EM-70
< REMOVAL AND INSTALLATION >
ENGINE ASSEMBLY
1. Install engine slingers into front of cylinder head (bank 1) (3) and
rear of cylinder head (bank 2) (2).
2. Remove power steering oil pump, power steering piping and power steering bracket from engine and tran-
saxle assembly. Refer to ST-34, "
Exploded View".
3. Disconnect vacuum hoses of front engine mounting insulator and rear engine mounting insulator.
4. Lift with hoist the engine and the transaxle assembly and front suspension member.
CAUTION:
Before and during this lifting, always check if any harnesses are left connected.
Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove rear torque rod and rear torque rod bracket.
6. Remove each engine mounting insulator and each engine mounting bracket from engine, transaxle and
front suspension member.
7. Separate engine and transaxle assembly from front suspension member.
CAUTION:
Before and during this lifting, always check if any harnesses are left connected.
Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
8. Separate engine and transaxle assembly. Refer to TM-332, "
Exploded View" (VQ25DE) or TM-168,
"Exploded View" (VQ35DE).
INSTALLATION
Note the following, and install in the reverse order of removal.
CAUTION:
Never allow engine mounting insulator to be damage and careful no oil gets on it.
Check all mounting insulators are seated properly, then tighten mounting nuts and bolts.
Preparation
1. Install the engine mounting bracket (RH) to the engine as follows:
1 : Engine rear slinger
4 : Engine front slinger (upper)
5 : Engine front slinger (lower)
: Engine front
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ENGINE ASSEMBLY
EM-75
< REMOVAL AND INSTALLATION >
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a. Tighten the bolt No. 2 as shown in the figure. (temporarily)
b. Tighten the bolts in numerical order as shown in the figure.
(specified torque)
InspectionINFOID:0000000003802274
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-11, "
Fluids and Lubricants".
Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- 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 check there is no leakage of fuel, exhaust gases, or any oil/fluids including
engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.: Vehicle front
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Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
EM-76
< DISASSEMBLY AND ASSEMBLY >
ENGINE STAND SETTING
DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
SettingINFOID:0000000003802278
NOTE:
Explained here is how to disassemble with engine stand supporting transaxle surface. When using different
type of engine stand, note with difference in steps and etc.
1. Remove the engine assembly from the vehicle. Refer to EM-67, "
Exploded View".
2. Remove the parts that may restrict installation of engine to widely use engine stand.
NOTE:
The procedure is described assuming that you use a widely use engine stand holding the surface, to
which transmission is installed.
Remove drive plate. Fix crankshaft pulley with the pulley holder (commercial service tool), and remove
mounting bolts.
Loosen mounting bolts in diagonal order.
Check for deformation or damage drive plate.
CAUTION:
Never disassemble drive plate.
Never place drive plate with signal plate facing down.
When handling signal plate, take care not to damage or scratch it.
Handle signal plate in a manner that prevents it from becoming magnetized.
3. Remove pilot converter using the pilot bushing puller (SST) as
necessary.
4. Lift the engine with hoist to install it onto the widely use engine stand.
CAUTION:
Use an engine stand that has a load capacity [220 kg (485 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 intake manifold collector. Refer to EM-28, "
Exploded View".
- Remove intake manifold. Refer to EM-32, "
Exploded View".
- Remove fuel injector and fuel tube assembly. Refer to EM-44, "
Exploded View".
- Remove ignition coil. Refer to EM-49, "
Exploded View".
- Remove rocker cover. Refer to EM-49, "
Exploded View".
- Remove exhaust manifold. Refer to EM-34, "
Exploded View".
- Other removable brackets.
NOTE:
SEM005G
ENGINE STAND SETTING
EM-77
< DISASSEMBLY AND ASSEMBLY >
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The figure shows an example of widely use engine stand (A)
that can hold mating surface of transaxle with drive plate
removed.
CAUTION:
Before removing the hanging chains, check the engine
stand is stable and there is no risk of overturning.
5. Drain engine oil. Refer to LU-8, "
Draining".
6. Drain engine coolant by removing water drain plugs (A) and (B)
from cylinder block both sides as shown in the figure.
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C: Plug
D : Connector bolt
Tightening torque : Refer to EM-110, "Disassem-
bly and Assembly".
PBIC2487E
EM-78
< DISASSEMBLY AND ASSEMBLY >
ENGINE UNIT
ENGINE UNIT
DisassemblyINFOID:0000000003802279
1. Remove intake manifold collector. Refer to EM-28, "Exploded View".
2. Remove intake manifold. Refer to EM-32, "
Exploded View".
3. Remove exhaust manifold. Refer to EM-34, "
Exploded View".
4. Remove oil pan (lower). Refer to EM-38, "
Exploded View".
5. Remove ignition coil, spark plug and rocker cover. Refer to EM-49, "
Exploded View".
6. Remove fuel injector and fuel tube. Refer to EM-44, "
Exploded View".
7. Remove timing chain and rear timing chain case. Refer to EM-52, "
Exploded View" and EM-79, "Exploded
View".
8. Remove camshaft. Refer to EM-84, "
Exploded View".
9. Remove cylinder head. Refer to EM-96, "
Exploded View".
AssemblyINFOID:0000000003802280
Assembly in the reverse order of disassembly.
EM-80
< DISASSEMBLY AND ASSEMBLY >
REAR TIMING CHAIN CASE
Disassembly and Assembly
INFOID:0000000003802282
DISASSEMBLY
1. Remove front timing chain case and timing chain. Refer to EM-52, "Exploded View".
2. Remove water pump. Refer to CO-18, "
Exploded View".
3. Remove oil pans (upper and lower) and oil strainer. Refer to EM-38, "
Exploded View".
4. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in reverse order as shown in
the figure.
b . C u t l i q u i d g a s k e t 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)] and remove rear timing chain case.
CAUTION:
Never remove plate metal cover (1) of oil passage.
After removal, handle rear timing chain case carefully so
it does not tilt, cant, or warp under a load.
5. Remove O-rings (1) from cylinder block.
6. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-84, "
Exploded View".
19. Valve timing control cover (bank 1) 20.Intake valve timing control sole-
noid valve (bank 1)21. Seal ring
22. Water pump cover 23. Front oil seal 24. Crankshaft pulley
25. Crankshaft pulley bolt 26.Intake valve timing control sole-
noid valve (bank 2)27. Valve timing control cover (bank 2)
28.Valve timing control cover gasket
(bank 2)
A. Refer to EM-80
Refer to GI-4, "Components" for symbols in the figure.
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: Engine front
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CAMSHAFT
EM-91
< DISASSEMBLY AND ASSEMBLY >
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Check if surface of valve lifter has any wear or cracks.
If anything above is found, replace valve lifter. Refer to EM-136,
"Camshaft".
Valve Lifter Clearance
VALVE LIFTER OUTER DIAMETER Measure the outer diameter at 1/2 height of valve lifter with a
micrometer (A) since valve lifter is in barrel shape.
VALVE LIFTER HOLE DIAMETER Measure the inner diameter of valve lifter hole of cylinder head with
an inside micrometer.
VALVE LIFTER CLEARANCE (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter)
If the calculated value is out of the standard, referring to each standard of valve lifter outer diameter and
valve lifter hole diameter, replace either or both valve lifter and cylinder head.
INSPECTION AFTER INSTALLATION
Inspection of Camshaft Sprocket (INT) Oil Groove
CAUTION:
Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-III
and it is directed according to inspection procedure of EC section. Refer to EC-137, "
Diagnosis Pro-
cedure".
Check when engine is cold so as to prevent burns from the splashing engine oil.
1. Check engine oil level. Refer to LU-7, "
Inspection".
2. Perform the following procedure so as to prevent the engine from being unintentionally started while
checking.
a. Release the fuel pressure. Refer to EC-411, "
Inspection".
KBIA0182E
Standard
: Refer to EM-136, "Camshaft".
(Intake and exhaust)
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Standard
: Refer to EM-136, "Camshaft".
(Intake and exhaust)
SEM867E
Standard
: Refer to EM-136, "Camshaft".
(Intake and exhaust)
EM-92
< DISASSEMBLY AND ASSEMBLY >
CAMSHAFT
b. Disconnect ignition coil and injector harness connectors. Refer to EM-49, "Exploded View" and EM-44,
"Exploded View".
3. Remove intake valve timing control solenoid valve. Refer to EM-79, "
Exploded View".
4. Crank engine, and then check that engine oil comes out from
intake valve timing control solenoid valve hole (A). End crank
after checking.
WARNING:
Be careful not to touch rotating parts. (drive belt, idler pul-
ley, and crankshaft pulley, etc.)
CAUTION:
Prevent splashing by using a shop cloth so as to prevent
the worker from injury from engine oil and so as to prevent engine oil contamination.
Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to
engine and vehicle. Especially, be careful no to apply engine oil to rubber parts of drive belt,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
5. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid
valve oil hole of the cylinder head.
Remove oil filter, and then clean it. Refer to LU-10, "
Removal and Installation".
Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-2,
"EngineLubricationSystem".
6. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT),
and then check each oil groove for clogging.
Clean oil groove if necessary. Refer to LU-2, "
EngineLubricationSystem".
7. After inspection, install removed parts in the reverse order.
Inspection for Leakage
The following are procedures for checking fluids leak, lubricates leak. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-11, "
Fluids and Lubricants".
Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may
generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after
hydraulic pressure rises.
Warm up engine thoroughly to check there is no leakage of fuel, or any oil/fluids including engine oil and
engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
*: Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.1 : Valve timing control cover (bank 2)
: Engine front
JPBIA1783ZZ
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage