EM-248
[VK45DE]
CYLINDER BLOCK
Revision: 2005 July 2005 FX
10. Remove piston rings from piston.
Before removing the piston rings, check the piston ring side clearance. Refer to EM-263, "PISTON
RING SIDE CLEARANCE" .
Use piston ring expander (commercial service tool).
CAUTION:
When removing piston rings, be careful not to damage
piston.
Be careful not to damage piston rings by expanding them
excessively.
11. Remove piston from connecting rod as follows:
a. Using snap ring pliers, remove the snap rings.
b. Heat piston to 60 to 70 °C (140 to 158 °F) with industrial use drier
or equivalent.
c. Push out piston pin with stick of outer diameter approximately 20 mm (0.8 in).
12. Remove rear oil seal retainer from cylinder block.
Insert screwdriver or similar tool between rear end of crankshaft counter weight and rear oil seal
retainer, and separate liquid gasket to remove.
CAUTION:
Be careful not to damage the mating surfaces.
13. Using screwdriver or similar tool, and lever off rear oil seal from rear oil seal retainer.
PBIC0087E
PBIC0088E
PBIC0089E
EMM0072D
PRECAUTIONS GI-5
C
D E
F
G H
I
J
K L
M B
GI
Revision: 2005 July 2005 FX
Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before working
on the vehicle.
These operations should be done on a level surface.
When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
Dispose of drained oil or the solvent used for cleaning parts in
an appropriate manner.
Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel
spray and possibly a fire.
Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new
ones.
Replace inner and outer races of tapered roller bearings and needle bearings as a set.
Arrange the disassembled parts in accordance with their assembled locations and sequence.
Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents when required.
Use hand tools, power tools (disassembly only) and recom-
mended special tools where specified for safe and efficient ser-
vice repairs.
When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
SGI231
SEF289H
SGI233
PBIC0190E
GI-20
HOW TO USE THIS MANUAL
Revision: 2005 July 2005 FX
Detectable Lines and Non-Detectable Lines
In some wiring diagrams, two kinds of lines, representing wires, with different weight are used.
A line with regular weight (wider line) represents a “detectable
line for DTC (Diagnostic Trouble Code)”. A “detectable line for
DTC” is a circuit in which ECM can detect its malfunctions with
the on board diagnostic system.
A line with less weight (thinner line) represents a “non-detect-
able line for DTC”. A “non-detectable line for DTC” is a circuit in
which ECM cannot detect its malfunctions with the on board
diagnostic system.
SGI862-B
HEADLAMP - XENON TYPE - LT-35
C
D E
F
G H
I
J
L
M A
B
LT
Revision: 2005 July 2005 FX
Aiming AdjustmentAKS00CHK
PREPARATION BEFORE ADJUSTING
For details, refer to the regulations in your own country.
Before performing aiming adjustment, check the following.
1. Keep all tires inflated to correct pressures.
2. Place vehicle on level ground.
3. Set that there is no-load in vehicle other than the driver (or equivalent weight placed in driver's position). Coolant, engine oil filled up to correct level and full fuel tank.
LOW BEAM AND HIGH BEAM
1. Turn headlamp low beam ON.
CAUTION:
Be sure aiming switch is set to “0” when performing aiming
adjustment.
2. Use adjusting screws to perform aiming adjustment.
SKIA5544E
PKIB3650E
FRONT FOG LAMP LT-89
C
D E
F
G H
I
J
L
M A
B
LT
Revision: 2005 July 2005 FX
Aiming AdjustmentAKS007CT
Front fog lamp is a semi-sealed beam type which uses a replaceable halogen bulb. Before performing aiming
adjustment, make sure of the following.
Keep all tires inflated to correct pressure.
Place vehicle on level ground.
See that vehicle is unloaded (except for full levels of coolant, engine oil and fuel, and spare tire, jack, and
tools). Have the driver or equivalent weight placed in driver seat.
Adjust aiming in the vertical direction by turning adjusting screw.
1. Set the distance between the screen and the center of front fog lamp lens as shown at left.
2. Turn front fog lamps ON.
3. Adjust front fog lamps using adjusting screw so that the top edge of the high intensity zone is 100 mm (3.94 in) below the height of
front fog lamp centers as shown at left.
When performing adjustment, if necessary, cover headlamps
and opposite front fog lamp.
SKIA5557E
PKIB1672E
PKIB1673E
OIL PUMP LU-19
[VQ35DE]
C
D E
F
G H
I
J
K L
M A
LU
Revision: 2005 July 2005 FX
Regulator Valve Clearance
(Clearance) = (Valve hole diameter) – (Regulator valve outer diame-
ter)
If the calculated value is out of the standard, replace oil pump
assembly.
CAUTION:
Coat regulator valve with engine oil.
Make sure that it falls smoothly into valve hole by its own
weight.
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
Install oil pump inner rotor with the groove faced to oil pump
cover side. Standard : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
PBIC0822E
PBIC0832E
OIL PUMP LU-33
[VK45DE]
C
D E
F
G H
I
J
K L
M A
LU
Revision: 2005 July 2005 FX
OIL PUMP BODY INNER DIAMETER
–Measure the inner diameter of oil pump body with inside
micrometer. (Position 6)
OIL PUMP INNER DIAMETER TO OIL PUMP BODY CLEARANCE
–(Clearance) = (Oil pump body inner diameter) – (Oil pump inner rotor outer diameter)
If the measured/calculated values are out of the standard, replace oil pump assembly.
Regulator Valve Clearance
(Clearance) = D1 (Valve hole diameter) – D2 (Regulator valve outer
diameter of valve)
If the calculated value is out of the standard, replace oil pump
assembly.
CAUTION:
Coat regulator valve with engine oil.
Make sure that it falls smoothly into regulator valve hole by
its own weight.
ASSEMBLY
Note the following, and assemble in the reverse order of disassembly.
Install oil pump inner rotor and oil pump outer rotor with the
punched marks on the oil pump cover side.
PBIC0142E
Standard : 0.045 - 0.091 mm (0.0018 - 0.0036 in)
Standard : 0.040 - 0.097 mm (0.0016 - 0.0038 in)
PBIC0143E
PBIC0144E
MA-1
MAINTENANCE
L MAINTENANCE
CONTENTS
C
D E
F
G H
I
J
K
M
SECTION MA
A
B
MA
Revision: 2005 July 2005 FX
MAINTENANCE
PREPARATION ........................................................... 3
Special Service Tools .......................................... ..... 3
Commercial Service Tools ................................... ..... 3
GENERAL MAINTENANCE .................................. ..... 4
Explanation of General Maintenance .................. ..... 4
PERIODIC MAINTENANCE .................................. ..... 7
Introduction of Periodic Maintenance .................. ..... 7
Schedule 1 .......................................................... ..... 8
EMISSION CONTROL SYSTEM MAINTE-
NANCE ............................................................. ..... 8
CHASSIS AND BODY MAINTENANCE .......... ..... 9
Schedule 2 .......................................................... ... 10
EMISSION COMTROL SYSTEM MAINTE-
NANCE ............................................................. ... 10
CHASSIS AND BODY MAINTENANCE .......... .... 11
RECOMMENDED FLUIDS AND LUBRICANTS ... ... 12
Fluids and Lubricants .......................................... ... 12
SAE Viscosity Number ........................................ ... 13
GASOLINE ENGINE OIL ................................. ... 13
Anti-Freeze Coolant Mixture Ratio ...................... ... 13
ENGINE MAINTENANCE (VQ35DE ENGINE) ...... ... 14
Checking Drive Belts ........................................... ... 14
Drive Belts Tension Adjustment .......................... ... 14
ALTERNATOR AND POWER STEERING OIL
PUMP BELT ..................................................... ... 15
A/C COMPRESSOR BELT .............................. ... 15
Changing Engine Coolant ................................... ... 15
DRAINING ENGINE COOLANT ...................... ... 15
REFILLING ENGINE COOLANT ..................... ... 16
FLUSHING COOLING SYSTEM ...................... ... 17
Checking Fuel Lines ............................................ ... 17
Changing Air Cleaner Filter ................................. ... 18
VISCOUS PAPER TYPE .................................. ... 18
Changing Engine Oil ........................................... ... 18
Changing Oil Filter .............................................. ... 19
REMOVAL ........................................................ ... 19
INSTALLATION ................................................ ... 19
INSPECTION AFTER INSTALLATION ............ ... 20
Changing Spark Plugs (Platinum-Tipped Type) .. ... 20
REMOVAL ........................................................ ... 20 INSPECTION AFTER REMOVAL ....................
... 20
INSTALLATION ................................................ ... 21
Checking EVAP Vapor Lines ............................... ... 21
ENGINE MAINTENANCE (VK45DE ENGINE) ...... ... 22
Checking Drive Belts ........................................... ... 22
Tension Adjustment ............................................. ... 22
Changing Engine Coolant .................................... ... 22
DRAINING ENGINE COOLANT ....................... ... 23
REFILLING ENGINE COOLANT ...................... ... 23
FLUSHING COOLING SYSTEM ...................... ... 24
Checking Fuel Lines ............................................ ... 25
Changing Air Cleaner Filter ................................. ... 25
VISCOUS PAPER TYPE .................................. ... 25
Changing Engine Oil ............................................ ... 25
Changing Oil Filter ............................................... ... 26
REMOVAL ........................................................ ... 26
INSTALLATION ................................................ ... 26
INSPECTION AFTER INSTALLATION ............. ... 27
Changing Spark Plugs (Platinum-Tipped Type) ... ... 27
REMOVAL ........................................................ ... 27
INSPECTION AFTER REMOVAL .................... ... 27
INSTALLATION ................................................ ... 28
Checking EVAP Vapor Lines ............................... ... 28
CHASSIS AND BODY MAINTENANCE ................ ... 29
Checking Exhaust System ................................... ... 29
Checking A/T Fluid .............................................. ... 29
Changing A/T Fluid .............................................. ... 31
Checking Transfer Fluid ...................................... ... 31
Changing Transfer Fluid ...................................... ... 32
Checking Propeller Shaft ..................................... ... 32
Checking Differential Gear Oil ............................. ... 32
Changing Differential Gear Oil ............................. ... 33
Balancing Wheels (Bonding Weight Type) .......... ... 33
REMOVAL ........................................................ ... 33
WHEEL BALANCE ADJUSTMENT .................. ... 33
Tire Rotation ........................................................ ... 35
Checking Brake Fluid Level and Leaks ............... ... 35
Checking Brake Lines and Cables ...................... ... 35
Changing Brake Fluid .......................................... ... 35
Checking Disc Brake ........................................... ... 36