CAMSHAFTEM-55
< SERVICE INFORMATION >
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5. Install the camshaft sprockets using the following procedure:
• A: LH bank shown
a. Install the camshaft sprockets aligning them with the matching marks painted on the timing chain (B) and the camshaft sprock-
ets (C) before removal. Align the camshaft sprocket key groove
with the dowel pin on the camshaft front edge at the same time.
Then temporarily tighten camshaft sprocket bolts.
• Install the intake camshaft sprocket (VTC) (A) and exhaust
camshaft sprockets (B) by select ively using the groove of the
dowel pin according to the bank. (Common part used for both
exhaust banks.)
NOTE:
Use the groove marked "R" for RH bank and "L" for LH bank.
b. Lock the hexagonal part of the camshaft in the same way as for removal, and tighten the camshaft sprocket bolts.
c. Check again that the timing alignment mark on the timing chain and on each sprocket are aligned.
6. Install the chain tensioner using the following procedure: NOTE:
LH is shown.
a. Install the chain tensioner. • Compress the plunger and hold it using a stopper pin wheninstalling.
• Loosen the slack guide side timing chain by rotating the cam- shaft hexagonal part if mounting space is small.
b. Remove the stopper pin and release the plunger, and then apply tension to the timing chain.
c. Install the chain tensioner cover onto the front cover. • Apply liquid gasket as shown.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-45, "
Recommended Chemical Product and Sealant".
7. Check and adjust valve clearances. Refer to EM-56, "
Va l v e
Clearance".
8. Installation of the remaining components is in the reverse order of removal.
Inspection after InstallationINFOID:0000000003531535
INSPECTION OF CAMSHAFT SPROCKET (INT) OIL GROOVE
CAUTION:
• Perform this inspection only when DTC P0011 is de tected in self-diagnostic results of CONSULT II
and it is directed according to inspect ion procedure of EC section. Refer to EC-159, "
Component
Inspection".
• Check when engine is cold so as to pr event burns from any splashing engine oil.
1. Check engine oil level. Refer to LU-8, "
Inspection".
AWBIA0152ZZ
AWBIA0151ZZ
Chain tensioner bolts : 6.9 N·m (0.70 kg-m, 61 in-lb)
Tensioner cover bolts : 9.0 N·m (0.92 kg-m, 80 in-lb)KBIA2479E
KBIA2547E
EM-62
< SERVICE INFORMATION >
OIL SEAL
3. Remove the front oil seal using suitable tool.CAUTION:
Do not damage front cover and oil pump drive spacer.
INSTALLATION
1. Apply new engine oil to both the oil seal lip and dust seal lip of the new front oil seal.
2. Install the front oil seal.• Install the front oil seal so that each seal lip is oriented as
shown.
• Press-fit until the height of the front oil seal is level with the mounting surface using suitable tool.
CAUTION:
• Do not damage front timing chain case and crankshaft.
• Press-fit straight and avoid causing burrs or tilting oil
seal.
3. Installation of the remaining components is in the reverse order of removal.
Removal and Installation of Rear Oil SealINFOID:0000000003531539
REMOVAL
1. Remove the transmission assembly. Refer to AT-223, "Removal and Installation (2WD)" or AT-225,
"Removal and Installation (4WD)".
2. Lock the drive plate using Tool A.
CAUTION:
Do not damage the drive plat e. Especially, avoid deforming
and damaging the signal plat e teeth (circumference posi-
tion).
Keep magnetic materials away from signal plate.
NOTE:
Remove the bolts diagonally.
SBIA0359E
SEM715A
PBIC2931E
Tool number : — (J-47245)
LBIA0455E
EM-64
< SERVICE INFORMATION >
CYLINDER HEAD
CYLINDER HEAD
On-Vehicle ServiceINFOID:0000000003531540
CHECKING COMPRESSION PRESSURE
1. Warm up the engine thoroughly. Then stop the engine.
2. Release the fuel pressure. Refer to EC-80, "
Fuel Pressure Check".
CAUTION:
If CONSULT-II is not used to release fuel pressure leave the fu el pump fuse disconnected until
step 7.
3. Remove the spark plug from each cylinder. Refer to EM-29, "
Removal and Installation".
4. Connect the engine tachometer (not required in use of CONSULT-II).
5. Install the compression tester with Tool into the spark plug hole.
6. With the accelerator pedal fully depressed, turn the ignition switch to “START” for cranking. When the gauge pointer stabi-
lizes, read the compression pressure and engine rpm. Perform
these steps to check each cylinder.
Unit: kPa (kg/cm2, psi) /rpm
CAUTION:
Always use a fully charged battery to obtain specified engine speed.
• If the engine speed is out of the specified range, che ck the battery liquid for proper gravity. Check the
engine speed again with normal battery gravity.
• If the compression pressure is below the minimum value, check the valve clearances and parts associ- ated with the combustion chamber (valve, valve seat , piston, piston ring, cylinder bore, cylinder head,
cylinder head gasket). After checking, measure the compression pressure again.
• If some cylinders have low compression pressure, pour a small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, t he piston rings may be worn out or damaged. Check
the piston rings and replace if necessary.
- If the compression pressure remains at a low level despite the addition of engine oil, the valves may be
malfunctioning. Check the valves for damage. R eplace the valve or valve seat accordingly.
• If two adjacent cylinders have respectively low co mpression pressure and their compression remains
low even after the addition of engine oil, the gaskets may be leaking, or a valve in adjacent cylinders
may be damaged. Inspect and repair as required.
7. Install the components in the reverse order of removal.
8. Start the engine and confirm that it runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-32
.
Tool number : EG15050500 (J-45402)
Standard Minimum
Deference limit be-
tween cylinders
1,520 (15.5, 220) / 200 1,324 (13.5, 192) / 200 98 (1.0, 14) / 200WBIA0605E
ENGINE ASSEMBLY
EM-75
< SERVICE INFORMATION >
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6. Remove the engine room cover using power tools.
7. Remove the air duct and air cleaner case assembly. Refer to EM-15, "
Removal and Installation".
8. Disconnect the vacuum hose between the vehicle and engine and set it aside.
9. Remove the radiator assembly and hoses. Refer to CO-13, "
Removal and Installation".
10. Remove the drive belts. Refer to EM-15, "
Removal and Installation".
11. Remove the fan blade. Refer to CO-16, "
Removal and Installation (Crankshaft Driven Type)".
12. Disconnect the engine room harness from the fuse box and set it aside.
13. Disconnect the ECM.
14. Disconnect the engine room harness from the engine side and set it aside.
15. Disconnect the engine harness grounds.
16. Disconnect the power steering reservoir tank from the engine and move it aside.
17. Disconnect the power steering oil pump from the engine. Move it aside and secure it using suitable wire or
rope. Refer to PS-21, "
Removal and Installation".
18. Remove the A/C compressor bolts and set the compressor aside. Refer to ATC-154, "
Removal and Instal-
lation for Compressor" (ATC).
19. Disconnect the brake booster vacuum line.
20. Disconnect the EVAP line.
21. Disconnect the fuel hose at the engine side connection. Refer to EM-31, "
Removal and Installation".
22. Disconnect the heater hoses at the cowl, and install plugs to avoid leakage of engine coolant.
23. Remove the A/T oil level indicator and indicator tube upper bolts.
24. Remove the front final drive assembly (4WD only). Refer to FFD-12, "
Removal and Installation".
25. Remove the exhaust manifolds. Refer to EM-21, "
Removal and Installation".
26. Install the engine slingers into the left bank cylinder head and
right bank cylinder head.
27. Remove the A/T. Refer to AT-223, "
Removal and Installation
(2WD)" or AT-225, "Removal and Installation (4WD)".
28. Lift using a hoist and secure the engine in position.
29. Remove the engine assembly from the vehicle, avoid interfer-
ence with the vehicle body.
CAUTION:
• Before and during lifting, always check if any harnesses
are left connected.
30. Remove the parts that may restrict installation of the engine to the engine stand.
NOTE:
This procedure is described assuming that you use an engine stand mounting to the surface to which the
transmission mounts.
WBIA0795E
Engine slinger torque: 45.0 N·m (4.6 kg-m, 33 ft-lb)
WBIA0715E
EM-76
< SERVICE INFORMATION >
ENGINE ASSEMBLY
a. Before removing the drive plate, put a match mark (A) on the
crankshaft and drive plate for alignment during installation.
b. Remove the drive plate.
• Holding the crankshaft pulley bolt, lock the crankshaft to remove the drive plate bolts.
• Loosen the bolts diagonally.
CAUTION:
• Be careful not to damage the drive plate. Especially
avoid deforming and damaging of the signal plate teeth
(circumference position).
• Place the drive plate with the signal plate surface facing
other than downward.
• Keep magnetic materials away from the signal plate.
CAUTION:
Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough
for supporting the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to
reduce the potential risk of overturning the stand.
- Remove the fuel tube and fuel injector assembly. Refer to EM-31, "
Removal and Installation".
- Remove the intake manifold. Refer to EM-17, "
Removal and Installation".
- Remove the ignition coil. Refer to EM-28, "
Removal and Installation".
- Remove the rocker cover. Refer to EM-35, "
Removal and Installation".
- Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning.
31. Remove the generator. Refer to SC-22, "
Removal and Installation".
32. Remove the engine mounting insulator and bracket using power tool.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
• When replacing an engine or transmission you must make sure the dowels are installed correctly
during re-assembly.
• Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of driv-
etrain components.
INSPECTION AFTER INSTALLATION
• Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are
lower than required quantity, fill to the specified level. Refer to MA-10, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel
leakage at the connection points.
ALBIA0522ZZ
KBIA2491E
ENGINE ASSEMBLY
EM-77
< SERVICE INFORMATION >
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• 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 make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to
specified level if necessary.
• 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 fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
EM-84
< SERVICE INFORMATION >
CYLINDER BLOCK
• Tap until flattened with the front edge of the rear oil seal
retainer using suitable tool.
• Fit the rear oil seal until it is level with the rear end surface of
rear oil seal retainer.
9. Install rear oil seal retainer.
• Apply liquid gasket thoroughly to rear oil seal retainer as
shown.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-45, "
Recommended Chemical Product and Sealant".
• Apply new engine oil on the lips of rear oil seal. Do not touch.
10. Install the piston to the connecting rod.
a. Install the snap ring to the grooves of the piston rear side.
• Insert it fully into the groove to install.
b. Install the piston to the connecting rod.
• Heat piston until piston pin can be pushed in by hand without excess force [approx. 60° to 70 C° (140° to
158 °F)]. From the front to the rear, insert the piston pin into the piston and the connecting rod.
• Assemble so that the front mark on the piston crown and the
oil holes and cylinder No. on the connecting rod are positioned
as shown.
c. Install the snap ring to the grooves of the piston front side.
• Insert it fully into the groove to install.
• After installing, make sure connecting rod moves smoothly.
11. Install piston rings.
CAUTION:
Do not damage piston.
• Position each ring with the gap as shown, referring to the pis-
ton front mark.
• Install the second ring with the stamped surface facing
upward.
PBIC0097E
SBIA0391E
KBIA2534E
Stamped mark Second ring : 2N
PBIC0100E
DIFFERENTIAL GEAR OIL
FFD-7
< SERVICE INFORMATION >
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DIFFERENTIAL GEAR OIL
Changing Differential Gear OilINFOID:0000000003532588
DRAINING
1. Stop the engine.
2. Remove the drain plug from the front final drive assembly to drain the differential gear oil.
3. Install the drain plug with sealant applied on the threads to the front final drive assembly. Tighten to the
specified torque. Refer to FFD-13, "
Disassembly and Assembly".
• Use High Performance Thread Sealant or equivalent. Refer to GI-45, "
Recommended Chemical Product
and Sealant".
FILLING
1. Remove the filler plug from the front final drive assembly.
2. Fill the front final drive assembly with new differential gear oil
until the level reaches the specified level near the filler plug hole.
3. Install the filler plug with sealant applied on the threads to the
front final drive assembly. Tighten to the specified torque. Refer
to FFD-13, "
Disassembly and Assembly".
• Use High Performance Thread Sealant or equivalent. Refer to
GI-45, "
Recommended Chemical Product and Sealant".
Checking Differential Gear OilINFOID:0000000003532589
DIFFERENTIAL GEAR OIL LEAKAGE AND LEVEL
1. Make sure that differential gear oil is not leaking from the front final drive assembly or around it.
2. Check the differential gear oil level from the filler plug hole as
shown.
CAUTION:
Do not start engine while checking differential gear oil level.
3. Install the filler plug with sealant applied on the threads to the
front final drive assembly. Tighten to the specified torque. Refer
to FFD-13, "
Disassembly and Assembly".
• Use High Performance Thread Sealant or equivalent. Refer to
GI-45, "
Recommended Chemical Product and Sealant". Differential gear oil
grade and capacity: Refer to MA-10, "
Fluids
and Lubricants".
LDIA0176E
LDIA0176E