EM-1
ENGINE
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SECTION EM
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CONTENTS
ENGINE MECHANICAL
VQ35DE
SERVICE INFORMATION .. ..........................
4
PRECAUTIONS .............................................. .....4
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ............................... ......
4
Precaution for Drain Engine Coolant and Engine
Oil ..............................................................................
4
Precaution for Disconnecting Fuel Piping .................4
Precaution for Removal and Disassembly ................4
Precaution for Inspection, Repair and Replace-
ment ..........................................................................
4
Precaution for Assembly and Installation ..................5
Precaution for Angle Tightening ................................5
Precaution for Liquid Gasket .....................................5
PREPARATION ...................................................7
Special Service Tool ........................................... ......7
Commercial Service Tool ..........................................9
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ............................
12
NVH Troubleshooting - Engine Noise ................. ....12
Use the Chart Below to Help You Find the Cause
of the Symptom .......................................................
12
DRIVE BELTS ....................................................14
Checking Drive Belts ........................................... ....14
Tension Adjustment ................................................14
Removal and Installation .........................................15
AIR CLEANER AND AIR DUCT ........................17
Component .......................................................... ....17
Removal and Installation .........................................17
Changing Air Cleaner Filter .....................................18
INTAKE MANIFOLD COLLECTOR ...................19
Component .......................................................... ....19
Removal and Installation .........................................19
INTAKE MANIFOLD ...........................................24
Component .......................................................... ....24
Removal and Installation .........................................24
EXHAUST MANIFOLD AND THREE WAY
CATALYST ........................................................
26
Component ..............................................................26
Removal and Installation .........................................26
OIL PAN AND OIL STRAINER .........................30
Component (2WD Models) ......................................30
Removal and Installation (2WD Models) .................30
Component (AWD Models) ......................................35
Removal and Installation (AWD Models) .................36
IGNITION COIL .................................................42
Component ..............................................................42
Removal and Installation .........................................42
SPARK PLUG (PLATINUM-TIPPED TYPE) .....43
Component ..............................................................43
Removal and Installation .........................................43
FUEL INJECTOR AND FUEL TUBE ................45
Component ..............................................................45
Removal and Installation .........................................45
ROCKER COVER .............................................51
Component ..............................................................51
Removal and Installation .........................................51
FRONT TIMING CHAIN CASE .........................54
Removal and Installation .........................................54
TIMING CHAIN ..................................................64
Component .......................................................... ....64
Removal and Installation .........................................65
CAMSHAFT .......................................................83
Component ..............................................................83
Removal and Installation .........................................84
Valve Clearance ......................................................91
OIL SEAL ..........................................................97
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EM-2
Removal and Installation of Valve Oil Seal .............97
Removal and Installation of Front Oil Seal .............97
Removal and Installation of Rear Oil Seal ..............98
CYLINDER HEAD ............................................100
On-Vehicle Service .............................................. ..100
Component ............................................................101
Removal and Installation .......................................101
Disassembly and Assembly ...................................105
Inspection After Disassembly ................................107
ENGINE ASSEMBLY .......................................112
Component (2WD Models) .................................. ..112
Removal and Installation (2WD Models) ...............112
Component (AWD Models) ....................................117
Removal and Installation (AWD Models) ...............117
CYLINDER BLOCK .........................................122
Component .......................................................... ..122
Disassembly and Assembly ...................................123
How to Select Piston and Bearing .........................134
Inspection After Disassembly ................................138
SERVICE DATA AND SPECIFICATIONS
(SDS) ................................................................
149
Standard and Limit .............................................. ..149
VK45DE
SERVICE INFORMATION ..........................
160
PRECAUTIONS .............................................. .160
Precaution Necessary for Steering Wheel Rota-
tion After Battery Disconnect ............................... ..
160
Precaution for Drain Engine Coolant and Engine
Oil ..........................................................................
160
Precaution for Disconnecting Fuel Piping ..............160
Precaution for Removal and Disassembly .............160
Precaution for Inspection, Repair and Replace-
ment .......................................................................
160
Precaution for Assembly and Installation ..............161
Parts Requiring Angle Tightening ..........................161
Precaution for Liquid Gasket .................................161
PREPARATION .............................................. .163
Special Service Tool ............................................ ..163
Commercial Service Tool ......................................164
NOISE, VIBRATION AND HARSHNESS
(NVH) TROUBLESHOOTING ..........................
167
NVH Troubleshooting - Engine Noise .................. ..167
Use the Chart Below to Help You Find the Cause
of the Symptom .....................................................
167
ENGINE ROOM COVER ..................................169
Component .......................................................... ..169
Removal and Installation .......................................169
DRIVE BELTS ..................................................170
Component .......................................................... ..170
Checking Drive Belts .............................................170
Tension Adjustment ...............................................170
Removal and Installation ...................................... .170
Component ...........................................................171
Drive Belt Auto Tensioner and Idler Pulley ...........172
AIR CLEANER AND AIR DUCT .......................173
Component .......................................................... .173
Removal and Installation .......................................173
Changing Air Cleaner Filter ...................................174
INTAKE MANIFOLD .........................................175
Component .......................................................... .175
Removal and Installation .......................................176
EXHAUST MANIFOLD AND THREE WAY
CATALYST .......................................................
179
Component .......................................................... .179
Removal and Installation .......................................179
OIL PAN AND OIL STRAINER ........................183
Component .......................................................... .183
Removal and Installation .......................................183
IGNITION COIL .................................................187
Component .......................................................... .187
Removal and Installation .......................................187
SPARK PLUG (PLATINUM-TIPPED TYPE) ....188
Component .......................................................... .188
Removal and Installation .......................................188
FUEL INJECTOR AND FUEL TUBE ................190
Component .......................................................... .190
Removal and Installation .......................................190
ROCKER COVER .............................................196
Component .......................................................... .196
Removal and Installation .......................................196
TIMING CHAIN .................................................199
Component .......................................................... .199
Removal and Installation .......................................200
CAMSHAFT ......................................................211
Component .......................................................... .211
Removal and Installation .......................................211
Valve Clearance ....................................................218
OIL SEAL ..........................................................222
Removal and Installation of Valve Oil Seal ...........222
Removal and Installation of Front Oil Seal ........... .222
Removal and Installation of Rear Oil Seal ............224
CYLINDER HEAD .............................................226
On-Vehicle Service .............................................. .226
Component ...........................................................227
Removal and Installation .......................................227
Disassembly and Assembly ..................................229
Inspection After Disassembly ................................232
ENGINE ASSEMBLY ..................................... ..237
Component .......................................................... .237
Removal and Installation .......................................237
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EM-34
< SERVICE INFORMATION >[VQ35DE]
OIL PAN AND OIL STRAINER
Tighten mounting bolts in numerical order as shown in the fig-
ure.
There are two types of mounting bolts. Refer to the following
for locating bolts.
f. Tighten transmission joint bolts. Refer to AT-241, "
Removal and Installation (2WD Models)".
2. Install oil strainer to oil pump.
3. Install oil pan (lower) as follows:
a. Use scraper to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of oil pan(upper).
Remove old liquid gasket from the bolt holes and thread.
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket.
b. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the oil pan (lower) as shown in the
figure.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-44, "
Recommended Chemical Product and Sealant".
CAUTION:
Attaching should be done with in 5 minutes after coating.
c. Install oil pan (lower). M8
× 100 mm (3.94 in) : 5, 7, 8, 11
M8 × 25 mm (0.98 in) : Except the above
PBIC0783E
SEM958F
PBIC2657E
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EM-40
< SERVICE INFORMATION >[VQ35DE]
OIL PAN AND OIL STRAINER
d. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to the cylinder block mating surface of
oil pan (upper) to a limited portion as shown in the figure.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-44, "
Recommended Chemical Product and Sealant".
CAUTION:
For bolt holes with marks (5 locations), apply liquid
gasket outside the holes.
Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) in diame-
ter to area “A”.
Attaching should be done wit hin 5 minutes after coating.
e. Install oil pan (upper). CAUTION:
Install avoiding misalignment of both oil pan gasket and O-rings.
Tighten mounting bolts in numerical order as shown in the fig- ure.
There are two types of mounting bolts. Refer to the following
for locating bolts.
f. Tighten transmission joint bolts. Refer to AT-241, "
Removal and Installation (2WD Models)".
3. Install oil strainer to oil pump.
4. Install oil pan (lower) as follows:
a. Use scraper to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of oil pan(upper).
Remove old liquid gasket from the bolt holes and thread.
CAUTION:
Do not scratch or damage the mating surfaces when clean-
ing off old liquid gasket. M8
× 100 mm (3.94 in) : 5, 7, 8, 11
M8 × 25 mm (0.98 in) : Except the above
PBIC2300E
PBIC0783E
SEM958F
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3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
FRONT TIMING CHAIN CASEEM-61
< SERVICE INFORMATION > [VQ35DE]
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e. Tighten mounting bolts to the specified torque in numerical order
as shown in the figure.
There are two types of mounting bolts. Refer to the followingfor locating bolts.
f. After all bolts tightened, retighten them to the specified torque in numerical order as shown in the figure.
6. Install two mounting bolts in front of oil pan (upper) in numerical order as shown in figure.
7. Install oil pan (lower). Refer to EM-30, "
Component (2WD Models)".
8. Install intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
b. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to intake valve timing control covers as
shown in the figure.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-44, "
Recommended Chemical Product and Sealant".
c. Install new collared O-rings in front timing chain case oil hole (left and right sides).
d. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with the holes to install intake valve timing control covers.M8 bolts : 1, 2
: 28.4 N·m (2.9 kg-m, 21 ft-lb)
M6 bolts : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
: 17.2 N·m (1.8 kg-m, 13 ft-lb)
KBIA1303E
PBIC1116E
SBIA0492E
PBIC2631E
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EM-74
< SERVICE INFORMATION >[VQ35DE]
TIMING CHAIN
Apply liquid gasket on installa
tion position of water pump and cylinder head very completely.
d. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block and install rear timing chain case.
Make sure O-rings stay in place during installation to cylinder block and cylinder head.
e. Tighten mounting bolts in numerical order as shown in the fig- ure.
There are two types mounting bolts. Refer to the following forlocating bolts.
f. After all bolts are tightened, retighten them to the s pecified torque in numerical order shown in the figure.
If liquid gasket protrudes, wipe it off immediately.
g. After installing rear timing chain case, check the surface height difference between the following parts on the oil pan (upper)
mounting surface.
If not within the standard, repeat the installation procedure.Bolt length: Bolt position
20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
Standard Rear timing chain case to cylinder block:
–0.24 to 0.14 mm (–0.009 to 0.006 in)
PBIC2680E
SEM735G
SEM943G
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EM-80
< SERVICE INFORMATION >[VQ35DE]
TIMING CHAIN
a. Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to front timing chain case back side as
shown in the figure.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-44, "
Recommended Chemical Product and Sealant".
b. Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case.
c. Tighten mounting bolts to the specified torque in numerical order as shown in the figure.
There are two types of mounting bolts. Refer to the followingfor locating bolts.
d. After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure.
CAUTION:
Be sure to wipe off any excessive liquid gasket l eaking on surface mating with oil pan (upper).
e. After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper)
mounting surface.
If not within the standard, repeat the installation procedure.
15. Install right and left intake valve timing control covers as follows:
a. Install new seal rings in shaft grooves.
PBIC2658E
M8 bolts : 1, 2 : 28.4 N·m (2.9 kg-m, 21 ft-lb)
M6 bolts : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
Standard Front timing chain case to rear timing chain case:
–0.14 to 0.14 mm (–0.006 to 0.006 in)
KBIA1303E
SEM943G
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EM-178
< SERVICE INFORMATION >[VK45DE]
INTAKE MANIFOLD
Check the surface distortion of both the intake manifold (upper and
lower) mating surfaces with straightedge and feeler gauge.
If it exceeds the limit, replac e intake manifolds (lower and/or
upper).
INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold (Lower)
Tighten in numerical order as shown in the figure.
There are two types of mounting bolts. Refer to the following for locating bolts.
Intake Manifold (Upper)
Tighten in numerical order as shown in the figure.
Electric Throttle Control Actuator
Install gasket with its directional protrusion set up/downward.
Tighten mounting bolts of electric throttle cont rol actuator equally and diagonally in several steps.
After installation perform procedure in "INSPECTION AFTER INSTALLATION".
Water Hose
Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
Va c u u m H o s e
Refer to EC-684, "Vacuum Hose Drawing".
INSPECTION AFTER INSTALLATION
Perform the “Throttle Valve Closed Position Learning” when harness connector of electric throttle control
actuator is disconnected. Refer to EC-663, "
Throttle Valve Closed Position Learning".
Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when electric throttle
control actuator is replaced. Refer to EC-663, "
Idle Air Volume Learning".
Limit : 0.1 mm (0.004 in)
PBIC0016E
: Engine front
M8
× 90 mm (3.54 in) : 7, 8
M8 × 35 mm (1.38 in) : Except the above
PBIC3298E
: Engine front
PBIC3297E
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