Page 1922 of 5121

FUEL INJECTOR AND FUEL TUBE
EM-47
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Upper and lower O-ring are different. Be careful not to confuse them.
Handle O-ring with bare hands. Never wear gloves.
Lubricate O-ring with new engine oil.
Never clean O-ring with solvent.
Check that O-ring and its mating part are free of foreign material.
When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to
twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly
into fuel tube.
Insert O-ring straight into fuel injector. Never decenter or twist it.
3. Install fuel injector to fuel tube as follows:
a. Insert clip (3) into clip mounting groove (F) on fuel injector (5).
Insert clip so that protrusion (E) of fuel injector matches cutout
(C) of clip.
CAUTION:
Never reuse clip. Replace it with new one.
Be careful to keep clip from interfering with O-ring. If
interference occurs, replace O-ring.
b. Insert fuel injector into fuel tube (1) with clip attached.
Insert it while matching it to the axial center.
Insert fuel injector so that protrusion (A) of fuel tube matches
cutout (B) of clip.
Check that fuel tube flange (G) is securely fixed in flange fixing
groove (D) on clip.
c. Check that installation is complete by checking that fuel injector
does not rotate or come off.
Check that protrusions of fuel injectors and fuel tubes are
aligned with cutouts of clips after installation.
4. Install fuel tube and fuel injector assembly to intake manifold.
CAUTION:
Be careful not to let tip of injector nozzle come in contact with other parts.
Tighten mounting bolts in two steps in numerical order as
shown in the figure.
5. Connect fuel injector harness.
6. Install intake manifold collector. Refer to EM-28, "
Exploded View".
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure:
a. Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage
on them.
b. Thinly apply new engine oil around fuel tube from tip end to spool end.Fuel tube side : Black
Nozzle side : Green
2 : O-ring (black)
4 : O-ring (green)
JPBIA1959ZZ
: Engine front
1st step: 10.1 N·m (1.0 kg-m, 7 ft-lb)
2nd step: 22.0 N·m (2.2 kg-m, 16 ft-lb)
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Page 1923 of 5121

EM-48
< ON-VEHICLE REPAIR >
FUEL INJECTOR AND FUEL TUBE
c. Align center to insert quick connector straightly into fuel tube.
Insert quick connector (1) to fuel tube until top spool (2) is
completely inside quick connector, and 2nd level spool (3)
exposes right below quick connector.
CAUTION:
Hold (A) position as shown in the figure when inserting
fuel tube into quick connector.
Carefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
Insert until you hear a “click” sound and actually feel the engagement.
To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
d. Pull quick connector by hand holding (A) position. Check it is
completely engaged (connected) so that it does not come out
from fuel tube (2).
e. Install quick connector cap (3) to quick connector.
Install quick connector cap with arrow on surface facing in
direction of quick connector (fuel feed hose side).
CAUTION:
If quick connector cap cannot be installed smoothly, quick
connector may have not been installed correctly. Check connection again.
f. Secure fuel feed hose to clamp of quick connector cap.
8. Install in the reverse order of removal after this step.
InspectionINFOID:0000000003802266
INSPECTION AFTER INSTALLATION
Check on Fuel Leakage
1. Turn ignition switch “ON” (with the engine stopped). With fuel pressure applied to fuel piping, check there
are no fuel leakage at connection points.
NOTE:
Use mirrors for checking at points out of clear sight.
2. Start the engine. With engine speed increased, check again that there are no fuel leakage at connection
points.
CAUTION:
Never touch the engine immediately after stopped, as the engine becomes extremely hot.
B : Fitted condition
: Upright insertion
1 : Fuel feed hose
B : Upper view
JPBIA0275ZZ
JPBIA0039ZZ
Page 1926 of 5121

IGNITION COIL, SPARK PLUG AND ROCKER COVER
EM-51
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1. Apply liquid gasket to the position shown in the figure with the
following procedure:
Use Genuine Liquid Gasket or equivalent.
a. Refer to figure (E) to apply liquid gasket to joint part of camshaft
bracket (No. 1) (1) and cylinder head.
b. Refer to figure (H) to apply liquid gasket in 90 degrees to figure.
2. Install rocker cover gasket to rocker cover.
3. Install rocker cover.
Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
4. Tighten bolts in two steps separately in numerical order as
shown in the figure.
5. Install in the reverse order of removal after this step.
A : Liquid gasket application point
F: View F
b: 4 mm (0.16 in)
c: φ2.5 - 3.5 mm (0.098 - 0.138 in)
d: 5 mm (0.20 in)
g : 10 mm (0.39 in)
I : End surface of camshaft bracket (No. 1)
: Engine front
JPBIA0274ZZ
: Engine front
1st step: 1.96 N·m (0.2 kg-m, 17 in-lb)
2nd step: 8.33 N·m (0.85 kg-m, 74 in-lb)
JPBIA1634ZZ
Page 1929 of 5121

EM-54
< ON-VEHICLE REPAIR >
TIMING CHAIN
b. Check that intake and exhaust cam noses on No. 1 cylinder
(engine front side of bank 1) are located as shown in the figure.
If not, turn crankshaft one revolution (360 degrees) and align
as shown in the figure.
10. Remove crankshaft pulley as follows:
a. Fix crankshaft with the pulley holder (commercial service tool)
(A).
b. Loosen crankshaft pulley bolt and locate bolt seating surface at
10 mm (0.39 in) from its original position.
CAUTION:
Never remove crankshaft pulley bolt as it will be used as a
supporting point for suitable puller.
c. Place suitable puller tab on holes of crankshaft pulley, and pull
crankshaft pulley through.
CAUTION:
Never put suitable puller tab on crankshaft pulley periphery,
as this will damage internal damper.
11. Remove front timing chain case as follows:
a. Loosen mounting bolts in reverse order as shown in the figure.
: Engine front
JPBIA0044ZZ
1 : Crankshaft pulley
PBIC3961E
SEM915E
JPBIA1640ZZ
Page 1936 of 5121
TIMING CHAIN
EM-61
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a. Install crankshaft sprocket (1).
Check the mating marks on crankshaft sprocket face the front
of the engine.
b. Install timing chain (primary).
Install timing chain (primary) so the mating mark (punched) on
camshaft sprocket (INT) is aligned with the pink link on timing
chain, while the mating mark (notched) on crankshaft sprocket
is aligned with the orange one on timing chain, as shown in the
figure.
When it is difficult to align mating marks of timing chain (pri-
mary) with each sprocket, gradually turn camshaft using
wrench on the hexagonal portion to align it with the mating
marks.
During alignment, be careful to prevent dislocation of mating
mark alignments of timing chains (secondary).
6. Install internal chain guide, slack guide and timing chain ten-
sioner (primary).
A : Crankshaft side
B : Engine front side
C : Mating mark (Front side)
JPBIA0273ZZ
PBIC3494E
PBIC2109E
Page 1937 of 5121

EM-62
< ON-VEHICLE REPAIR >
TIMING CHAIN
CAUTION:
Never overtighten slack guide mounting bolt (2). It is nor-
mal for a gap (A) to exist under the bolt seat when mounting
bolt is tightened to specification.
7. Install the timing chain tensioner (primary) with the following procedure:
a. Pull plunger stopper tab (A) up (or turn lever downward) so as to
remove plunger stopper tab from the ratchet of plunger (D).
NOTE:
Plunger stopper tab and lever (C) are synchronized.
b. Push plunger into the inside of tensioner body.
c. Hold plunger in the fully compressed position by engaging
plunger stopper tab with the tip of ratchet.
d. To secure lever, insert stopper pin (E) through hole of lever into
tensioner body hole (B).
The lever parts and the tab are synchronized. Therefore, the
plunger will be secured under this condition.
NOTE:
Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.
e. Install timing chain tensioner (primary) (1).
Remove any dirt and foreign materials completely from the
back and the mounting surfaces of timing chain tensioner (pri-
mary).
f. Pull out stopper pin (A) after installing, and then release plunger.
8. Check again that the mating marks on each sprocket and each timing chain have not slipped out of align-
ment.
9. Install new O-rings (1) on rear timing chain case.
10. Install new front oil seal on front timing chain case.
Apply new engine oil to both oil seal lip and dust seal lip.
1 : Slack guide
3 : Cylinder block
JPBIA0117ZZ
JPBIA0118ZZ
JPBIA0119ZZ
A: Bank 1
B: Bank 2
JPBIA1111ZZ
Page 1938 of 5121
TIMING CHAIN
EM-63
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Install it so that each seal lip is oriented as shown in the figure.
Using a suitable drift [outer diameter: 60 mm (2.36 in)], press-
fit oil seal until it becomes flush with front timing chain case
end face.
Check the garter spring is in position and seal lip is not
inverted.
11. Install water pump cover to front timing chain case.
Apply a continuous bead of liquid gasket with the tube presser
(commercial service tool) to water pump cover (1) as shown in
the figure.
Use Genuine Liquid Gasket or equivalent.
12. Install front timing chain case as follows:
A: Oil seal lip
B : Dust seal lip
: Engine inside
: Engine outside
JPBIA0054ZZ
PBIC0790E
a: φ2.3 - 3.3 mm (0.091 - 0.130 in)
JPBIA1722ZZ
Page 1940 of 5121

TIMING CHAIN
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c. Tighten mounting bolts in numerical order as shown in the fig-
ure.
14. Install crankshaft pulley as follows:
a. Install crankshaft pulley, taking care not to damage front oil seal.
When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference).
b. Fix crankshaft with the pulley holder (commercial service tool).
c. Tighten crankshaft pulley bolt.
d. Place a paint mark (A) on crankshaft pulley (1) aligning with the
angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90
degrees (angle tightening).
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns
smoothly.
16. Install in the reverse order of removal after this step.
InspectionINFOID:0000000003802271
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and any excessive wear at link plates and roller
links of timing chain. Replace timing chain as necessary.
INSPECTION AFTER INSTALLATION
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".
A: Bank 1
B: Bank 2
C : Dowel pin hole
JPBIA1639ZZ
: 44.1 N·m (4.5 kg-m, 33 ft-lb)
PBIC4627J
A: Crack
B: Wear
JPBIA0091ZZ