" .
11. Remove power steering oil pump bracket. Refer to PS-29, "
POWER STEERING OIL PUMP" .
12. Remove idler pulley and bracket. Refer to EM-173, "
TIMING CHAIN" .
13. Separate engine harnesses removing their brackets from front timing chain case.
14. Remove rocker covers (right and left bank). Refer to EM-160, "
ROCKER COVER" .
NOTE:
When only timing chain (primary) is removed, rocker cover does not need to be removed.
15. Obtain No. 1 cylinder at TDC of its compression stroke as follows:
NOTE:
When timing chain is not removed/installed, this step is not required.
a. Rotate crankshaft pulley clockwise to align timing mark (grooved
line without color) with timing indicator.
SEM918G
FRONT TIMING CHAIN CASE
EM-171
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e. Tighten mounting bolts in numerical order as shown in the fig-
ure.
12. Install crankshaft pulley as follows:
a. Install crankshaft pulley, taking care not to damage front oil seal.
When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference).
b. Fix crankshaft with pulley holder [SST: KV10109300].
c. Tighten crankshaft pulley bolt.
d. Place a matching mark (A) on crank pulley (1) aligning with the
matching (B) of crank pulley mounting bolt (2). Tighten the bolts
90 degrees (one marks).
e. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
13. For the following operations, perform steps in the reverse order of removal.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluid leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-14, "
RECOMMENDED FLUIDS AND LUBRICANTS" .
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
Warm up engine thoroughly to make sure there is no leakage of 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.
PBIC0918E
: 44.1 N·m (4.5 kg-m, 33 ft-lb)
PBIC4627J
EM-172
[VQ]
FRONT TIMING CHAIN CASE
Summary of the inspection items:
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
EM-174
[VQ]
TIMING CHAIN
NOTE:
This section describes procedures for removal/installation front timing chain case and timing chain related
parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul,
etc.
To removal/installation front timing chain case, timing chain, and timing chain related parts without remov-
ing oil pan (upper), refer to EM-163, "
FRONT TIMING CHAIN CASE" .
REMOVAL
1. Remove engine assembly from vehicle, and separate front suspension member and transaxle from
engine. Refer to EM-223, "
ENGINE ASSEMBLY" .
2. Install engine sub-attachment with engine stand shaft [SST: KV10117001 and KV10106500] to right side
of cylinder block, then lift engine, and mount it onto engine stand [SST: ST0501S000]. Refer to EM-228,
"CYLINDER BLOCK" .
3. Drain engine oil. Refer to LU-21, "
Changing Engine Oil" .
4. Drain engine coolant from inside engine. Refer to EM-229, "
DISASSEMBLY" .
5. Remove intake manifold collectors (upper and lower). Refer to EM-133, "
INTAKE MANIFOLD COLLEC-
TOR" .
6. Remove rocker covers (right and left banks). Refer to EM-160, "
ROCKER COVER" .
7. Remove oil pans (lower and upper) and oil strainer. Refer to EM-145, "
OIL PAN AND OIL STRAINER" .
8. Remove idler pulley and bracket.
9. Separate engine harness removing their brackets from front timing chain case
10. Remove right and left intake valve timing control covers.
Loosen mounting bolts in the reverse order as shown in the
figure.
U s e s e a l c u t t e r [ S S T: K V 1 0 1111 0 0 ] t o c u t l i q u i d g a s k e t f o r
removal.
CAUTION:
Shaft is internally jointed with camshaft sprocket (INT) cen-
ter hole. When removing, keep it horizontal until it is com-
pletely disconnected.
11. Remove collared O-ring from front timing chain case oil hole (left
and right sides).
1. O-ring 2. Timing chain tensioner (secondary) 3. Internal chain guide
4. Timing chain tensioner (secondary) 5. Camshaft sprocket (EXH) 6. Timing chain (secondary)
7. Timing chain (primary) 8. Camshaft sprocket (INT) 9. Slack guide
10. Timing chain tensioner (primary) 11. Camshaft sprocket (EXH) 12. Timing chain (secondary)
13. Camshaft sprocket (INT) 14. Crankshaft sprocket 15. Collared O-ring
16. Seal ring 17. Intake valve timing control cover 18. Chain tensioner cover
19. Intake valve timing control cover 20. Water pump cover 21. Front oil seal
22. Crankshaft pulley 23. Idler pulley 24. Idler pulley bracket
25. Center shaft 26. Washer 27. Front timing chain case
28. Rear timing chain case 29. Water drain plug (front) 30. Tension guide
PBIC0918E
PBIC2631E