
CAMSHAFT
EM-53
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5. Install camshaft bracket bolts in three stage in numerical order
as shown in numerical order as shown.
• There are two types of bolts. Locate the bolts as shown.
6. Tighten all bolts in numerical order in three steps.
7. Install the camshaft sprocket (INT) to the camshaft (INT).
NOTE:
When the camshaft sprocket (INT) (2) is removed, align the
paint mark (A) put according to step “3”. Securely align the
knock pin and the pin hole, and then install them.
8. Tighten camshaft (INT) sprocket bolt.
NOTE:
Secure the hexagonal part of camshaft (INT) using wrench to tighten bolt.
9. Turn 67 degrees clockwise (angle tightening) using Tool.
CAUTION:
Never judge by visual inspection without an angle wrench.
: Engine front
M6 bolts [thread length: 57.5 mm (2.264 in)]
: 13, 14 and 15 as shown
M6 bolts [thread length: 35.00 mm (1.378 in)]
: Except the above
Step 1 : 1.96 N·m (0.20 kg-m, 17 in-lb)
Step 2 : 5.88 N·m (0.60 kg-m, 52 in-lb)
Step 3 : 9.5 N·m (0.97 kg-m, 84 in-lb)
1 : Camshaft bracket
: Engine front
PBIC3176J
PBIC3992J
Camshaft sprocket bolt (INT) : 35.0 N·m (3.6 kg-m, 26 ft-lb)
1 : Camshaft sprocket (INT)
A : Camshaft (INT) hexagonal part
Tool number : KV10112100 (BT-8653-A)
PBIC3455J

CAMSHAFT
EM-55
< SERVICE INFORMATION >
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4. Clean the mating area of intake valve timing control solenoid
valve. Insert a clean shop cloth (with no oil adhesion) into the oil
hole (A) of the cylinder head.
5. Install engine mounting bracket (RH), engine mounting insulator,
and torque rod (RH) under the Step 4 condition. (With intake
valve timing control solenoid valve removed, and a shop cloth
inserted into the oil hole.) Refer to EM-72, "
Component".
6. Crank engine, and then make sure that engine oil comes out
from intake valve timing control solenoid valve hole (A). End crank after checking.
• Check engine oil leakage by oil amount adhered to the waste inserted into the oil hole.
WARNING:
Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.).
CAUTION:
• Do not perform cranking without installing right engine mount bracket, right engine mount insu-
lator, and right torque rod.
• 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 not to apply engine oil to rubber parts of drive belts,
engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed.
7. 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 (for intake valve timing control), and then clean it. Refer to EM-76, "
Component".
• Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-5
.
8. 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-5
.
9. Installation of the remaining components is in the reverse order of removal
Valve ClearanceINFOID:0000000001702497
INSPECTION
Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if
there is unusual engine conditions regarding valve clearance.
1. Remove rocker cover. Refer to EM-30
.
2. Measure the valve clearance with the following procedure:
a. Set No. 1 cylinder at TDC of its compression stroke.
• Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front
cover.
1 : Front cover
:Vehicle front
WBIA0781E
C : White paint mark (Not use for service)
PBIC3960E

CYLINDER HEAD
EM-65
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3. Install cylinder head, follow the steps below to tighten cylinder
head bolts in numerical order as shown.
: Engine front
CAUTION:
Check and confirm the tightening angle by using Tool (A) or
protractor. Never judge by visual inspection without the
tool.
4. Installation of the remaining components is in the reverse order of removal.
ComponentINFOID:0000000001702504
Step a : 40 N·m (4.1 kg-m, 30 ft-lb)
Step b : 100° clockwise
Step c : Loosen to 0 N·m in the reverse order of tight-
ening.
Step d : 40 N·m (4.1 kg-m, 30 ft-lb)
Step e : 100° clockwise
Step f : 100° clockwise
Tool number : KV10112100 (BT-8653-A)
PBIC3206J
PBIC3208J
PBIC3543J

EM-82
< SERVICE INFORMATION >
CYLINDER BLOCK
15. Tighten main bearing cap bolts in two steps.
NOTE:
Tighten main bearing cap bolts in numerical order as shown:
• After installing bolts, make sure that crankshaft can be rotated smoothly by hand.
• Check crankshaft end play. Refer to EM-93, "
Inspection After Disassembly".
16. Using snap ring pliers, install new snap ring to the groove of the piston rear side.
• Insert it fully into groove to install.
17. Assemble piston to connecting rod.
• Using a suitable tool, heat the piston until the piston pin can be pushed in by hand without excess force
[approximately 60° to 70 °C (140° to 158 °F)]. From the front to the rear, insert piston pin into piston and
connecting rod.
• Assemble so that the front mark (A) on the piston head and
the oil hole (B) and the cylinder number (C) on connecting rod
are positioned as shown.
18. Install new snap ring to the groove of the piston front side.
• Insert it fully into groove to install.
• After installing, make sure that connecting rod moves
smoothly.
19. Using a suitable tool, install piston rings.
CAUTION:
• Be careful not to damage piston.
• Be careful not to damage piston rings by expanding them excessively.
: Engine front
Step 1 : 34.3 N·m (3.5 kg-m, 25 ft-lb)
Step2 60° clockwise
PBIC3235J
Tool number : KV10112100 (BT-8653-A)
PBIC3240J
D : Big end diameter grade
E : Small end diameter grade
F : Front mark (connecting rod bearing cap)
PBIC3587J

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-5
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FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
ComponentINFOID:0000000001703099
Removal and InstallationINFOID:0000000001703100
REMOVAL
WARNING:
Be sure to read “General Precautions” before working on the fuel system. Refer to FL-4, "
General Pre-
caution" .
1. Check fuel level with the vehicle on a level surface. If the fuel
gauge indicates more than the level as shown (7/8 full), drain
fuel from the fuel tank until the fuel gauge indicates level as
shown (7/8 full).
NOTE:
Fuel will be spilled when removing fuel pump assembly if fuel
level is above the fuel pump assembly installation surface.
• As a guide, fuel level is at the level as shown or below when
approximately 12 (3 1/8 US gal, 2 5/8 Imp gal) of fuel is
drained from a full fuel tank.
• In case fuel pump does not operate, perform the following pro-
cedure.
a. Insert fuel tubing of less than 25 mm (0.98 in) in diameter into fuel filler tube through fuel filler opening to
drain fuel from fuel filler tube.
b. Disconnect fuel filler hose from fuel filler tube. Refer to FL-9
.
c. Insert fuel tubing into fuel tank through fuel filler hose to drain fuel from fuel tank.
2. Open fuel door and unscrew the fuel filler cap to release the pressure inside the fuel tank.
3. Release the fuel pressure from the fuel lines. Refer to EC-78, "
Fuel Pressure Check" .
4. Remove rear seat bottom. Refer to SE-14
.
5. Turn the four retainers 90° in a clockwise direction and remove the fuel pump inspection hole cover.
1. Lock ring 2. Fuel level sensor unit, fuel filter and fuel pump assembly 3. O-ring
4. Fuel tank
WCIA0590E
KBIA3505J

FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-7
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Make sure that the fuel level sensor unit, fuel filter and fuel pump is free from defects and foreign materials.
INSTALLATION
Installation is in the reverse order of removal.
Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly
1. Install O-ring to fuel tank without twisting.
2. Install fuel level sensor unit with aligning mating marks (A) on
fuel tank and fuel level sensor unit as shown.
•⇐: Front
• Turn the lock ring (1) until the lock ring is fully rotated into the
fuel tank lock tabs (A) as shown.
Quick Connector
Connect fuel feed tube quick connector using the following procedure.
1. Check the connection for damage or any foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a “click” sound is
heard.
3. After connecting, make sure that the connection is secure using the following procedure.
• Visually confirm that the two retainer tabs are secured to the connector.
• Pull the tube and the connector to make sure they are securely
connected.
4. Connect electrical harness connector.
Inspection Hole Cover
• Before installing inspection hole cover, confirm that there are no fuel leaks. Refer to "INSPECTION AFTER
INSTALLATION" .
1. Install inspection hole cover with the front mark (arrow) facing front of vehicle.
2. Lock clips by turning counterclockwise.
INSPECTION AFTER INSTALLATION
Use the following procedure to check for fuel leaks.
PBIC4732E
WBIA0783E
PBIC1653E

FUEL TANK
FL-9
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FUEL TANK
ComponentINFOID:0000000001703101
Removal and InstallationINFOID:0000000001703102
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on the fuel system. Refer to FL-4, "
General Pre-
caution" .
1. Drain fuel from fuel tank if necessary. Refer to FL-5, "
Removal and Installation" .
CAUTION:
• Because fuel tank becomes unstable when installing/removing, fuel should be drained if the
level exceeds specification FL-5, "
Removal and Installation" .
• Situate vehicle on a flat and solid surface.
2. Open fuel door and unscrew the fuel filler cap to release the pressure inside the fuel tank.
3. Release the fuel pressure from the fuel lines. Refer to EC-78, "
Fuel Pressure Check" .
4. Remove rear seat bottom. Refer to SE-14
.
5. Turn the three retainers 90° in a clockwise direction and remove the fuel pump inspection hole cover.
1. Lock ring 2. Fuel pump 3. O-ring
4. Fuel tank 5. Fuel tank band (LH) 6. Fuel tank band (RH)
7. EVAP hose 8. Hose clamp 9. Fuel filler hose
10. Hose clamp 11. Fuel filler pipe shield 12. Fuel filler tube
13. Grommet 14. Fuel filler cap⇐Front of vehicle
WCIA0591E

SQUEAK AND RATTLE TROUBLE DIAGNOSES
GW-5
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SQUEAK AND RATTLE TROUBLE DIAGNOSES
Work FlowINFOID:0000000001704132
CUSTOMER INTERVIEW
Interview the customer if possible, to determine the conditions that exist when the noise occurs. Use the Diag-
nostic Worksheet during the interview to document the facts and conditions when the noise occurs and any
customer's comments; refer to GW-9, "
Diagnostic Worksheet". This information is necessary to duplicate the
conditions that exist when the noise occurs.
• The customer may not be able to provide a detailed description or the location of the noise. Attempt to obtain
all the facts and conditions that exist when the noise occurs (or does not occur).
• If there is more than one noise in the vehicle, be sure to diagnose and repair the noise that the customer is
concerned about. This can be accomplished by test driving the vehicle with the customer.
• After identifying the type of noise, isolate the noise in terms of its characteristics. The noise characteristics
are provided so the customer, service adviser and technician are all speaking the same language when
defining the noise.
• Squeak —(Like tennis shoes on a clean floor)
Squeak characteristics include the light contact/fast movement/brought on by road conditions/hard surfaces
= higher pitch noise/softer surfaces = lower pitch noises/edge to surface = chirping.
• Creak—(Like walking on an old wooden floor)
Creak characteristics include firm contact/slow movement/twisting with a rotational movement/pitch depen-
dent on materials/often brought on by activity.
• Rattle—(Like shaking a baby rattle)
Rattle characteristics include the fast repeated contact/vibration or similar movement/loose parts/missing
clip or fastener/incorrect clearance.
• Knock —(Like a knock on a door)
Knock characteristics include hollow sounding/sometimes repeating/often brought on by driver action.
• Tick—(Like a clock second hand)
Tick characteristics include gentle contacting of light materials/loose components/can be caused by driver
action or road conditions.
• Thump—(Heavy, muffled knock noise)
Thump characteristics include softer knock/dead sound often brought on by activity.
• Buzz—(Like a bumble bee)
Buzz characteristics include high frequency rattle/firm contact.
• Often the degree of acceptable noise level will vary depending upon the person. A noise that you may judge
as acceptable may be very irritating to the customer.
• Weather conditions, especially humidity and temperature, may have a great effect on noise level.
DUPLICATE THE NOISE AND TEST DRIVE
If possible, drive the vehicle with the customer until the noise is duplicated. Note any additional information on
the Diagnostic Worksheet regarding the conditions or location of the noise. This information can be used to
duplicate the same conditions when you confirm the repair.
SBT842