EI-8
< SERVICE INFORMATION >
SQUEAK AND RATTLE TROUBLE DIAGNOSES
Most of these incidents can be repaired by adjusting, securing or insulating the item(s) or component(s) caus-
ing the noise.
SUNROOF/HEADLINING
Noises in the sunroof/headlining area c an often be traced to one of the following:
1. Sunroof lid, rail, linkage or seals making a rattle or light knocking noise
2. Sun-visor shaft shaking in the holder
3. Front or rear windshield touching headlining and squeaking
Again, pressing on the components to stop the noise while duplicating the conditions can isolate most of these
incidents. Repairs usually consist of insulating with felt cloth tape.
SEATS
When isolating seat noise it's important to note the pos ition the seat is in and the load placed on the seat when
the noise is present. These conditions should be dupl icated when verifying and isolating the cause of the
noise.
Cause of seat noise include:
1. Headrest rods and holder
2. A squeak between the seat pad cushion and frame
3. The rear seatback lock and bracket
These noises can be isolated by moving or pressing on the suspected components while duplicating the con-
ditions under which the noise occurs. Most of thes e incidents can be repaired by repositioning the component
or applying urethane tape to the contact area.
UNDERHOOD
Some interior noise may be caused by components under the hood or on the engine wall. The noise is then
transmitted into the passenger compartment.
Causes of transmitted under-hood noise include:
1. Any component mounted to the engine wall
2. Components that pass through the engine wall
3. Engine wall mounts and connectors
4. Loose radiator mounting pins
5. Hood bumpers out of adjustment
6. Hood striker out of adjustment
These noises can be difficult to isolate since they cannot be reached from the interior of the vehicle. The best
method is to secure, move or insulate one component at a time and test drive the \
vehicle. Also, engine RPM
or load can be changed to isolate the noise. Repairs can usually be made by moving, adjusting, securing, or
insulating the component causing the noise.
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
PRECAUTIONSEM-5
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Precaution for Assembly and InstallationINFOID:0000000001325697
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.
Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, make sure that dowel pins are installed in the original position.
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 re move 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 Angle TighteningINFOID:0000000001325698
Use the angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap bolts
- Crankshaft pulley bolt (No the angle wrench is required as bolt flange is provided with notches for angletightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid GasketINFOID:0000000001325699
REMOVAL OF LIQUID GASKET SEALING
After removing mounting nuts and bolts, separate the mating sur- face using the seal cutter (SST) and remove old liquid gasket seal-
ing.
CAUTION:
Be careful not to damage the mating surfaces.
Tap the seal cutter to insert it, and then slide it by tapping on the side as shown in the figure.
In areas where the seal cutter is difficult to use, use a plastic ham-
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reason tool such as a screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove old liquid gasket adhering to the gasket application surface and the mating surface.
Remove liquid gasket completely from the groove of the gas-
ket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur- face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0002E
PBIC0003E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
TIMING CHAINEM-69
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29. Remove internal chain guide, tension guide and slack guide.
NOTE:
Tension guide can be removed after removing timing chain (pri-
mary).
30. Remove timing chain (primary) and crankshaft sprocket. CAUTION:
After removing timing chain (primary), do not tu rn crankshaft and camshaft separately, or valves
will strike th e piston heads.
31. Remove timing chain (secondary) and camshaft sprockets as follows:
a. Attach suitable stopper pin to the right and left timing chain ten- sioners (secondary).
NOTE:
Use approximately 0.5 mm (0.020 in) dia. hard metal pin as astopper pin.
For removal of timing chain tensioner (secondary), refer to
EM-83, "
Component". [Removing camshaft bracket (No. 1) is
required.]
b. Remove camshaft sprocket (INT and EXH) mounting bolts. Secure the hexagonal portion of camshaft using a wrench to
loosen mounting bolts.
CAUTION:
Do not loosen the mounting bolts with securing anything
other than the camshaft hexagonal portion or with ten-
sioning the timing chain.
c. Remove timing chain (secondary) together with camshaft sprockets. Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side.
PBIC2266E
PBIC2047E
KBIA1698J
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
CYLINDER HEADEM-107
< SERVICE INFORMATION > [VQ35DE]
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8. Install valve collet.
Compress valve spring with the valve spring compressor, theattachment and the adapter (SST). Install valve collet with a
magnet hand.
CAUTION:
When working, take care not to damage valve lifter holes.
Tap valve stem edge lightly with plastic hammer after installa- tion to check its installed condition.
9. Install valve lifter. Install it in the original position.
10. Install spark plug tube. Press-fit spark plug tube as follows:
a. Remove old liquid gasket adhering to cylinder head mounting hole.
b. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side.
Use Genuine High Strength Locking Sealant or equivalent. Refer to GI-44
.
c. Using drift, press-fit spark plug tube so that its height “H” is as specified in the figure.
CAUTION:
When press-fitting, take care not to deform spark plugtube.
After press-fitting, wipe o ff liquid gasket protruding onto
cylinder-head upper face.
11. Install spark plug with spark plug wrench (commercial service tool).
Inspection After DisassemblyINFOID:0000000001325741
VALVE DIMENSIONS
Check the dimensions of each valv e. For the dimensions, refer to EM-149, "Standard and Limit".
If dimensions are out of the standard, replace valve and check valve seat contact. Refer to "VALVE SEAT
CONTACT".
VALVE GUIDE CLEARANCE
Valve Stem Diameter
Measure the diameter of va lve stem with micrometer.
Valve Guide Inner Diameter
Measure the inner diameter of valve guide with an inside micrometer.
PBIC1803E
Standard press-fit height “H”:
: 38.1 - 39.1 mm (1.500 - 1.539 in)
PBIC2638E
StandardIntake : 5.965 - 5.980 mm (0.2348 - 0.2354 in)
Exhaust : 5.955 - 5.970 mm (0.2344 - 0.2350 in)
SEM938C
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3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-146
< SERVICE INFORMATION >[VQ35DE]
CYLINDER BLOCK
If the calculated value exceeds the limit, select
proper connecting rod bearing according to connecting rod
big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to
EM-134, "
How to Select Piston and Bearing".
Method of Using Plastigage
Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely.
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 connecting rod bearing cap, and tighten connecting rod bolts to the specified torque. Refer to EM-123, "
Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
Do not rotate crankshaft.
Remove connecting rod 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 limit is
same as that described in the “Method by Calculation”.
MAIN BEARING OIL CLEARANCE
Method by Calculation
Install main bearings to cylinder block and main bearing caps, and
tighten main bearing cap bolts with main bearing beam to the
specified torque. Refer to EM-123, "
Disassembly and Assembly"
for the tightening procedure.
Measure the inner diameter of main bearing with a bore gauge.
(Oil clearance) = (Main bearing inner diameter) – (Crankshaft main
journal diameter)
If the calculated value exceeds the limit, select proper main bearing according to main bearing inner diame-
ter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to EM-134,
"How to Select Piston and Bearing".
Method of Using Plastigage
Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely.
Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil
holes.
Install main bearing to cylinder block and main bearing cap, and tighten main bearing bolts with main bear-
ing beam to the specified torque. Refer to EM-123, "
Disassembly and Assembly" for the tightening proce-
dure.
CAUTION:
Never rotate crankshaft.
PBIC1149E
Standard : 0.035 - 0.045 mm (0.0014 - 0.0018 in)
(actual clearance)
Limit : 0.065 mm (0.0026 in)
PBIC1644E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
PRECAUTIONSEM-161
< SERVICE INFORMATION > [VK45DE]
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Precaution for Assembly and InstallationINFOID:0000000001325756
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.
Guide pins are used for several parts alignment. When replacing and reassembling parts with guide pins, make sure that guide pins are installed in the original portion.
Avoid damaging sliding or mating surfaces. Completely re move 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 engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust gases for leakage.
Parts Requiring Angle TighteningINFOID:0000000001325757
Use angle wrench [SST: KV10112100 (BT8653-A)] for the final tightening of the following engine parts:
- Cylinder head bolts
- Main bearing cap bolts
- Connecting rod cap nuts
- Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angletightening)
Do not use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid GasketINFOID:0000000001325758
REMOVAL OF LIQUID GASKET SEALING
After removing mounting nuts and bolts, separate the mating sur- face using seal cutter (SST) and remove old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
Tap seal cutter to insert it, and then slide it by tapping on the side
as shown in the figure.
In areas where seal cutter (SST) is difficult to use, use plastic ham-
mer to lightly tap the parts, to remove it.
CAUTION:
If for some unavoidable reaso n tool such as screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using scraper, remove old liquid gasket adhering to the liquid gasket application surface and the mating surface.
Remove liquid gasket completely from the groove of the liquid
gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating sur- face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
PBIC0002E
PBIC0003E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
TIMING CHAINEM-203
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NOTE:
To remove timing chain and related parts, start with those on left bank. The procedure for removing parts
on right bank is omitted because it is
the same as that for left bank.
a. Press tab in the direction of arrow (or turn lever in the direction of arrow) to unlock the locking with the groove that stops ten-
sioner plunger from returning.
Lightly press tensioner plunger to release the tension of springfor this operation.
b. Push in tensioner plunger to align the hole on lever and that on pump main body.
Pushing in tensioner too far does not allow the holes to align.Therefore, push in plunger to the degree at which the start of
stopper groove and tab engages.
c. Insert stopper pin [hard wire with approx. 0.5 mm (0.020 in) diameter or similar tool] to fix plunger. With plunger fixed,
remove chain tensioner.
17. Remove chain tension guide and timing chain slack guide.
18. Remove timing chain and crankshaft sprocket. CAUTION:
After removing timing chain, do not turn cranksh aft and camshaft separately, or valves will strike
the piston head.
19. With hexagonal part of camshaft locked with wrench, loosen mounting bolts securing camshaft sprocket to remove camshaft
sprocket.
CAUTION:
Do not loosen mounting bolts with securing anything other
than the camshaft hexagonal porti on or with tensioning the
timing chain.
20. Perform same procedure as for left bank, remove timing chain and related parts on right side.
21. Use scraper to remove all traces of old liquid gasket from front cover and opposite mating surfaces. Remove oil liquid gasket from bolt hole and thread.
22. Use scraper to remove all trace of liquid gasket from chain tensioner cover and intake valve timing control covers.
INSPECTION AFTER REMOVAL
Timing Chain
PBIC2343E
PBIC0030E
PBIC2084E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C
EM-206
< SERVICE INFORMATION >[VK45DE]
TIMING CHAIN
4. Install timing chains and related parts.
Align the mating mark on each sprocket and timing chain for installation.NOTE:
Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for
that on each sprocket for alignment.
CAUTION:
For the above reason, after the mating marks ar e aligned, keep them aligned by holding them
with a hand.
Install slack guides and tension guides onto correct si de by checking with identification mark on surface.
Install chain tensioner with plunger fixed as described in its removal.
CAUTION:
Before and after the installation of chain tens ioner, make sure that the mating mark on timing
chain is not out of alignment.
After installing chain tensioner, remove stoppe r pin to release tensioner. Make sure tensioner
is released.
To avoid chain-link skipping of timing chain, do not move crankshaft or camshafts until front
cover is installed.
5. Perform the same procedure as for right bank, install timing chain and related parts on left side.
6. Install oil pump. Refer to LU-29
.
7. Install oil pump drive spacer as follows:
a. Insert oil pump drive spacer according to the directions of crank- shaft key and the two flat surfaces of oil pump inner rotor.
If the positional relationship does not allow the insertion, rotate
oil pump inner rotor with a finger to allow spacer.
b. After confirming that the position of each part is in correct condi- tion to allow for spacer, force fit spacer by lightly tapping with
plastic hammer until it contacts and does not go further.
8. Install front oil seal on front cover. Apply new engine oil to both oil seal lip and dust seal lip.
PBIC2344E
PBIC0058E
3AA93ABC3ACD3AC03ACA3AC03AC63AC53A913A773A893A873A873A8E3A773A983AC73AC93AC03AC3
3A893A873A873A8F3A773A9D3AAF3A8A3A8C3A863A9D3AAF3A8B3A8C