
EM-116
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
If there is stamped mark on ring, mount it with marked side up.
NOTE:
If there is no stamp on ring, no specific orientation is required
for installation.
Position each ring with the gap as shown in the figure referring
to the piston front mark (D).
Check the piston rings side clearance. Refer to EM-119, "
Inspection".
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap.
CAUTION:
Be careful not to drop connecting rod bearing, and to scratch the surface.
Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply
engine oil to the back surface, but thoroughly clean it.
When installing, align connecting rod bearing stopper protru-
sion (B) with cutout (C) of connecting rod and connecting rod
bearing cap to install.
Ensure the oil hole (A) on connecting rod and that on the cor-
responding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft.
Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center.
Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal.
Match the cylinder position with the cylinder number on connecting rod to install.
Be sure that front mark on piston crown is facing front of engine.
Using a piston ring compressor [SST: EM03470000 (J8037)]
(A) or suitable tool, install piston with the front mark on the pis-
ton crown facing the front of the engine.
CAUTION:
Be careful not to damage the cylinder wall and crankshaft
pin, resulting from an interference of the connecting rod big
end.Stamped mark: VQ25DE VQ35DE
To p r i n g ( A ) : R : —
Second ring (B) : R 2 : 2 R
JPBIA0263ZZ
C : Top ring gap
E : Oil ring upper or lower rail gap (either of then)
F : Second ring and oil ring spacer gap
a : 90 degrees
b : 45 degrees
JPBIA0205ZZ
JPBIA0206ZZ
JPBIA0207ZZ

CYLINDER BLOCK
EM-117
< DISASSEMBLY AND ASSEMBLY >
C
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13. Install connecting rod bearing cap.
Match the stamped cylinder number marks on connecting rod
with those on connecting rod bearing cap to install.
Be sure that front mark (H) on connecting rod bearing cap is facing front of the engine.
14. Tighten connecting rod bolt as follows:
a. Inspect the outer diameter of connecting rod bolt. Refer to EM-119, "
Inspection".
b. Apply engine oil to the threads and seats of connecting rod bolts.
c. Tighten connecting rod bolts.
d. Then tighten all connecting rod bolts 90 degrees clockwise (angle tightening).
CAUTION:
Always use the angle wrench [SST: KV10112100 (BT8653-
A)]. Avoid tightening based on visual check alone.
After tightening connecting rod bolts, check that crankshaft
rotates smoothly.
Check the connecting rod side clearance. Refer to EM-119,
"Inspection".
15. Install baffle plate to main bearing beam.
16. Install new rear oil seal retainer to cylinder block. Refer to EM-94, "
REAR OIL SEAL : Removal and Instal-
lation".
17. Install pilot converter.
With drift [outer diameter: approximately 33 mm (1.30 in)],
press-fit as far as it will go.
A: Sample codes
B : Bearing stopper groove
C : Small-end diameter grade
D : Standard stamp
E : Weight grade
F : Cylinder No.
G : Management code
I : Management code
JPBIA0208ZZ
: 19.6 N·m (2.0 kg-m, 14 ft-lb)
SEM953E
PBIC0899E

EM-118
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Press-fit pilot converter with its chamfer facing crankshaft as
shown in the figure.
18. Install knock sensors.
VQ25DE
- Install knock sensor so that connector faces the front of the
engine.
- After installing knock sensor, connect harness connector, and
lay it out to rear of engine.
CAUTION:
Never tighten mounting bolts while holding connector.
If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE:
Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
Check that knock sensor does not interfere with other parts.
VQ35DE
- Install knock sensor so that connector faces the rear of the
engine.
- After installing knock sensor, connect harness connector, and
lay it out to rear of engine.
CAUTION:
Never tighten mounting bolts while holding connector.
If any impact by dropping is applied to knock sensor,
replace it with new one.
NOTE:
Check that there is no foreign material on the cylinder block
mating surface and the back surface of knock sensor.
Check that knock sensor does not interfere with other parts.
19. Note the following, assemble in the reverse order of disassem-
bly after this step.
Drive plate When installing drive plate to crankshaft, be sure to correctly
align crankshaft side dowel pin and drive plate side dowel pin
hole.
- If these are not aligned correctly, engine runs roughly and “MI” turns on.
: Crankshaft side
JPBIA0210ZZ
PBIC0810E
A: Bank 1
B: Bank 2
: Engine front
JPBIA0211ZZ

EM-120
< DISASSEMBLY AND ASSEMBLY >
CYLINDER BLOCK
Measure the outer diameter of piston pin with a micrometer (A).
Piston to Piston Pin Oil Clearance
(Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter)
If the calculated value is out of the standard, replace piston and piston pin assembly.
When replacing piston and piston pin assembly, refer to EM-129, "
Description".
NOTE:
Piston is available together with piston pin as assembly.
Piston pin (piston pin hole) grade is provided only for the parts installed at the plant. For service parts, no
piston pin grades can be selected. (Only “0” grade is available.)
PISTON RING SIDE CLEARANCE
Measure the side clearance of piston ring (1) and piston ring
groove with a feeler gauge (C).
If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, replace piston also.
PISTON RING END GAP
Check that the cylinder bore inner diameter is within the specification. Refer to EM-143, "CylinderBlock".
Lubricate with new engine oil to piston (1) and piston ring (2), and
then insert piston ring until middle of cylinder with piston, and mea-
sure the piston ring end gap with a feeler gauge (B).
If the measured value exceeds the limit, replace piston ring, and
measure again. If it still exceeds the limit, rebore cylinder and use
oversize piston and piston rings.
CONNECTING ROD BEND AND TORSION
Standard : Refer to EM-143, "CylinderBlock".
JPBIA0218ZZ
Standard : Refer to EM-143, "CylinderBlock".
A: NG
B: OK
Standard and limit : Refer to EM-143, "CylinderBlock".
JPBIA0219ZZ
A : Press-fit
C : Measuring point
Standard and limit : Refer to EM-143, "CylinderBlock".
JPBIA0220ZZ

EX-6
< ON-VEHICLE REPAIR >
EXHAUST SYSTEM
Remove deposits from the sealing surface of each connection. Connect them securely to avoid
gases leakage.
When installing each mounting rubber, use silicon oil to avoid twisting.
Temporarily tighten mounting nuts and bolts. Check each part for unusual interference, and then
tighten them to the specified torque.
When installing each mounting rubber, avoid twisting or unusual extension in up/down, front/rear
and right/left directions.
InspectionINFOID:0000000003793263
INSPECTION AFTER INSTALLATION
Check clearance between tail tube and rear bumper is even.
With engine running, check exhaust tube joints for gas leakage and unusual noises.
Check to ensure that mounting brackets and mounting rubbers are installed properly and free from undue
stress. Improper installation could result in excessive noise and vibration.

EXL-2
COMMON ITEM ........................................................27
COMMON ITEM : CONSULT-III Function (BCM -
COMMON ITEM) ....................................................
27
HEADLAMP ..............................................................28
HEADLAMP : CONSULT-III Function (BCM -
HEAD LAMP) ..........................................................
28
FLASHER ..................................................................30
FLASHER : CONSULT-III Function (BCM -
FLASHER) ..............................................................
30
DIAGNOSIS SYSTEM (IPDM E/R) ....................32
Diagnosis Description .............................................32
CONSULT-III Function (IPDM E/R) ........................34
DIAGNOSIS SYSTEM (HEADLAMP LEVEL-
IZER) ..................................................................
37
CONSULT-III Functions (HEADLAMP LEVELIZ-
ER) .........................................................................
37
COMPONENT DIAGNOSIS ........................38
B2080 ECU TROUBLE ......................................38
Description ..............................................................38
DTC Logic ...............................................................38
Diagnosis Procedure ..............................................38
B2081 INITIAL NOT DONE ...............................39
DTC Logic ...............................................................39
Diagnosis Procedure ..............................................39
B2082 SENSOR OUT OF RANGE ....................40
DTC Logic ...............................................................40
Diagnosis Procedure ..............................................40
B2083 SEN SIG NOT PLAUSIBLE ...................41
DTC Logic ...............................................................41
Diagnosis Procedure ..............................................41
B2084 VOLTAGE UNDER LIMIT ......................42
DTC Logic ...............................................................42
Diagnosis Procedure ..............................................42
B2085 LOWBEAM SIG OPEN LINE .................43
Description ..............................................................43
DTC Logic ...............................................................43
Diagnosis Procedure ..............................................43
B2086 FRQ. OVER LIMIT ..................................45
Description ..............................................................45
DTC Logic ...............................................................45
Diagnosis Procedure ..............................................45
B2087 SHORT TO GROUND ............................47
DTC Logic ...............................................................47
Diagnosis Procedure ..............................................47
B2088 SHORT TO BATTERY ...........................48
DTC Logic ...............................................................48
Diagnosis Procedure ..............................................48
B208A PARA NOT PROG .................................49
DTC Logic ...............................................................49
Diagnosis Procedure ...............................................49
POWER SUPPLY AND GROUND CIRCUIT .....50
BCM (BODY CONTROL MODULE) ..........................50
BCM (BODY CONTROL MODULE) : Diagnosis
Procedure ...............................................................
50
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) ..............................
50
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) : Diagnosis Pro-
cedure .....................................................................
50
AUTO LEVELIZER CONTROL UNIT ........................51
AUTO LEVELIZER CONTROL UNIT : Diagnosis
Procedure ...............................................................
51
EXTERIOR LAMP FUSE ...................................53
Description ..............................................................53
Diagnosis Procedure ...............................................53
HEADLAMP (HI) CIRCUIT ................................54
Component Function Check ...................................54
Diagnosis Procedure ...............................................54
HEADLAMP (LO) CIRCUIT ...............................56
Component Function Check ...................................56
Diagnosis Procedure ...............................................56
XENON HEADLAMP .........................................58
Description ..............................................................58
Diagnosis Procedure ...............................................58
HEADLAMP LEVELIZER CIRCUIT ..................60
Description ..............................................................60
Component Function Check ...................................60
Diagnosis Procedure ...............................................60
FRONT FOG LAMP CIRCUIT ...........................62
Component Function Check ...................................62
Diagnosis Procedure ...............................................62
PARKING LAMP CIRCUIT ................................64
Component Function Check ...................................64
Diagnosis Procedure ...............................................64
TURN SIGNAL LAMP CIRCUIT ........................66
Description ..............................................................66
Component Function Check ...................................66
Diagnosis Procedure ...............................................66
OPTICAL SENSOR ...........................................69
Description ..............................................................69
Component Function Check ...................................69
Diagnosis Procedure ...............................................69
HAZARD SWITCH .............................................72
Component Function Check ...................................72
Diagnosis Procedure ...............................................72

EXL-3
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TAIL LAMP CIRCUIT .........................................74
Component Function Check ....................................74
Diagnosis Procedure ...............................................74
LICENSE PLATE LAMP CIRCUIT .....................76
Component Function Check ....................................76
Diagnosis Procedure ...............................................76
REAR FOG LAMP CIRCUIT ..............................77
Component Function Check ....................................77
Diagnosis Procedure ...............................................77
HEADLAMP SYSTEM ........................................79
Wiring Diagram - HEADLAMP - ..............................79
AUTO LIGHT SYSTEM ......................................83
Wiring Diagram - AUTO LIGHT SYSTEM - .............83
FRONT FOG LAMP SYSTEM ............................87
Wiring Diagram - FRONT FOG LAMP - ..................87
TURN SIGNAL AND HAZARD WARNING
LAMP SYSTEM ..................................................
90
Wiring Diagram - TURN AND HAZARD WARN-
ING LAMPS - ..........................................................
90
PARKING, LICENSE PLATE AND TAIL
LAMPS SYSTEM ................................................
95
Wiring Diagram - PARKING, LICENSE PLATE
AND TAIL LAMPS - .................................................
95
STOP LAMP .......................................................99
Wiring Diagram - STOP LAMP - .............................99
BACK-UP LAMP ..............................................102
Wiring Diagram - BACK-UP LAMP - .....................102
REAR FOG LAMP SYSTEM ............................105
Wiring Diagram - REAR FOG LAMP - ..................105
ECU DIAGNOSIS .......................................108
BCM (BODY CONTROL MODULE) .................108
Reference Value ...................................................108
Wiring Diagram - BCM - ........................................131
Fail-safe ................................................................137
DTC Inspection Priority Chart .............................139
DTC Index ............................................................140
IPDM E/R (INTELLIGENT POWER DISTRI-
BUTION MODULE ENGINE ROOM) ...............
142
Reference Value ...................................................142
Wiring Diagram - IPDM E/R - ................................150
Fail-safe ................................................................153
DTC Index ............................................................155
AUTO LEVELIZER CONTROL UNIT ...............156
Reference Value ...................................................156
Wiring Diagram — HEADLAMP AIMING CON-
TROL SYSTEM — ................................................
158
Fail-safe ................................................................161
DTC Inspection Priority Chart ...............................162
DTC Index .............................................................163
SYMPTOM DIAGNOSIS ............................164
EXTERIOR LIGHTING SYSTEM SYMPTOMS .164
Symptom Table .....................................................164
NORMAL OPERATING CONDITION .............167
Description .............................................................167
BOTH SIDE HEADLAMPS (HI) ARE NOT
TURNED ON ...................................................
168
Description .............................................................168
Diagnosis Procedure .............................................168
BOTH SIDE HEADLAMPS (LO) ARE NOT
TURNED ON ...................................................
169
Description .............................................................169
Diagnosis Procedure .............................................169
PARKING, LICENSE PLATE AND TAIL
LAMPS ARE NOT TURNED ON .....................
170
Description .............................................................170
Diagnosis Procedure .............................................170
BOTH SIDE FRONT FOG LAMPS ARE NOT
TURNED ON ...................................................
171
Description .............................................................171
Diagnosis Procedure .............................................171
PRECAUTION ............................................172
PRECAUTIONS ...............................................172
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
172
Precautions For Xenon Headlamp Service ...........172
ON-VEHICLE MAINTENANCE ..................173
HEADLAMP AIMING ADJUSTMENT .............173
Description .............................................................173
Aiming Adjustment Procedure (Low Beam) ...........174
Aiming Adjustment Procedure (High Beam) ..........175
FRONT FOG LAMP AIMING ADJUSTMENT .178
Description .............................................................178
Aiming Adjustment Procedure ...............................178
ON-VEHICLE REPAIR ...............................180
FRONT COMBINATION LAMP ......................180
Exploded View .......................................................180
Removal and Installation .......................................181
Replacement .........................................................181
Disassembly and Assembly ...................................182
FRONT FOG LAMP ........................................183
Exploded View .......................................................183
Removal and Installation .......................................183
Replacement .........................................................183

EXL-5
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P IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) ............................
224
IPDM E/R (INTELLIGENT POWER DISTRIBU-
TION MODULE ENGINE ROOM) : Diagnosis Pro-
cedure ...................................................................
224
EXTERIOR LAMP FUSE ..................................226
Description ............................................................226
Diagnosis Procedure .............................................226
HEADLAMP (HI) CIRCUIT ...............................227
Component Function Check ..................................227
Diagnosis Procedure .............................................227
HEADLAMP (LO) CIRCUIT ..............................229
Component Function Check ..................................229
Diagnosis Procedure .............................................229
FRONT FOG LAMP CIRCUIT ..........................231
Component Function Check ..................................231
Diagnosis Procedure .............................................231
PARKING LAMP CIRCUIT ...............................233
Component Function Check ..................................233
Diagnosis Procedure .............................................233
TURN SIGNAL LAMP CIRCUIT .......................235
Description ............................................................235
Component Function Check ..................................235
Diagnosis Procedure .............................................235
OPTICAL SENSOR ..........................................238
Description ............................................................238
Component Function Check ..................................238
Diagnosis Procedure .............................................238
HAZARD SWITCH ............................................241
Component Function Check ..................................241
Diagnosis Procedure .............................................241
TAIL LAMP CIRCUIT .......................................243
Component Function Check ..................................243
Diagnosis Procedure .............................................243
LICENSE PLATE LAMP CIRCUIT ...................245
Component Function Check ..................................245
Diagnosis Procedure .............................................245
REAR FOG LAMP CIRCUIT ............................246
Component Function Check ..................................246
Diagnosis Procedure .............................................246
HEADLAMP SYSTEM ......................................248
Wiring Diagram - HEADLAMP - ............................248
AUTO LIGHT SYSTEM ....................................252
Wiring Diagram - AUTO LIGHT SYSTEM - ...........252
HEADLAMP AIMING CONTROL SYSTEM
(MANUAL) ........................................................
256
Description ............................................................256
Wiring Diagram - HEADLAMP AIMING CON-
TROL SYSTEM (MANUAL) - .................................
256
Component Inspection ...........................................257
FRONT FOG LAMP SYSTEM .........................259
Wiring Diagram - FRONT FOG LAMP - ................259
TURN SIGNAL AND HAZARD WARNING
LAMP SYSTEM ...............................................
262
Wiring Diagram - TURN AND HAZARD WARN-
ING LAMPS - .........................................................
262
PARKING, LICENSE PLATE AND TAIL
LAMPS SYSTEM ............................................
267
Wiring Diagram - PARKING, LICENSE PLATE
AND TAIL LAMPS - ...............................................
267
STOP LAMP ....................................................271
Wiring Diagram - STOP LAMP - ............................271
BACK-UP LAMP .............................................274
Wiring Diagram - BACK-UP LAMP - ......................274
REAR FOG LAMP SYSTEM ...........................277
Wiring Diagram - REAR FOG LAMP - ...................277
ECU DIAGNOSIS .......................................280
BCM (BODY CONTROL MODULE) ...............280
Reference Value ....................................................280
Wiring Diagram - BCM - ........................................303
Fail-safe .................................................................309
DTC Inspection Priority Chart .............................311
DTC Index .............................................................312
IPDM E/R (INTELLIGENT POWER DISTRI-
BUTION MODULE ENGINE ROOM) ..............
314
Reference Value ....................................................314
Wiring Diagram - IPDM E/R - ................................322
Fail-safe .................................................................325
DTC Index .............................................................327
SYMPTOM DIAGNOSIS ............................328
EXTERIOR LIGHTING SYSTEM SYMPTOMS .328
Symptom Table .....................................................328
BOTH SIDE HEADLAMPS (HI) ARE NOT
TURNED ON ...................................................
331
Description .............................................................331
Diagnosis Procedure .............................................331
BOTH SIDE HEADLAMPS (LO) ARE NOT
TURNED ON ...................................................
332
Description .............................................................332
Diagnosis Procedure .............................................332
PARKING, LICENSE PLATE AND TAIL
LAMPS ARE NOT TURNED ON .....................
333
Description .............................................................333
Diagnosis Procedure .............................................333