EM-6
< PRECAUTION >
PRECAUTIONS
3. Disconnect both battery cables. The steering lock will remain released with both battery cables discon-
nected and the steering wheel can be turned.
4. Perform the necessary repair operation.
5. When the repair work is completed, re-connect both battery cables. With the brake pedal released, turn
the push-button ignition switch from ACC position to ON position, then to LOCK position. (The steering
wheel will lock when the push-button ignition switch is turned to LOCK position.)
6. Perform self-diagnosis check of all control units using CONSULT-III.
Precaution for Drain Engine Coolant and Engine OilINFOID:0000000003802227
Drain engine coolant and engine oil when the engine is cooled.
Precaution for Disconnecting Fuel PipingINFOID:0000000003802228
Before starting work, check no fire or spark producing items are in the work area.
Release fuel pressure before disconnecting and disassembly.
After disconnecting pipes, plug openings to stop fuel leakage.
Precaution for Removal and DisassemblyINFOID:0000000003802229
When instructed to use SST, use the specified tools. Always be careful to work safely, avoid forceful or unin-
structed operations.
Exercise maximum care to avoid damage to mating or sliding surfaces.
Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins,
check that dowel pins are installed in the original position.
Cover openings of engine system with a tape or the equivalent, if necessary, to seal out foreign materials.
Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used
in the step.
Precaution for Inspection, Repair and ReplacementINFOID:0000000003802230
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precaution for Assembly and InstallationINFOID:0000000003802231
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,
check 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 remove 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:0000000003802232
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 angle
tightening)
Never use a torque value for final tightening.
The torque value for these parts are for a preliminary step.
PRECAUTIONS
EM-7
< PRECAUTION >
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Ensure thread and seat surfaces are clean and coated with engine oil.
Precaution for Liquid GasketINFOID:0000000003802233
REMOVAL OF LIQUID GASKET SEALING
After removing mounting nuts and bolts, separate the mating sur-
f a c e u s i n g t h e s e a l c u t t e r [ S S T: K V 1 0 1111 0 0 ( J37228)] (A) and
remove old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.
Tap the seal cutter [SST: KV10111100 (J37228)] to insert it (B), and
then slide it (C) by tapping on the side as shown in the figure.
In areas where the seal cutter [SST: KV10111100 (J37228)] is diffi-
cult to use, use a plastic hammer 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 (A), 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.
3. Attach liquid gasket tube to the tube presser (commercial ser-
vice tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply liquid gasket without breaks to the specified location with
the specified dimensions.
If there is a groove for liquid gasket application, apply liquid
gasket to the groove.
As for bolt holes, normally apply liquid gasket inside the holes.
Occasionally, it should be applied outside the holes. Check to
read the text of this manual.
Within 5 minutes of liquid gasket application, install the mating
component.
If liquid gasket protrudes, wipe it off immediately.
Never retighten mounting bolts or nuts after the installation.
After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe
them.
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EMA0622D
SEM159F
DRIVE BELT
EM-13
< ON-VEHICLE MAINTENANCE >
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3. Hold the hexagonal part in center of drive belt auto-tensioner
pulley with a box wrench securely. Then move the wrench han-
dle in the direction of arrow (loosening direction of drive belt).
CAUTION:
Avoid placing hand in a location where pinching may
occur if the holding tool accidentally comes off.
Never loosen the hexagonal part in center of drive belt
auto-tensioner pulley (Never turn it counterclockwise). If
turned counterclockwise, the complete drive belt auto-
tensioner must be replaced as a unit, including the pulley.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as
short-length screwdriver into the hole (A) of the retaining boss to
fix drive belt auto-tensioner pulley.
Keep drive belt auto-tensioner pulley arm locked after drive belt is removed.
5. Loosen drive belt from water pump pulley in sequence, and remove it.
INSTALLATION
1. Hook drive belt on to all pulleys except for drive belt auto-tensioner pulley, and then onto drive belt auto-
tensioner pulley finally.
CAUTION:
Confirm drive belt is completely set to pulleys.
Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each
pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator is within the possible use range. Refer to EM-12, "
Exploded
View".
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INTAKE MANIFOLD COLLECTOR
EM-29
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Removal and InstallationINFOID:0000000003802254
REMOVAL
WARNING:
To avoid the danger of being scalded, never drain engine coolant when the engine is hot.
1. Remove engine cover. Refer to EM-24, "
Exploded View".
CAUTION:
Be careful not to damage or scratch engine cover.
1. Vacuum hose 2. Clamp 3. Clamp
4. PCV hose 5. Intake manifold collector 6. Gasket
7. Vacuum hose 8. Bracket 9.Electronic controlled engine mount
control solenoid valve
10. Vacuum hose 11. Vacuum hose 12. Vacuum hose
13. Vacuum gallery 14. Vacuum hose 15. Vacuum hose
16. VIAS control solenoid valve 2 17. VIAS control solenoid valve 1 18.EVAP canister purge control solenoid
valve
19. Clamp 20. EVAP hose 21. Service port
22. Bracket 23. EVAP hose 24. EVAP hose
25. EVAP pipe 26. EVAP hose 27. Clamp
28. Water hose 29. Water hose 30. Bracket
31. Electric throttle control actuator 32. Gasket
A. To brake booster B. To rocker cover (bank 1) C. To vacuum tube (rear)
D. To vacuum pipe E. To heater pipe F. To water outlet
: Engine front
Refer to GI-4, "
Components" for symbols in the figure.
JPBIA1713GB
EM-30
< ON-VEHICLE REPAIR >
INTAKE MANIFOLD COLLECTOR
2. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly. Refer to
EM-26, "
Exploded View".
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-8, "
Draining".
CAUTION:
Perform this step when the engine is cold.
4. Remove front wiper arm and extension cowl top. Refer to WW-105, "
Exploded View" and EXT-20,
"Exploded View".
5. Disconnect water hoses from electric throttle control actuator.
When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant
leakage.
6. Remove electric throttle control actuator as follows:
a. Disconnect harness connector.
b. Loosen mounting bolts in reverse order as shown in the figure.
CAUTION:
Handle carefully to avoid any shock to electric throttle
control actuator.
Never disassemble.
7. Remove the following parts:
Vacuum hose
PCV hose
High pressure piping from intake manifold collector: Refer to ST-34, "
Exploded View".
Electronic controlled engine mount control solenoid valve
8. Disconnect EVAP hoses and harness connector from EVAP canister purge control solenoid valve.
9. Remove EVAP canister purge control solenoid valve and bracket assembly.
10. Remove VIAS control solenoid valve mounting bolts and vacuum gallery mounting bolts, and then move
vacuum gallery.
Add mating marks as necessary for easier installation.
11. Loosen mounting nuts and bolts in reverse order as shown in
the figure, and remove intake manifold collector and gasket.
CAUTION:
Cover engine openings to avoid entry of foreign materials.
NOTE:
Figure is shown as an example of VQ35DE.
INSTALLATION
Note the following, and install in the reverse order of removal.
Intake Manifold Collector
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: Engine front
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EM-38
< ON-VEHICLE REPAIR >
OIL PAN AND OIL STRAINER
OIL PAN AND OIL STRAINER
Exploded ViewINFOID:0000000003802261
Removal and InstallationINFOID:0000000003802262
REMOVAL
CAUTION:
To avoid the danger of being scalded, never drain engine oil when the engine is hot.
NOTE:
When removing oil pan (lower) or oil strainer only, take step 1 then step 18 and 19.
1. Drain engine oil. Refer to LU-8, "
Draining".
CAUTION:
Never spill engine oil on drive belt.
2. Drain engine coolant. Refer to CO-8, "
Draining".
CAUTION:
Never spill engine coolant on drive belt.
3. Remove following parts:
Front road wheel and tires (RH and LH)
1. Oil pan (upper) 2. O-ring 3. Oil pan gasket (front)
4. Relief valve 5. Oil pressure switch 6. Oil cooler
7. Connector bolt 8. Oil filter 9. Oil strainer
10. Drain plug 11. Drain plug washer 12. Oil pan (lower)
13. Rear plate cover 14. Crankshaft position sensor (POS) 15. Oil pan gasket (rear)
A. Refer to LU-10
B. To oil pump C. Oil pan side
Refer to GI-4, "
Components" for symbols in the figure.
JPBIA1636GB
EM-44
< ON-VEHICLE REPAIR >
FUEL INJECTOR AND FUEL TUBE
FUEL INJECTOR AND FUEL TUBE
Exploded ViewINFOID:0000000003802264
CAUTION:
Never remove or disassemble parts unless instructed as shown in the figure.
Removal and InstallationINFOID:0000000003802265
REMOVAL
WARNING:
Put a “CAUTION: FLAMMABLE” sign in the workshop.
Be sure to work in a well ventilated area and furnish workshop with a CO
2 fire extinguisher.
Never smoke while servicing fuel system. Keep open flames and sparks away from the work area.
To avoid the danger of being scalded, never drain engine coolant when engine is hot.
1. Remove air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct assem-
bly. Refer to EM-26, "
Exploded View".
2. Remove engine cover. Refer to EM-24, "
Exploded View".
3. Release the fuel pressure. Refer to EC-411, "
Inspection".
4. Remove front wiper arm and extension cowl top. Refer to WW-105, "
Exploded View" and EXT-20,
"Exploded View".
1. Fuel feed hose 2. Quick connector cap 3. Fuel tube
4. O-ring 5. Fuel damper 6. Fuel damper cap
7. Clip 8. O-ring (black) 9. Fuel injector
10. O-ring (green)
A. Refer to EM-44
Refer to GI-4, "Components" for symbols in the figure.
JPBIA1714GB
FUEL INJECTOR AND FUEL TUBE
EM-45
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5. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leak-
age. Refer to CO-8, "
Draining" or EM-28, "Exploded View".
CAUTION:
Perform this step when the engine is cold.
6. Remove intake manifold collector. Refer to EM-28, "
Exploded View".
7. When separating fuel feed hose and fuel tube connection, disconnect quick connector as follows:
a. Remove quick connector cap from quick connector.
b. Disconnect quick connector from fuel tube as follows:
CAUTION:
Disconnect quick connector by using the quick connector release [SST: — (J-45488)], not by pick-
ing out retainer tabs.
i. With the sleeve side of quick connector release facing to quick connector, install the quick connector
release onto fuel tube.
ii. Insert the quick connector release (A) into quick connector (2)
until sleeve (B) contacts and goes no further. Hold quick connec-
tor release on that position.
CAUTION:
Inserting quick connector release hard will not disconnect
quick connector. Hold quick connector release where it
contacts and goes no further.
iii. Draw and pull out quick connector straight from fuel tube (1).
CAUTION:
Pull quick connector (E) holding position (D) as shown in
the figure.
Never pull with lateral force applied. O-ring inside quick connector may be damaged.
Prepare container and cloth beforehand as fuel will leak out.
Avoid fire and sparks.
Keep parts away from heat source. Especially, be careful when welding is performed around
them.
Never expose parts to battery electrolyte or other acids.
Never bend or twist connection between quick connector and fuel feed hose (with damper) dur-
ing installation/removal.
To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags, etc. (A) or something similar.
8. Disconnect harness connector from fuel injector.
C : Insert and retain
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