ENGINE MECHANICAL GI

SECTION EM MA

LC

EC

CONTENTS FE

PRECAUTIONS ...............................................................3 VALVE SEATS .........................................................44

CL
Parts Requiring Angular Tightening.............................3 REPLACING VALVE SEAT FOR SERVICE PARTS ....44
Liquid Gasket Application Procedure ..........................3 VALVE DIMENSIONS ...............................................45
MT
PREPARATION ...............................................................4 VALVE SPRING .......................................................45
VALVE LIFTER ........................................................46
Special Service Tools ..................................................4
Assembly ...................................................................47 AT
Commercial Service Tools ...........................................6
Installation..................................................................47
OUTER COMPONENT PARTS .......................................8
Valve Clearance.........................................................52
Removal and Installation .............................................8
TIGHTENING PROCEDURES ...................................10
CHECKING .............................................................52 AX
ADJUSTING ............................................................54
MEASUREMENT OF COMPRESSION PRESSURE ....11
ENGINE ASSEMBLY.....................................................57
OIL PAN.........................................................................12
Removal and Installation ...........................................57 SU
Components...............................................................12
REMOVAL ...............................................................58
Removal.....................................................................12
INSTALLATION........................................................59
Installation..................................................................15 CYLINDER BLOCK .......................................................60 BR
TIMING CHAIN ..............................................................19 Components...............................................................60
Components...............................................................19 Removal and Installation ...........................................61
POSITION FOR APPLYING LIQUID GASKET ............20 ST
Disassembly...............................................................61
Removal.....................................................................22
PISTON AND CRANKSHAFT ....................................61
Inspection...................................................................30 Inspection...................................................................61
Installation..................................................................30
RS
PISTON AND PISTON PIN CLEARANCE ..................61
OIL SEAL.......................................................................35 PISTON RING SIDE CLEARANCE ............................62
Replacement..............................................................35 PISTON RING END GAP..........................................62 BT
VALVE OIL SEAL .....................................................35 CONNECTING ROD BEND AND TORSION ...............63
OIL SEAL INSTALLATION DIRECTION .....................36 CYLINDER BLOCK DISTORTION AND WEAR ...........63
FRONT OIL SEAL ....................................................36 PISTON-TO-BORE CLEARANCE ..............................64 HA
REAR OIL SEAL ......................................................37 CRANKSHAFT.........................................................65
CYLINDER HEAD..........................................................38 BEARING CLEARANCE ...........................................66
Components...............................................................38 CONNECTING ROD BUSHING CLEARANCE SC
Removal.....................................................................39 (SMALL END) ..........................................................68
Disassembly...............................................................39 REPLACEMENT OF CONNECTING ROD
Inspection...................................................................41 BUSHING (SMALL END) ..........................................69 EL
CYLINDER HEAD DISTORTION ...............................41 FLYWHEEL/DRIVE PLATE RUNOUT ........................69
CAMSHAFT VISUAL CHECK ....................................41 Assembly ...................................................................69
CAMSHAFT RUNOUT ..............................................41 PISTON ..................................................................69 IDX
CAMSHAFT CAM HEIGHT .......................................41 CRANKSHAFT.........................................................70
CAMSHAFT JOURNAL CLEARANCE ........................42 REPLACEMENT OF PILOT BUSHING (M/T) OR
CAMSHAFT END PLAY............................................43 PILOT CONVERTER (A/T)........................................72
CAMSHAFT SPROCKET RUNOUT ...........................43 SERVICE DATA AND SPECIFICATIONS (SDS) .........73
VALVE GUIDE CLEARANCE ....................................43 General Specifications...............................................73
VALVE GUIDE REPLACEMENT ................................43 Compression Pressure ..............................................73
CONTENTS (Cont’d)
Cylinder Head ............................................................73 AVAILABLE PISTON ................................................83
Valve ..........................................................................74 PISTON RING .........................................................83
VALVE ....................................................................74 PISTON PIN ............................................................83
VALVE CLEARANCE................................................74 Connecting Rod .........................................................84
AVAILABLE SHIMS ..................................................75 Crankshaft..................................................................84
VALVE SPRING .......................................................77 Available Main Bearing..............................................86
VALVE LIFTER ........................................................77 UNDERSIZE ............................................................86
VALVE GUIDE .........................................................78 Available Connecting Rod Bearing............................87
Valve Seat..................................................................79 CONNECTING ROD BEARING .................................87
VQ20DE ..................................................................79 UNDERSIZE ............................................................87
VQ30DE ..................................................................79 Miscellaneous Components.......................................87
Camshaft and Camshaft Bearing ..............................80 BEARING CLEARANCE ...........................................87
Cylinder Block............................................................81
Piston, Piston Ring and Piston Pin ...........................83

EM-2
PRECAUTIONS
Parts Requiring Angular Tightening

Parts Requiring Angular Tightening NFEM0001

I Use an angle wrench for the final tightening of the following
engine parts: GI
a) Cylinder head bolts
b) Main bearing cap bolts MA
c) Connecting rod cap nuts
d) Crankshaft pulley bolt
I Do not use a torque value for final tightening.
I The torque value for these parts are for a preliminary step.
I Ensure thread and seat surfaces are clean and coated with LC
engine oil.

EC

FE

CL

MT
Liquid Gasket Application Procedure NFEM0002
1. Use a scraper to remove all traces of old liquid gasket AT
from mating surfaces and grooves. Also, completely clean
any oil from these areas.
2. Apply a continuous bead of liquid gasket to mating sur-
AX
faces. (Use Genuine Liquid Gasket or equivalent.)
I Be sure liquid gasket diameter is as specified. SU

BR
SEM164F

3. Apply liquid gasket around the inner side of bolt holes

(unless otherwise specified). ST
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and RS
engine coolant.

BT

HA
AEM080

SC

EL

IDX

EM-3
PREPARATION
Special Service Tools

Special Service Tools NFEM0003

Tool number
Description
Tool name

ST0501S000 Disassembling and assembling

Engine stand assembly
1 ST05011000
Engine stand
2 ST05012000
Base

NT042

KV10106500
Engine stand shaft

NT028

KV10117000 KV10117000 has been replaced with

Engine sub-attachment KV10117001 (KV10117000 is no longer in
production, but it is usable).

NT373

KV10117001 Installing on the cylinder block

Engine sub-attachment

NT372

ST10120000 Loosening and tightening cylinder head bolt

Cylinder head bolt a: 13 (0.51) dia.
wrench b: 12 (0.47)
c: 10 (0.39)
Unit: mm (in)

NT583

KV10116200 Disassembling valve mechanism

Valve spring compres-
sor
1 KV10115900
Attachment

NT022

EM-4
PREPARATION
Special Service Tools (Cont’d)

Tool number
Description
Tool name
GI
KV10115600 Installing valve oil seal
Valve oil seal drift Use side A.
Side A MA
a: 20 (0.79) dia.
b: 13 (0.51) dia.
c: 10.3 (0.406) dia.
d: 8 (0.31) dia.
e: 10.7 (0.421)
NT603 f: 5 (0.20)
Unit: mm (in) LC
KV101151S0 Changing shims
Lifter stopper set EC
1 KV10115110
Camshaft pliers
2 KV10115120
Lifter stopper
FE
NT041

EM03470000 Installing piston assembly into cylinder bore

CL
Piston ring compressor

MT

NT044 AT
ST16610001 Removing crankshaft pilot bushing
Pilot bushing puller
AX

SU
NT045

KV10111100 Removing steel oil pan and rear timing chain

Seal cutter case BR

ST
NT046

WS39930000 Pressing the tube of liquid gasket RS

Tube presser

BT
NT052

KV10112100 Tightening bolts for bearing cap, cylinder

HA
Angle wrench head, etc.

SC

EL
NT014

IDX

EM-5
PREPARATION
Special Service Tools (Cont’d)

Tool number
Description
Tool name

KV10115800 Removing oil filter

KV10115801
(Kent-Moore Europe
make)
Oil filter wrench

NT362

Commercial Service Tools NFEM0004

Tool number
Description
Tool name

Spark plug wrench Removing and installing spark plug

NT047

Valve seat cutter set Finishing valve seat dimensions

NT048

Piston ring expander Removing and installing piston ring

NT030

Valve guide drift Removing and installing valve guide

Intake & Exhaust:
a = 9.5 mm (0.374 in) dia.
b = 5.5 mm (0.217 in) dia.

NT015

Valve guide reamer Reaming valve guide 1 or hole for oversize valve
guide 2
Intake & Exhaust:
d1 = 6.0 mm (0.236 in) dia.
d2 = 10.2 mm (0.402 in) dia.

NT016

Oxygen sensor thread Reconditioning the exhaust system threads before

cleaner installing a new oxygen sensor (Use with anti-seize
lubricant shown below.)
a = [18 mm (0.71 in) dia. and pitch of 1.5 mm
(0.059 in)] for zirconia oxygen sensor
b = [12 mm (0.47 in) dia. and pitch of 1.25 mm
(0.0492 in)] for titania oxygen sensor

AEM488

EM-6
PREPARATION
Commercial Service Tools (Cont’d)

Tool number
Description
Tool name
GI
Anti-seize lubricant Lubricating oxygen sensor thread cleaning tool
(Permatex 133AR or when reconditioning exhaust system threads
equivalent meeting MIL MA
specification MIL-A-
907)

LC
AEM489

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

EM-7
OUTER COMPONENT PARTS
Removal and Installation

Removal and Installation NFEM0006

SEM092G

1. Intake manifold collector support 5. Fuel tube assembly 9. Intake manifold

2. Intake manifold collector 6. Fuel pressure regulator 10. Throttle body
3. Fuel damper and fuel feed hose 7. Ignition coil with power transistor 11. IACV-AAC valve
assembly 8. Ornament engine cover 12. EVAP canister purge volume con-
4. Injector trol solenoid valve

EM-8
OUTER COMPONENT PARTS
Removal and Installation (Cont’d)

GI

MA

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT
SEM093G

1. EGR valve 4. Thermostat with water inlet 8. Water control valve HA

2. EGR temperature sensor 5. Exhaust manifold 9. Water connector
3. Camshaft position sensor 6. Water outlet 10. Cylinder block water outlet
(PHASE) 7. EGR guide tube SC

EL

IDX

EM-9
OUTER COMPONENT PARTS
Removal and Installation (Cont’d)
TIGHTENING PROCEDURES NFEM0006S01
Intake Manifold NFEM0006S0101
I Tighten in numerical order shown in the figure.
1. Tighten all bolts and nuts to 5 to 10 N·m (0.5 to 1.0 kg-m, 44
to 86 in-lb).
2. Finally tighten all bolts and nuts to 26 to 31 N·m (2.7 to 3.2
kg-m, 20 to 23 ft-lb).
I Tighten all bolts and nuts to the final torque, evenly dividing the
tightening into at least five steps.
SEM950F

Fuel Tube NFEM0006S0102

I Tighten in numerical order shown in the figure.
1. Tighten all bolts to 9.3 to 10.8 N·m (0.95 to 1.1 kg-m, 83 to 95
in-lb).
2. Then tighten all bolts to 21 to 26 N·m (2.1 to 2.7 kg-m, 15 to
20 ft-lb).

SEM951F

Fuel Pressure Regulator NFEM0006S0103

Tighten fuel pressure regulator to 2.9 to 3.8 N·m (0.3 to 0.39 kg-m,
26.0 to 33.9 in-lb).
I Tighten screws evenly several times to have the fuel pres-
sure regulator tightened at the specified torque.
I Always replace O-ring with new ones.
I Lubricate O-ring with new engine oil.

SEM952F

Throttle Body NFEM0006S0105

I Tighten in numerical order shown in the figure.
1. Tighten all bolts to 8.8 to 10.8 N·m (0.9 to 1.1 kg-m, 79 to 95
in-lb).
2. Then tighten all bolts to 17.7 to 21.6 N·m (1.8 to 2.2 kg-m, 13
to 16 ft-lb).

SEM953F

Intake Manifold Collector NFEM0006S0107

Tighten bolts and nuts to 11 to 15 N·m (1.1 to 1.6 kg-m, 8 to 11 ft-lb)
in numerical order shown in the figure.

SEM954F

EM-10
NFEM0007

MEASUREMENT OF COMPRESSION PRESSURE

1. Warm up engine.
2. Turn ignition switch OFF.
3. Release fuel pressure. GI
Refer to EC-34, “Fuel Pressure Release”.
4. Disconnect ignition coil with power transistor harness
connectors, then remove ignition coils. MA
5. Remove all spark plugs.
6. Remove fuel injector fuse.

SEM087G LC
7. Attach a compression tester to No. 1 cylinder.
8. Depress accelerator pedal fully to keep throttle valve wide
open.
EC
9. Crank engine and record highest gauge indication.
10. Repeat the measurement on each cylinder as shown above. FE
I Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm CL
Difference limit
Engine Standard Minimum
between cylinders
SEM909E
MT
VQ20DE 1,275 (12.75, 981 (9.81, 10.0, 98 (0.98, 1.0, 14)/
VQ30DE 13.0, 185)/300 142)/300 300
AT
11. If compression in one or more cylinders is low:
a. Pour a small amount of engine oil into cylinders through spark
plug holes. AX
b. Retest compression.
I If adding oil helps compression, piston rings may be worn SU
or damaged. If so, replace piston rings after checking pis-
ton.
I If pressure stays low, a valve may be sticking or seating BR
SEM387C improperly. Inspect and repair valve and valve seat. (Refer
to SDS, EM-74 and EM-79.) If valve or valve seat is dam-
aged excessively, replace them. ST
I If compression stays low in two cylinders that are next to
each other:
a) The cylinder head gasket may be leaking, or RS
b) Both cylinders may have valve component damage. Inspect
and repair as necessary. BT

HA

SC

EL

IDX

EM-11
OIL PAN
Components

Components NFEM0008

SEM088G

Removal NFEM0009
CAUTION:
When removing the aluminum oil pan from engine, first
remove the crankshaft position sensors (POS and REF) from
the assembly.
Be careful not to damage sensor edges and signal plate teeth.
1. Remove engine undercover.
2. Drain engine oil.

3. Remove steel oil pan bolts.

SEM956F

4. Remove steel oil pan.

a. Insert Tool between aluminum oil pan and steel oil pan.
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be
deformed.

SEM957FA

EM-12
OIL PAN
Removal (Cont’d)
b. Slide Tool by tapping on the side of the Tool with a hammer.
c. Remove steel oil pan.
GI

MA

SEM960FA LC
5. Remove oil strainer.
EC

FE

CL

SEM809E
MT
6. Remove front exhaust tube and its support.
Refer to FE-10, “Removal and Installation”. AT

AX

SU

BR
SEM810E

ST

RS

BT

HA
SEM089G

SC

EL

IDX

EM-13
OIL PAN
Removal (Cont’d)
7. Set a suitable transmission jack under transaxle and hoist
engine with engine slinger.
8. Remove crankshaft position sensors (POS and REF) from oil
pan.
9. Remove front and rear engine mounting nuts and bolts.
10. Remove center member.

SEM811E

11. Remove drive belts.

12. Remove air compressor and bracket.

SEM812E

13. Remove rear cover plate.

SEM813E

14. Remove oil filter, oil cooler fixing bolt and water hoses or pipes
(For models with oil cooler).

SEM154F

EM-14
OIL PAN
Removal (Cont’d)
15. Remove aluminum oil pan bolts in numerical order.

GI

MA

SEM184F LC
16. Remove four engine-to-transaxle bolts.
EC

FE

CL

SEM815E
MT
17. Remove aluminum oil pan.
a. Insert an appropriate size tool into the notch of aluminum oil AT
pan as shown in the figure.
I Be careful not to damage aluminum mating surface.
I Do not insert screwdriver, or oil pan flange will be AX
deformed.
b. Pry off aluminum oil pan by moving the tool up and down. SU
c. Remove aluminum oil pan.

BR
SEM155F

18. Remove O-rings from cylinder block and oil pump body.
ST

RS

BT

HA
SEM819E

Installation NFEM0010
SC
1. Install aluminum oil pan.
a. Use a scraper to remove old liquid gasket from mating sur-
faces.
EL
I Also remove old liquid gasket from mating surface of cyl-
inder block, front cover and steel oil pan. IDX
I Remove old liquid gasket from the bolt hole and thread.

MEM108A

EM-15
OIL PAN
Installation (Cont’d)
b. Apply sealant to front cover gasket and rear oil seal retainer
gasket.

SEM964E

c. Apply a continuous bead of liquid gasket to mating surface of

aluminum oil pan.
I Use Genuine Liquid Gasket or equivalent.

SEM159F

d. Apply liquid gasket to inner sealing surface as shown in figure.

I Be sure liquid gasket is 4.0 to 5.0 mm (0.157 to 0.197 in)
or 4.5 to 5.5 mm (0.177 to 0.217 in) wide.
I Attaching should be done within 5 minutes after coating.

SEM185FA

e. Install O-rings, cylinder block and oil pump body.

SEM819E

f. Install aluminum oil pan.

I Tighten bolts in numerical order.
I Wait at least 30 minutes before refilling engine oil.
g. Install oil cooler, water hoses and pipes (For models with oil
cooler).

SEM186F

EM-16
OIL PAN
Installation (Cont’d)
2. Install the four engine-to-transaxle bolts. For tightening torque,
refer to MT-9 or AT-229, “Installation”.
3. Install rear cover plate. GI
For tightening torque of the oil cooler fixing bolt, refer to LC-7,
“Oil Cooler”.
MA

SEM822E LC
4. Install air compressor and bracket.
Refer to HA-199, “REMOVALAND INSTALLATION”, “Compres-
sor”. EC
5. Install drive belts.
6. Install center member. FE
7. Install front and rear engine mounting insulator nuts and bolts.

CL

SEM812E
MT
8. Install crankshaft position sensors (POS and REF) and front
heated oxygen sensor (left bank) harness clamp. AT
I Make sure that crankshaft position sensor (POS) and front
heated oxygen sensor (left bank) harness clamp are
installed correctly as shown in figure. AX
9. Install front exhaust tube and its support.
10. Install oil strainer.
SU

BR
SEM222F

11. Install steel oil pan.

a. Use a scraper to remove old liquid gasket from mating sur-
ST
faces.
I Also remove old liquid gasket from mating surface of alu- RS
minum oil pan.

BT

HA
SEM958F

b. Apply a continuous bead of liquid gasket to mating surface of SC

steel oil pan.
I Use Genuine Liquid Gasket or equivalent.
EL

IDX

SEM159F

EM-17
OIL PAN
Installation (Cont’d)
I Be sure liquid gasket is 4.5 to 5.5 mm (0.177 to 0.217 in)
wide.
I Attaching should be done within 5 minutes after coating.

SEM959F

c. Install steel oil pan.

I Tighten in numerical order shown in the figure.
I Wait at least 30 minutes before refilling engine oil.

SEM956F

EM-18
TIMING CHAIN
Components

Components NFEM0011

GI

MA

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

SEM094G
HA
1. Rear timing chain case 8. Timing chain 14. Water pump cover
2. Left camshaft chain tensioner 9. Crankshaft sprocket 15. Chain tensioner cover SC
3. Internal chain guide 10. Lower chain guide 16. Exhaust camshaft sprocket 2ND
4. Camshaft chain 11. Upper chain guide 17. Intake camshaft sprocket 2ND
5. Right camshaft chain tensioner 12. Front timing chain case 18. Camshaft sprocket 1ST EL
6. Timing chain tensioner 13. Crankshaft pulley 19. Water pump
7. Slack side chain guide
IDX

EM-19
TIMING CHAIN
Components (Cont’d)
POSITION FOR APPLYING LIQUID GASKET =NFEM0011S01
Refer to “Installation” in “OIL PAN”, EM-15.
I Before installation, wipe off the protruding sealant.

EM-20
TIMING CHAIN
Components (Cont’d)

GI

MA

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX
SEM443FA

EM-21
TIMING CHAIN
Components (Cont’d)
CAUTION:
I After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new
engine oil.
I Apply new engine oil to bolt threads and seat surfaces
when installing cylinder head, camshaft sprockets, crank-
shaft pulley, and camshaft brackets.
I Before disconnecting fuel hose, release fuel pressure.
Refer to EC-34, “Fuel Pressure Release”.
I When removing the oil pans, oil pump assembly and tim-
ing chain from engine, first remove the camshaft position
sensor (PHASE) and the crankshaft position sensors
(REF)/(POS) from the assembly.
Be careful not to damage sensor edges.
I Do not spill engine coolant on drive belts.

Removal NFEM0012
1. Drain engine oil.
2. Release fuel pressure.
Refer to EC-34, “Fuel Pressure Release”.
3. Drain coolant by removing cylinder block drain plugs. Refer to
MA-14, “Changing Engine Coolant”.
4. Remove left side ornament cover.
5. Remove air duct to intake manifold, collector, blow-by hose,
vacuum hoses, fuel hoses, wires, harness, connectors and so
on.
6. Remove the following.
I Vacuum hoses
I Water hoses
I EVAP canister purge hose
I Blow-by hose

7. Remove RH and LH ignition coils.

SMA040D

EM-22
TIMING CHAIN
Removal (Cont’d)
8. Remove EGR guide tube.

GI

MA

LC

EC

FE

CL

SEM961F
MT
9. Remove intake manifold collector supports and intake manifold
collector (RH cylinder head only). AT

AX

SU

BR

ST

RS

BT

HA
SEM962F

10. Remove fuel tube assembly. Refer to EC-36, “Injector Removal SC

and Installation”.

EL

IDX

SEM963F

EM-23
TIMING CHAIN
Removal (Cont’d)
11. Remove intake manifold in reverse order of installation. Refer
to “TIGHTENING PROCEDURES”, EM-10.

SEM964F

12. Remove RH and LH rocker covers from cylinder head.

SEM910E

13. Remove engine undercover.

14. Remove front RH wheel and engine side cover.
15. Remove drive belts and idler pulley bracket.

16. Remove power steering oil pump belt and power steering oil
pump assembly.

SEM911E

EM-24
TIMING CHAIN
Removal (Cont’d)
17. Remove camshaft position sensor (PHASE) and crankshaft
position sensors (REF)/(POS).
GI

MA

LC

EC

FE

CL

SEM912E
MT
18. Set No. 1 piston at TDC on the compression stroke by rotat-
ing crankshaft. AT

AX

SU

BR
SEM913E

19. Loosen crankshaft pulley bolt. (At this time remove oil pan rear
cover plate and set a suitable tool to ring gear so that crank- ST
shaft cannot rotate.)
I Be careful not to damage the signal plate teeth.
RS

BT

HA

SC

EL

IDX

SEM965F

EM-25
TIMING CHAIN
Removal (Cont’d)
20. Remove crankshaft pulley with a suitable puller.

SEM915E

21. Remove air compressor and bracket.

22. Remove front exhaust tube and its support.
23. Hang engine at right and left side engine slingers with a suit-
able hoist.
24. Remove right side engine mounting, mounting bracket and
nuts.
25. Remove center member assembly.
26. Remove upper and lower oil pans.
I For procedures described in steps 21 through 26, refer to
“Removal”, EM-12.
SEM812E

27. Remove water pump cover.

SEM916E

28. Remove front timing chain case bolts.

I Loosen bolts in numerical order as shown in the figure.

SEM917EA

EM-26
TIMING CHAIN
Removal (Cont’d)
29. Remove front timing chain case.
I Do not scratch sealing surfaces.
GI

MA

SEM156F LC
30. Remove internal chain guide.
31. Remove upper chain guide.
EC
32. Remove timing chain tensioner and slack side chain guide.

FE

CL

MT

AT

AX

SU

BR
SEM919E

I Remove timing chain tensioner. (Push piston and insert a suit-

able pin into pinhole.) ST

RS

BT

HA
SEM966F

SC

EL

IDX

EM-27
TIMING CHAIN
Removal (Cont’d)
33. Remove RH & LH camshaft sprocket 1ST bolts.
34. Remove camshaft sprockets 1ST on both sides, crankshaft
sprocket and timing chain.
I Apply paint to timing chain and camshaft sprockets 1ST
for alignment during installation.

SEM004G

35. Attach a suitable stopper pin to RH and LH camshaft chain

tensioners.

SEM927EA

36. Remove exhaust camshaft sprocket 2ND bolts on both sides.

I Apply paint to timing chain and camshaft sprockets 2ND
for alignment during installation.

SEM922E

EM-28
TIMING CHAIN
Removal (Cont’d)
37. Remove exhaust camshaft sprockets 2ND, intake camshaft
sprockets 2ND and camshaft chains on both sides.
GI

MA

SEM160F LC
38. Remove lower chain guide.
EC

FE

CL

SEM924E
MT
39. Use a scraper to remove all traces of liquid gasket from front
timing chain case. AT

AX

SU

BR
SEM925E

I Remove old liquid gasket from the bolt hole and thread.
ST

RS

BT

HA
SEM161F

40. Use a scraper to remove all traces of liquid gasket from water SC
pump cover.

EL

IDX

SEM926E

EM-29
TIMING CHAIN
Inspection

Inspection NFEM0013
Check for cracks and excessive wear at roller links. Replace
chain if necessary.

SEM928E

Installation NFEM0014
1. Install crankshaft sprocket on crankshaft.
I Make sure that mating marks on crankshaft sprocket face
front of engine.

SEM929E

2. Position crankshaft so that No. 1 piston is set at TDC on com-

pression stroke.

SEM930E

3. Install lower chain guide on dowel pin, with front mark on the
guide facing upside.

SEM931E

EM-30
TIMING CHAIN
Installation (Cont’d)
4. Align the marks on RH and LH intake camshaft sprockets 2ND,
exhaust camshaft sprockets 2ND and camshaft chain, as
shown. GI
5. Put LH camshaft dowel pin into camshaft sprocket dowel
groove and install these on camshaft. Tighten LH exhaust
camshaft sprocket 2ND bolt. MA
6. Put RH camshaft dowel pin in camshaft sprocket dowel groove
and install sprocket on camshaft.
7. Tighten RH exhaust camshaft sprocket 2ND bolt.
I Make sure that the timing marks on RH and LH intake
camshaft sprockets 2ND are aligned with the camshaft LC
chain mark.
I Lubricate threads and seat surfaces of camshaft sprocket
bolts with new engine oil. EC

FE

CL

SEM162F
MT
I Be careful not to confuse intake and exhaust camshaft
sprockets 2ND (their thicknesses are different). AT

AX

SU

BR
SEM932E

8. Remove RH and LH camshaft chain tensioner stopper pins.

ST

RS

BT

HA
SEM934E

SC

EL

IDX

EM-31
TIMING CHAIN
Installation (Cont’d)
9. Align mating mark on crankshaft sprocket with matchmark on
chain as shown.
10. Attach lower timing chain on the water pump sprocket.
11. Install RH and LH camshaft sprockets 1ST onto camshafts by
matching sprocket dowel grooves with camshaft.
12. Tighten RH and LH camshaft sprocket 1ST bolts.
I Lubricate threads and seat surfaces of the bolts with new
engine oil.
13. Install timing chain. Make sure that mating marks on crank-
shaft sprocket and RH and LH camshaft sprockets are aligned
with matchmarks on timing chain.

SEM163F

14. Install internal chain guide.

15. Install upper chain guide and slack side chain guide.

SEM919E

16. Install timing chain tensioner, then remove the stopper pin.
I When installing the timing chain tensioner, engine oil
should be applied to the oil hole and tensioner.
17. Apply liquid gasket to front timing chain case.
I Refer to “POSITION FOR APPLYING LIQUID GASKET”,
EM-20.
I Before installation, wipe off the protruding sealant.

SEM967F

EM-32
TIMING CHAIN
Installation (Cont’d)
18. Install rear case pin into dowel pin hole on front timing chain
case.
19. Tighten bolts to the specified torque in order shown in the fig- GI
ure.
I Leave the bolts unattended for 30 minutes or more after
tightening. MA

LC

EC

FE

CL

SEM938E
MT
20. Apply liquid gasket to water pump cover.
I Apply a continuous bead of liquid gasket to mating surface of AT
water pump cover. Refer to LC-14, “Water Pump Installation”.
21. Install water pump cover.
22. Apply liquid gasket to RH and LH rocker covers. AX
I Use genuine liquid gasket or equivalent.
I Refer to “POSITION FOR APPLYING LIQUID GASKET”, SU
EM-20.

BR
23. Install RH and LH rocker covers.
Rocker cover tightening procedure: ST
I Tighten in numerical order as shown in the figure.
a. Tighten bolts 1 to 10 in that order to 6.9 to 8.8 N·m (0.7 to 0.9 RS
kg-m, 61 to 78 in-lb).
b. Then tighten bolts 1 to 10 as indicated in figure to 6.9 to 8.8
N·m (0.7 to 0.9 kg-m, 61 to 78 in-lb). BT

HA
SEM941EA

SC

EL

IDX

SEM942EB

EM-33
TIMING CHAIN
Installation (Cont’d)
24. Install intake manifold. Tighten intake manifold nuts and bolts.
Refer to “TIGHTENING PROCEDURES”, EM-10.
25. Install fuel tube assembly.
26. Install intake manifold collector gasket.
27. Install intake manifold collector supports and intake manifold
collector bolt.
28. Install EGR guide tube.
29. Install RH and LH ignition coils.
30. Install rocker cover ornament on left side.
SEM944E

31. Install crankshaft pulley to crankshaft.

I Lubricate thread and seat surface of the bolt with new
engine oil.
a. Tighten to 39 to 49 N·m (4.0 to 5.0 kg-m, 29 to 36 ft-lb).
b. Put a paint mark on the crankshaft pulley.
c. Again tighten by turning 60° to 66°, about the angle from one
hexagon bolt head corner to another.

SEM968F

32. Install camshaft position sensor (PHASE), crankshaft position

sensors (REF)/(POS) and front heated oxygen sensor (left
bank) harness clamp.
I Make sure that crankshaft position sensor (POS) and front
heated oxygen sensor (left bank) harness clamp are
installed correctly as shown in figure.
33. Reinstall removed parts in reverse order of removal.
I When installing fuel tube assembly. Refer to EC-36, “REMOVAL
AND INSTALLATION”, “Injector”.
I After starting engine, keep idling for three minutes. Then
SEM963E rev engine up to 3,000 rpm under no load to purge air from
the high-pressure chamber of the chain tensioners. The
engine may produce a rattling noise. This indicates that
air still remains in the chamber and is not a matter of
concern.

SEM222F

EM-34
OIL SEAL
Replacement

Replacement NFEM0015
CAUTION:
When removing the oil pans, oil pump assembly and timing GI
chain from engine, first remove the camshaft position sensor
(PHASE) and the crankshaft position sensors (REF)/(POS)
from the assembly. MA
Be careful not to damage sensor edges.
VALVE OIL SEAL NFEM0015S01
1. Remove LH ornament cover.
2. Remove RH and LH ignition coils.
SEM948EB
3. Remove EGR guide tube.
LC
4. Remove intake manifold collector supports and intake manifold
collector (RH cylinder head only). EC
5. Remove RH and LH rocker covers from cylinder head.
6. Remove camshaft position sensor (PHASE) and crankshaft
position sensors (REF)/(POS). FE
7. Remove oil pan. Refer to “Removal”, EM-12.
8. Remove timing chain. Refer to “Removal”, EM-22. CL
9. Remove camshaft brackets and camshaft. Refer to
“Disassembly”, EM-39.
10. Remove valve lifters and shims. MT
11. Remove valve spring with Tool.
12. Reinstall any parts removed in reverse order of removal.
Before removing valve spring, fix valve as follows. AT
Method A:
Piston concerned should be set at TDC to prevent valve
from falling.
AX

SU

BR
Method B:
Remove spark plug, then install air hose adapter into ST
spark plug hole and apply air pressure to hold valves in
place. Apply a pressure of 490 kPa (4.9 bar, 5 kg/cm2, 71
psi). RS

BT

HA
SEM826E

Method C: SC
Install spark plug with suitable washer into spark plug
hole from combustion chamber side.
EL

IDX

SEM983D

EM-35
OIL SEAL
Replacement (Cont’d)
13. Remove valve oil seal.

SEM827E

14. Apply engine oil to new valve oil seal and install it with Tool.

SEM828EA

OIL SEAL INSTALLATION DIRECTION NFEM0015S02

I Install new oil seal in the direction shown in the figure.

SEM715A

FRONT OIL SEAL NFEM0015S03

1. Remove the following parts:
I Engine undercover
I Front RH wheel and engine side cover
I Drive belts
I Crankshaft position sensor (REF)
I Crankshaft pulley
Be careful not to damage sensor edge.

2. Remove front oil seal using a suitable tool.

Be careful not to scratch front cover.
3. Apply engine oil to new oil seal and install it using a suitable
tool.

SEM829E

EM-36
OIL SEAL
Replacement (Cont’d)
REAR OIL SEAL NFEM0015S04
1. Remove transaxle. Refer to MT-9 or AT-228.
2. Remove flywheel or drive plate. GI
3. Remove oil pan. Refer to EM-12.
4. Remove rear oil seal retainer. MA

SEM830EB LC
5. Remove old liquid gasket using scraper.
I Remove old liquid gasket from the bolt hole and thread.
EC

FE

CL

SEM831E
MT
6. Apply liquid gasket to rear oil seal retainer.
AT

AX

SU

BR
SEM832EA

ST

RS

BT

HA

SC

EL

IDX

EM-37
CYLINDER HEAD
Components

Components NFEM0016

SEM095G

1. Oil filler cap 6. Cylinder head 11. Valve spring

2. Rocker cover 7. Blow-by hose 12. Valve spring retainer
3. Camshaft bracket 8. Spark plug 13. Valve collet
4. Camshaft 9. Valve 14. Valve lifter
5. PCV valve 10. Valve spring seat 15. Shim

EM-38
CYLINDER HEAD
Components (Cont’d)
CAUTION:
I When installing camshafts, chain tensioners, oil seals, or
other sliding parts, lubricate contacting surfaces with new GI
engine oil.
I Apply new engine oil to threads and seat surfaces when
installing cylinder head, camshaft sprocket, crankshaft MA
pulley, and camshaft bracket.
I Attach tags to valve lifters so as not to mix them up.

LC
Removal NFEM0017
I This removal is the same procedure as that for timing EC
chain. Refer to “Removal”, EM-22.
I Apply paint to camshaft sprockets for alignment during
installation. FE

CL

MT
Disassembly NFEM0018
1. Remove rear timing chain case bolts. AT

AX

SU

BR
SEM167F

2. Remove rear timing chain case.

ST

RS

BT

HA
SEM096G

3. Remove intake and exhaust camshafts and camshaft brackets. SC

I Equally loosen camshaft bracket bolts in several steps in the
numerical order shown in the figure.
For reinstallation, be sure to put marks on camshaft EL
bracket before removal.
4. Remove valve component parts.
Refer to “VALVE OIL SEAL”, EM-35.
IDX

SEM856E

EM-39
CYLINDER HEAD
Disassembly (Cont’d)

SEM857E

5. Remove RH and LH camshaft chain tensioners from cylinder

head.

SEM489F

6. Remove cylinder head bolts.

I Cylinder head bolts should be loosened in two or three
steps.
I A warped or cracked cylinder head could result from
removing in incorrect order.

SEM859E

SEM860E

EM-40
CYLINDER HEAD
Disassembly (Cont’d)
7. Remove cylinder head.

GI

MA

SEM863E LC
Inspection NFEM0019
CYLINDER HEAD DISTORTION NFEM0019S01
EC
Clean surface of cylinder head.
Use a reliable straightedge and feeler gauge to check the flatness
of cylinder head surface. FE
Check along six positions shown in the figure.
Head surface flatness: Limit 0.1 mm (0.004 in)
If beyond the specified limit, resurface or replace it.
CL
The limit for cylinder head resurfacing is determined by the
cylinder block resurfacing. MT
SEM861E
Resurfacing limit:
Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”. AT
The maximum limit: A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates freely AX
by hand. If resistance is felt, cylinder head must be replaced.
Nominal cylinder head height:
126.3 - 126.5 mm (4.972 - 4.980 in) SU

BR

CAMSHAFT VISUAL CHECK

Check camshaft for scratches, seizure and wear.
NFEM0019S02 ST
CAMSHAFT RUNOUT
1.
NFEM0019S03
Measure camshaft runout at A and B as shown in the figure. RS
Runout (Total indicator reading):
Limit 0.05 mm (0.0020 in) BT
2. If it exceeds the limit, replace camshaft.

HA
SEM191F

CAMSHAFT CAM HEIGHT NFEM0019S04

SC
1. Measure camshaft cam height.

EL

IDX

SEM549A

EM-41
CYLINDER HEAD
Inspection (Cont’d)

Standard cam height Cam wear limit

43.355 - 43.545 mm
Intake
(1.7069 - 1.7144 in)
VQ20DE
43.405 - 43.595 mm
Exhaust
(1.7089 - 1.7163 in)
0.2 mm (0.008 in)
43.940 - 44.130 mm
Intake
(1.7299 - 1.7374 in)
VQ30DE
44.465 - 44.655 mm
Exhaust
(1.7506 - 1.7581 in)

2. If wear is beyond the limit, replace camshaft.

CAMSHAFT JOURNAL CLEARANCE NFEM0019S05

1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter “A” of camshaft bearing.
Standard inner diameter:
No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in)
No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)

SEM862E

3. Measure outer diameter of camshaft journal.

Standard outer diameter:
No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in)
No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)
4. If clearance exceeds the limit, replace camshaft and/or cylin-
der head.
Camshaft journal clearance:
Standard
No. 1: 0.045 - 0.086 mm (0.0018 - 0.0034 in)
SEM012A
No. 2, 3, 4: 0.035 - 0.076 mm (0.0014 - 0.0030 in)
Limit
0.15 mm (0.0059 in)

EM-42
CYLINDER HEAD
Inspection (Cont’d)
CAMSHAFT END PLAY NFEM0019S06
1. Install camshaft in cylinder head.
2. Measure camshaft end play. GI
Camshaft end play:
Standard MA
0.115 - 0.188 mm (0.0045 - 0.0074 in)
Limit
0.24 mm (0.0094 in)

SEM864E LC
CAMSHAFT SPROCKET RUNOUT NFEM0019S07
1. Install sprocket on camshaft. EC
2. Measure camshaft sprocket runout.
Runout (Total indicator reading):
Less than 0.15 mm (0.0059 in) FE
3. If it exceeds the limit, replace camshaft sprocket.
CL

SEM865E
MT
VALVE GUIDE CLEARANCE NFEM0019S08
1. Measure valve deflection as shown in the figure. (Valve and AT
valve guide mostly wear in this direction.)
Valve deflection limit (Dial gauge reading):
Intake 0.24 mm (0.0094 in)
AX
Exhaust 0.28 mm (0.0110 in)
SU

BR
SEM178F

2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diameter.
ST
b. Check that clearance is within specification.
Valve to valve guide clearance limit: RS
Intake 0.08 mm (0.0031 in)
Exhaust 0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
BT

HA
SEM938C

VALVE GUIDE REPLACEMENT NFEM0019S09

SC
1. To remove valve guide, heat cylinder head to 110 to 130°C
(230 to 266°F) by soaking in heated oil.
EL

IDX

SEM008A

EM-43
CYLINDER HEAD
Inspection (Cont’d)
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2
US ton, 2.0 Imp ton) pressure] or hammer and suitable tool.

SEM931C

3. Ream cylinder head valve guide hole.

Valve guide hole diameter (for service parts):
10.175 - 10.196 mm (0.4006 - 0.4014 in)

SEM932C

4. Heat cylinder head to 110 to 130°C (230 to 266°F) and press

service valve guide onto cylinder head.
Projection “L”:
12.6 - 12.8 mm (0.496 - 0.504 in)
5. Ream valve guide.
Finished size:
6.000 - 6.018 mm (0.2362 - 0.2369 in)

SEM950E

VALVE SEATS NFEM0019S10

Check valve seats for any evidence of pitting at valve contact
surface, and reseat or replace if it has worn out excessively.
I Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
I Use both hands to cut uniformly.

SEM934C

REPLACING VALVE SEAT FOR SERVICE PARTS NFEM0019S11

1. Bore out old seat until it collapses. Boring should not continue
beyond the bottom face of the seat recess in cylinder head. Set
the machine depth stop to ensure this.
2. Ream cylinder head recess for service valve seat.
Oversize [0.5 mm (0.020 in)]:
Intake 30.500 - 30.516 mm (1.2008 - 1.2014 in)
VQ20DE
Exhaust 25.500 - 25.516 mm (1.0039 - 1.0046 in)

SEM795A

EM-44
CYLINDER HEAD
Inspection (Cont’d)

Intake 37.500 - 37.516 mm (1.4764 - 1.4770 in)

VQ30DE
Exhaust 32.700 - 32.716 mm (1.2874 - 1.2880 in) GI
Be sure to ream in circles concentric to the valve guide
center. MA
This will enable valve seat to fit correctly.

LC
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking
in heated oil.
4. Press fit valve seat until it seats on the bottom.
EC
5. Cut or grind valve seat using suitable tool to the specified
dimensions as shown in SDS (EM-79). FE
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle “α”: 45° CL
Contacting width “W”:
Intake 1.09 - 1.31 mm (0.0429 - 0.0516 in) MT
SEM892B
Exhaust 1.29 - 1.51 mm (0.0508 - 0.0594 in)

AT

AX

SU

BR

VALVE DIMENSIONS
Check dimensions of each valve. For dimensions, refer to SDS
NFEM0019S12 ST
(EM-74).
When valve head has been worn down to 0.5 mm (0.020 in) in RS
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less. BT

HA
SEM188A

VALVE SPRING NFEM0019S13

SC
Squareness NFEM0019S1301
1. Measure dimension “S”.
Out-of-square “S”:
EL
VQ20DE Less than 2.3 mm (0.091 in)
IDX
VQ30DE Less than 2.1 mm (0.083 in)

2. If it exceeds the limit, replace spring.

SEM288A

EM-45
CYLINDER HEAD
Inspection (Cont’d)
Pressure NFEM0019S1302
Check valve spring pressure at specified spring height.
Pressure:
Engine VQ20DE VQ30DE

167 N (17 kg, 37 lb) at height 202 N (20.6 kg, 45.4 lb) at
Standard
37.0 mm (1.457 in) height 37.0 mm (1.457 in)

More than 298 N (30.4 kg, More than 436 N (44.5 kg,
Limit 67.0 lb) at height 29.25 mm 98.1 lb) at height 28.2 mm
(1.1516 in) (1.110 in)
EM113
If it exceeds the limit, replace spring.

VALVE LIFTER NFEM0019S14

1. Check contact and sliding surfaces for wear or scratches.

SEM960E

2. Check diameter of valve lifter and valve lifter guide bore.

Valve lifter outer diameter:
VQ20DE 29.965 - 29.975 mm (1.1797 - 1.1801 in)

VQ30DE 34.960 - 34.975 mm (1.3764 - 1.3770 in)

SEM961E

Lifter guide inner diameter:

IN 30.015 - 30.036 mm (1.1817 - 1.1825 in)
VQ20DE
EX 30.003 - 30.024 mm (1.1812 - 1.1820 in)

VQ30DE 35.000 - 35.021 mm (1.3780 - 1.3788 in)

SEM867E

EM-46
CYLINDER HEAD
Assembly

Assembly NFEM0020
1. Install valve component parts.
I Always use new valve oil seal. Refer to “VALVE OIL GI
SEAL”, EM-35.
I Before installing valve oil seal, install valve spring seat. MA
I Install valve spring (uneven pitch type) with its narrow
pitch side toward cylinder head side (paint mark).
I After installing valve component parts, tap valve stem tip with
plastic hammer to assure a proper fit.
SEM085D LC
Installation NFEM0021
1. Before installing rear timing chain case, remove old liquid gas- EC
ket from mating surface using a scraper.
I Also remove old liquid gasket from mating surface of cylinder
block. FE

CL

SEM891E
MT
I Remove old liquid gasket from the bolt hole and thread.
AT

AX

SU

BR
SEM161F

2. Before installing cam bracket, remove old liquid gasket from

mating surface using a scraper. ST
3. Remove O-rings from cylinder block.
RS

BT

HA
SEM892E

4. Turn crankshaft until No. 1 piston is set at approximately 240° SC

before TDC on compression stroke to prevent interference of
valves and pistons.
EL

IDX

SEM875E

EM-47
CYLINDER HEAD
Installation (Cont’d)
5. Install cylinder heads with new gaskets.
I Do not rotate crankshaft and camshaft separately, or
valves will strike piston heads.

SEM876E

CAUTION:
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between d1 and d2
exceeds the limit, replace them with new ones.
Limit (d1 - d2):
0.11 mm (0.0043 in)
I Lubricate threads and seat surfaces of the bolts with new
engine oil.

SEM957E

I Tightening procedure:
a. Tighten all bolts to 98 N·m (10 kg-m, 72 ft-lb).
b. Completely loosen all bolts.
c. Tighten all bolts to 34 to 44 N·m (3.5 to 4.5 kg-m, 25 to 33
ft-lb).
d. Turn all bolts 90 to 95 degrees clockwise.
e. Turn all bolts 90 to 95 degrees clockwise.
I Tighten in numerical order shown in the figure.

SEM877EA

SEM878EA

EM-48
CYLINDER HEAD
Installation (Cont’d)
6. Install cylinder head outside bolts.

GI

MA

SEM879EA LC
7. Install camshaft chain tensioners on both sides of cylinder
head.
EC

FE

CL

SEM490F
MT
8. Install exhaust and intake camshafts and camshaft brackets.
I Intake camshaft has a drill mark on camshaft sprocket AT
mounting flange. Install it on the intake side.

AX

SU

BR
SEM652F

I Identification marks are present on camshafts.

ST
Paint mark
Engine Bank INT/EXH ID mark Drill mark
M1 M2
RS
INT R2 Yes Yes No
RH
EXH R2 No No Yes BT
VQ20DE
INT L2 Yes Yes No
LH
EXH L2 No No Yes HA
SEM653F INT R3 Yes Yes No
RH
EXH R3 No No Yes SC
VQ30DE
INT L3 Yes Yes No
LH
EXH L3 No No Yes EL

IDX

EM-49
CYLINDER HEAD
Installation (Cont’d)
I Position camshaft
RH exhaust camshaft dowel pin at about 10 o’clock
LH exhaust camshaft dowel pin at about 2 o’clock

SEM888EA

9. Before installing camshaft brackets, apply sealant to mating

surface of No. 1 journal head.
I Use Genuine Liquid Gasket or equivalent.
I Refer to “POSITION FOR APPLYING LIQUID GASKET”,
EM-20.
I Install camshaft brackets in their original positions.
I Tighten camshaft bracket bolts gradually in two or three
stages.
I If any part of valve assembly or camshaft is replaced,
check valve clearance according to reference data.
After completing assembly check valve clearance. Refer
to “Checking” and “Adjusting” in “VALVE CLEARANCE”,
EM-52 and 54.
Reference data valve clearance (Cold):
Intake
0.26 - 0.34 mm (0.010 - 0.013 in)
Exhaust
0.29 - 0.37 mm (0.011 - 0.015 in)
I Lubricate threads and seat surfaces of camshaft bracket
bolts with new engine oil before installing them.

SEM884EB

I Align stamp mark as shown in the figure.

SEM188F

EM-50
CYLINDER HEAD
Installation (Cont’d)
I Tighten the camshaft brackets in the following steps.
Step Tightening torque Tightening order
GI
Tighten in the order of 7 to 10,
1 1.96 N·m (0.2 kg-m, 17 in-lb)
then tighten 1 to 6.

2 6 N·m (0.6 kg-m, 52 in-lb) Tighten in the numerical order.

MA
9.02 - 11.8 N·m (0.92 - 1.20 kg-m,
3 Tighten in the numerical order.
79.9 - 104.2 in-lb)

SEM885EA LC

EC

FE

CL

SEM886EA
MT
10. Install O-rings to cylinder block.
AT

AX

SU

BR
SEM887E

11. Apply sealant to the hatched portion of rear timing chain case.
I Apply continuous bead of liquid gasket to mating surface of
ST
rear timing chain case.
Refer to “POSITION FOR APPLYING LIQUID GASKET”,
EM-20.
RS
I Before installation, wipe off the protruding sealant.
BT

HA

SC

EL

IDX

EM-51
CYLINDER HEAD
Installation (Cont’d)
12. Align rear timing chain case with dowel pins, then install on
cylinder head and block.
13. Tighten rear chain case bolts.
a. Tighten bolts in numerical order shown in the figure.
b. Repeat above step a.
I This installation is the same procedure as that for timing chain.
Refer to “Installation”, EM-30.

SEM890EA

Valve Clearance NFEM0022

CHECKING NFEM0022S01
Check valve clearance while engine is cold and not running.
1. Remove intake manifold collector.
2. Remove rocker cover ornament.
3. Remove RH and LH rocker covers.
4. Remove all spark plugs.
5. Set No. 1 cylinder at TDC on its compression stroke.
I Align pointer with TDC mark on crankshaft pulley.
SEM868E I Check that valve lifters on No. 1 cylinder are loose and valve
lifters on No. 4 are tight.
If not, turn crankshaft one revolution (360°) and align as above.

EM-52
CYLINDER HEAD
Valve Clearance (Cont’d)
6. Check only those valves shown in the figure.
Valve
GI
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Crank
position INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH
MA
No. 1 TDC q q q q

LC

EC

FE

CL

SEM893E
MT
I Using a feeler gauge, measure clearance between valve lifter
and camshaft. AT
I Record any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim. AX
Valve clearance for checking (Cold):
Intake
SU
0.26 - 0.34 mm (0.010 - 0.013 in)
Exhaust
0.29 - 0.37 mm (0.011 - 0.015 in) BR
SEM139D

7. Turn crankshaft 240° and align as above.

8. Set No. 3 cylinder at TDC on its compression stroke.
ST
9. Check only those valves shown in the figure.
Valve RS
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Crank
position INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH
BT
No. 3 TDC q q q q
HA

SC

EL

IDX

SEM894E

EM-53
CYLINDER HEAD
Valve Clearance (Cont’d)
10. Turn crankshaft 240° and align as above.
11. Set No. 5 cylinder at TDC on its compression stroke.
12. Check only those valves shown in the figure.
Valve

No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

Crank
position INT EXH INT EXH INT EXH INT EXH INT EXH INT EXH

No. 5 TDC q q q q

13. If all valve clearances are within specification, install the fol-
lowing parts.
I Intake manifold collector
I RH and LH rocker covers
I All spark plugs
I Rocker cover ornament

SEM958E

ADJUSTING NFEM0022S02
Adjust valve clearance while engine is cold.
1. Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A), rotate notch toward center of cyl-
inder head (See figure.), to simplify shim removal later.
CAUTION:
Be careful not to damage cam surface with Tool (A).

SEM557EA

3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.

SEM869E

4. Place Tool (B) between camshaft and the edge of the valve
lifter to retain valve lifter.
CAUTION:
I Tool (B) must be placed as close to camshaft bracket as
possible.
I Be careful not to damage cam surface with Tool (B).
5. Remove Tool (A).

SEM870EA

EM-54
CYLINDER HEAD
Valve Clearance (Cont’d)
6. Blow air into the hole to separate adjusting shim from valve
lifter.
GI

MA

SEM871E LC
7. Remove adjusting shim using a small screwdriver and a mag-
netic finger.
8. Determine replacement adjusting shim size following formula.
EC
I Using a micrometer determine thickness of removed shim.
I Calculate thickness of new adjusting shim so valve clearance FE
comes within specified values.
R = Thickness of removed shim
N = Thickness of new shim CL
M = Measured valve clearance
Intake:
SEM872E N = R + [M − 0.30 mm (0.0118 in)] MT
Exhaust:
N = R + [M − 0.33 mm (0.0130 in)] AT
Shims are available in 64 sizes from 2.32 mm (0.0913 in)
to 2.95 mm (0.1161 in), in steps of 0.01 mm (0.0004 in).
I Select new shim with thickness as close as possible to calcu- AX
lated value.
SU

BR
SEM145D

ST

RS

BT

HA
SEM873E

9. Install new shim using a suitable tool. SC

I Install with the surface on which the thickness is stamped
facing down.
EL

IDX

SEM146D

EM-55
CYLINDER HEAD
Valve Clearance (Cont’d)
10. Place Tool (A) as mentioned in steps 2 and 3.
11. Remove Tool (B).
12. Remove Tool (A).
13. Recheck valve clearance.
Valve clearance:
Unit: mm (in)

Cold Hot* (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)

Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

SEM874E
*: Approximately 80°C (176°F)

EM-56
ENGINE ASSEMBLY
Removal and Installation

Removal and Installation NFEM0023

GI

MA

LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

SEM090G
HA
1. Front upper engine slinger 4. Rear engine mounting (Fluid type) 7. LH engine mounting
2. RH engine mounting 5. Center member 8. Rear engine slinger SC
3. Mounting bracket 6. Front engine mounting (Fluid type) 9. Insulator

WARNING:
EL
I Situate vehicle on a flat and solid surface.
I Place chocks at front and back of rear wheels. IDX
I Do not remove engine until exhaust system has com-
pletely cooled off. Otherwise, you may burn yourself
and/or fire may break out in fuel line.
I For safety during subsequent steps, the tension of wires
should be slackened against the engine.
EM-57
ENGINE ASSEMBLY
Removal and Installation (Cont’d)
I Before disconnecting fuel hose, release fuel pressure
from fuel line.
Refer to EC-34, “Fuel Pressure Release”.
I Before removing front axle from transaxle, place safety
stands under designated front supporting points. Refer to
GI-45, “Garage Jack and Safety Stand”.
I Be sure to hoist engine and transaxle in a safe manner.
I For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
I When lifting engine, be careful not to strike adjacent parts,
especially the following: Accelerator wire casing, brake
lines, and brake master cylinder.
I In hoisting the engine, always use engine slingers in a
safe manner.
I In removing drive shaft, be careful not to damage grease
seal of transaxle.
I Before separating engine and transaxle, remove the
crankshaft position sensor (POS) from the assembly.
I Always pay extra attention not to damage edge of crank-
shaft position sensor (POS) or ring gear teeth.

REMOVAL NFEM0023S01
1. Remove engine undercover and hood.
2. Drain coolant from both cylinder block and radiator. Refer to
MA-14, “Changing Engine Coolant”.
3. Remove vacuum hoses, fuel hoses, wires, harnesses, connec-
tors and so on.
4. Remove front exhaust tubes, ball joints and drive shafts.
5. Remove radiator and fans.
6. Remove drive belts.
7. Remove alternator, compressor and power steering oil pump
SEM971F
from engine.
8. Set a suitable transmission jack under transaxle. Hoist engine
with engine slinger.
9. Remove rear engine mounting.
10. Disconnect control rod and support rod from transaxle (M/T
model).
11. Disconnect control cable from transaxle (A/T model).

SEM835E

12. Remove front engine mounting.

SEM836E

EM-58
ENGINE ASSEMBLY
Removal and Installation (Cont’d)
13. Remove center member and then slowly lower transmission
jack.
GI

MA

SEM837E LC
14. Remove engine with transaxle as shown.
EC

FE

CL

MT

AT

AX

SU

BR
SEM972F

INSTALLATION
Installation is in the reverse order of removal.
NFEM0023S02 ST

RS

BT

HA

SC

EL

IDX

EM-59
CYLINDER BLOCK
Components

Components NFEM0024

SEM091G

1. Rear oil seal retainer 9. Main bearing cap 16. Drive plate reinforcement
2. Cylinder block 10. Main bearing beam 17. Oil ring
3. Knock sensor 11. Crankshaft 18. Piston pin
4. Upper main bearing 12. Pilot bushing or pilot converter 19. Connecting rod bearing
5. Lower main bearing 13. Flywheel with signal plate (M/T 20. Connecting rod
6. Water drain plug (LH side) models) 21. Piston
7. Water drain plug (RH side) 14. Drive plate with signal plate (A/T 22. Top ring
8. Water drain plug (Water pump model) 23. 2nd ring
side) 15. Flywheel reinforcement

EM-60
CYLINDER BLOCK
Removal and Installation

Removal and Installation NFEM0025

CAUTION:
I When installing bearings, pistons, or other sliding parts, GI
lubricate contacting surfaces with new engine oil.
I Place removed parts such as bearings and bearing caps
in their proper order and direction.
MA
I When installing connecting rod nuts, and main bearing
cap bolts, apply new engine oil to threads and seating
surfaces.
I Do not allow any magnetic materials to contact the signal
SEM180F plate teeth of flywheel or drive plate. LC
Disassembly NFEM0026
PISTON AND CRANKSHAFT NFEM0026S01
EC
1. Remove engine. Refer to “Removal and Installation”, EM-57.
2. Place engine on a work stand.
3. Drain coolant and oil. FE
4. Remove oil pan. Refer to “Removal”, EM-12.
5. Remove timing chain. Refer to “Removal”, EM-22. CL
6. Remove cylinder head. Refer to “Removal”, EM-39.

SEM841EA
MT
7. Remove pistons with connecting rods.
I When disassembling piston and connecting rod, remove snap AT
ring first, then heat piston to 60 to 70°C (140 to 158°F).
8. Remove rear oil seal retainer.
CAUTION:
AX
I When piston rings are not replaced, make sure that piston
rings are mounted in their original positions.
SU
I When replacing piston rings, if there is no punchmark,
install with either side up.
BR
SEM965A

9. Loosen bolts in numerical order as shown and remove main

bearing beam (for VQ30DE), bearing cap and crankshaft. ST
I Before removing bearing beam and bearing cap, measure
crankshaft end play. Refer to EM-70.
RS
I Bolts should be loosened in two or three steps.

BT

HA
SEM842E

Inspection NFEM0027
SC
PISTON AND PISTON PIN CLEARANCE NFEM0027S01
1. Measure inner diameter of piston pin hole “dp”. EL
Standard diameter “dp”:
Grade No. 0
21.993 - 21.999 mm (0.8659 - 0.8661 in) IDX
Grade No. 1
21.999 - 22.005 mm (0.8661 - 0.8663 in)

AEM023

EM-61
CYLINDER BLOCK
Inspection (Cont’d)
2. Measure outer diameter of piston pin “Dp”.
Standard diameter “Dp”:
Grade No. 0
21.989 - 21.995 mm (0.8657 - 0.8659 in)
Grade No. 1
21.995 - 22.001 mm (0.8659 - 0.8662 in)
3. Calculate interference fit of piston pin to piston.
Dp − dp = 0.002 - 0.006 mm (0.0001 - 0.0002 in)
If it exceeds the above value, replace piston assembly with pin.
AEM024

PISTON RING SIDE CLEARANCE NFEM0027S02

Side clearance:
Ring Engine Standard Limit

0.045 - 0.080 mm
VQ20DE
(0.0018 - 0.0031 in)
Top ring 0.11 mm (0.0043 in)
0.040 - 0.080 mm
VQ30DE
(0.0016 - 0.0031 in)

VQ20DE 0.030 - 0.070 mm

2nd ring 0.10 mm (0.0039 in)
SEM024AA VQ30DE (0.0012 - 0.0028 in)

VQ20DE 0.015 - 0.185 mm

Oil ring —
VQ30DE (0.0006 - 0.0073 in)

If out of specification, replace piston ring. If clearance exceeds

maximum limit with new ring, replace piston.

PISTON RING END GAP NFEM0027S03

End gap:
Ring Engine Standard Limit

0.18 - 0.28 mm
VQ20DE 0.51 mm (0.0201 in)
(0.0071 - 0.0110 in)
Top ring
0.22 - 0.32 mm
VQ30DE 0.55 mm (0.0217 in)
(0.0087 - 0.0126 in)

0.30 - 0.45 mm
VQ20DE 0.65 mm (0.0256 in)
(0.0118 - 0.0177 in)
SEM599A 2nd ring
0.32 - 0.47 mm
VQ30DE 0.85 mm (0.0335 in)
(0.0126 - 0.0185 in)

Oil ring (rail VQ20DE 0.20 - 0.60 mm

0.95 mm (0.0374 in)
ring) VQ30DE (0.0079 - 0.0236 in)

If out of specification, replace piston ring. If gap still exceeds the

limit even with a new ring, do the following. Rebore cylinder and
use oversized piston and piston rings.
Refer to SDS (EM-83).
I When replacing the piston, check the cylinder block surface for
scratches or seizure. If scratches or seizure is found, hone or

EM-62
CYLINDER BLOCK
Inspection (Cont’d)
replace the cylinder block.

GI

MA

LC
CONNECTING ROD BEND AND TORSION NFEM0027S04
Bend: EC
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion: FE
Limit 0.30 mm (0.0118 in)
per 100 mm (3.94 in) length CL
If it exceeds the limit, replace connecting rod assembly.

SEM038F
MT

AT

AX

SU

BR
SEM003F

CYLINDER BLOCK DISTORTION AND WEAR

I Clean upper surface of cylinder block.
NFEM0027S05 ST
Use a reliable straightedge and feeler gauge to check the flat-
ness of cylinder block surface. RS
Check along six positions shown in the figure.
Distortion limit: 0.10 mm (0.0039 in)
I If out of specification, resurface it. The limit for cylinder block BT
resurfacing is determined by cylinder head resurfacing in
engine.
Resurfacing limit: HA
SEM123C Amount of cylinder head resurfacing is “A”.
Amount of cylinder block resurfacing is “B”.
The maximum limit is as follows: SC
A + B = 0.2 mm (0.008 in)
Nominal cylinder block height from crankshaft center: EL
214.95 - 215.05 mm (8.4626 - 8.4665 in)
Refer to SDS (EM-81).
I If necessary, replace cylinder block. IDX

EM-63
CYLINDER BLOCK
Inspection (Cont’d)
PISTON-TO-BORE CLEARANCE NFEM0027S06
1. Using a bore gauge, measure cylinder bore for wear, out-of-
round and taper.
Cylinder bore inner diameter
Grade No. Engine Standard inner diameter Wear limit

76.000 - 76.010 mm
VQ20DE
(2.9921 - 2.9925 in)
No. 1
93.000 - 93.010 mm
VQ30DE
(3.6614 - 3.6618 in)
SEM843E
76.011 - 76.020 mm
VQ20DE
(2.9926 - 2.9929 in) 0.20 mm
No. 2
93.011 - 93.020 mm (0.0079 in)
VQ30DE
(3.6618 - 3.6622 in)

76.021 - 76.030 mm
VQ20DE
(2.9929 - 2.9933 in)
No. 3
93.021 - 93.030 mm
VQ30DE
(3.6622 - 3.6626 in)

If it exceeds the limit, rebore all cylinders. Replace cylinder

SEM321AA block if necessary.
Out-of-round (X − Y):
Limit 0.015 mm (0.0006 in)
Taper (A − B − C):
Limit 0.015 mm (0.0006 in)
2. Check for scratches and seizure. If seizure is found, hone it.

I If both cylinder block and piston are replaced with new

ones, select piston of the same grade number punched on
cylinder block rear position. These numbers are punched
in either Arabic or Roman numerals.

SEM174F

3. Measure piston skirt diameter.

Piston diameter “A”: Refer to SDS (EM-83).
Measuring point “a” (Distance from the top):
45.4 mm (1.787 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance “B”:
VQ20DE
0.010 - 0.030 mm (0.0004 - 0.0012 in)
VQ30DE
SEM258C 0.010 - 0.032 mm (0.0004 - 0.0013 in)

EM-64
CYLINDER BLOCK
Inspection (Cont’d)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. GI
Refer to SDS (EM-83).
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter “A”. MA
Rebored size calculation: D = A + B − C
where,
D: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance LC
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified torque.
Otherwise, cylinder bores may be distorted in final assembly.
EC
8. Cut cylinder bores.
I When any cylinder needs boring, all other cylinders must FE
also be bored.
I Do not cut too much out of cylinder bore at a time. Cut
only 0.05 mm (0.0020 in) or so in diameter at a time. CL
9. Hone cylinders to obtain specified piston-to-bore clearance.
10. Measure finished cylinder bore for out-of-round and taper.
MT
I Measurement should be done after cylinder bore cools
down.
AT

AX

SU

BR

CRANKSHAFT
1.
NFEM0027S07
Check crankshaft main and pin journals for score, wear or
ST
cracks.
2. With a micrometer, measure journals for taper and out-of- RS
round.
Out-of-round (X − Y):
Standard BT
0.002 mm (0.0001 in)
Taper (A − B): HA
Standard
SEM316A
0.002 mm (0.0001 in)
SC

EL

IDX

EM-65
CYLINDER BLOCK
Inspection (Cont’d)
3. Measure crankshaft runout.
Runout (Total indicator reading):
Limit 0.10 mm (0.0039 in)

SEM346D

BEARING CLEARANCE NFEM0027S08

I Use either of the following two methods, however, method “A”
gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearing NFEM0027S0801
1. Set main bearings in their proper positions on cylinder block
and main bearing cap.

SEM175F

2. Install main bearing cap and bearing beam to cylinder block.

Tighten all bolts in correct order.
3. Measure inner diameters “A” of each main bearing.

SEM845E

4. Measure outer diameters “Dm” of each crankshaft main jour-

nal.
5. Calculate main bearing clearance.
Main bearing clearance = A − Dm
Standard: 0.012 - 0.030 mm (0.0005 - 0.0012 in)
Limit: 0.065 mm (0.0026 in)
I If it exceeds the limit, replace bearing.
I If clearance cannot be adjusted using any standard bearing
grade, grind crankshaft journal and use undersized bearing.

AEM033

a. When grinding crankshaft journal, confirm that “L” dimension in

fillet roll is more than the specified limit.
“L”: 0.1 mm (0.004 in)
b. Refer to SDS for grinding crankshaft and available service
parts.

SEM964

EM-66
CYLINDER BLOCK
Inspection (Cont’d)
6. If crankshaft or cylinder block is replaced with a new one,
select thickness of main bearings as follows:
a. Grade number of each cylinder block main journal is punched GI
on the respective cylinder block. These numbers are punched
in either Arabic or Alphabet. Refer to SDS, EM-81.
If measured diameter is out of grade punched, decide suitable MA
grade using table in SDS.

SEM176F LC
b. Grade number of each crankshaft main journal is punched on
the respective crankshaft. These numbers are punched in
either Arabic or Alphabet. Refer to SDS, EM-84. EC
If measured diameter is out of grade punched, decide suitable
grade using table in SDS.
c. Select main bearing with suitable thickness according to the
FE
following table.
Refer to “SDS”, EM-86, for available main bearings. CL

SEM847E
MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

SEM078G EL

IDX

EM-67
CYLINDER BLOCK
Inspection (Cont’d)
Connecting Rod Bearing (Big end) NFEM0027S0802
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter “C” of connecting rod.

AEM027

4. Measure outer diameter “Dp” of each crankshaft pin journal.

5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C − Dp
Standard: 0.020 - 0.045 mm (0.0008 - 0.0018 in)
Limit: 0.070 mm (0.0028 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bearing.
Refer to “BEARING CLEARANCE — Main bearing”, EM-66.

AEM034

8. If crankshaft is replaced with a new one, select connecting rod

bearing according to the following table.
Connecting rod bearing grade number (Identification
color):
These numbers are punched in either Arabic or Roman numer-
als.
Crankshaft pin journal grade
Connecting rod bearing grade number
number

0 0 (Black)

SEM848E 1 1 (Brown)

2 2 (Green)

Method B (Using plastigage)

CAUTION:
I Do not turn crankshaft or connecting rod while plastigage
is being inserted.
I When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. If incor-
rect bearing clearance exists, use a thicker or undersized
main bearing to ensure specified clearance.
EM142

CONNECTING ROD BUSHING CLEARANCE (SMALL

END) NFEM0027S09
1. Measure inner diameter “C” of bushing.
2. Measure outer diameter “Dp” of piston pin.
3. Calculate connecting rod bushing clearance.
Connecting rod bushing clearance = C − Dp
Standard: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
Limit: 0.030 mm (0.0012 in)
If it exceeds the limit, replace connecting rod assembly or
connecting rod bushing and/or piston set with pin.
SEM673E

EM-68
CYLINDER BLOCK
Inspection (Cont’d)
REPLACEMENT OF CONNECTING ROD BUSHING
(SMALL END) NFEM0027S10
1. Drive in small end bushing until it is flush with end surface of GI
rod.
Be sure to align the oil holes.
2. After driving in small end bushing, ream the bushing. This is MA
to ensure the clearance between connecting rod bushing and
piston pin is the specified value.
Clearance between connecting rod bushing and piston
pin: 0.005 - 0.017 mm (0.0002 - 0.0007 in)
SEM062A LC
FLYWHEEL/DRIVE PLATE RUNOUT NFEM0027S11
Runout (Total indicator reading): EC
Flywheel (M/T model)★
Less than 0.15 mm (0.0059 in)
Drive plate (A/T model) FE
Less than 0.15 mm (0.0059 in)
★ Measurement position: CL
Approximately 145 mm (5.71 in) from the crankshaft center
CAUTION:
SEM849EA
I The signal plate is built into the flywheel assembly. Be MT
careful not to damage the signal plate, especially the
teeth.
I Check the drive plate and signal plate for deformation or AT
cracks.
I Never place the flywheel assembly with the signal plate
facing down. AX
I Keep any magnetized objects away from the signal plate.
I Do not allow any magnetic materials to contact the signal SU
plate teeth.
I Do not surface flywheel. Replace as necessary.
BR

Assembly NFEM0028 ST
PISTON NFEM0028S01
1. Install new snap ring on one side of piston pin hole.
2. Heat piston to 60 to 70°C (140 to 158°F) and assemble piston, RS
piston pin, connecting rod and new snap ring.
I Align the direction of piston and connecting rod.
BT
I Numbers stamped on connecting rod and cap correspond
to each cylinder.
I After assembly, make sure connecting rod swings HA
smoothly.
SEM838F

3. Set piston rings as shown. SC

CAUTION:
I When piston rings are not replaced, make sure that piston
rings are mounted in their original positions. EL
I When replacing piston rings, these without punchmarks,
present, piston rings can be mounted with either side up.
IDX

SEM965E

EM-69
CYLINDER BLOCK
Assembly (Cont’d)
I Align piston rings so that end gaps are positioned as
shown in the figure.

SEM160B

CRANKSHAFT NFEM0028S02
1. Set main bearings in their proper positions on cylinder block
and main bearing beam.
I Confirm that correct main bearings are used. Refer to
“Inspection” of this section.

SEM175F

2. Instructions for re-use of main bearing cap bolts.

I A plastic zone tightening method is used for tightening
main bearing cap bolts. Measure d1 and d2 as shown in
the figure.
d2: Select minimum diameter in the measuring area.
If the difference between d1 and d2 exceeds the limit,
replace the bolts with new ones.
Limit (d1 - d2): 0.11 mm (0.0043 in)

SEM177F

3. After installing crankshaft, main bearing cap, main bearing

beam (for VQ30DE) and bearing cap bolts, tighten bearing cap
bolts in numerical order as shown.
I Tightening procedure
a) Tighten all bolts to 32 to 38 N·m (3.3 to 3.9 kg-m, 24 to 28
ft-lb).
b) Turn all bolts 90 to 95 degrees clockwise with angle
wrench.
I Prior to tightening bearing cap bolts, place bearing beam
in its proper position by shifting crankshaft in the axial
SEM851E direction.
I After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
I Lubricate threads and seat surfaces of the bolts with new
engine oil.
4. Measure crankshaft end play.
Crankshaft end play:
Standard
0.10 - 0.25 mm (0.0039 - 0.0098 in)
Limit
0.30 mm (0.0118 in)
SEM852E If beyond the limit, replace bearing with a new one.
EM-70
CYLINDER BLOCK
Assembly (Cont’d)
5. Install connecting rod bearings in connecting rods and con-
necting rod caps.
I Confirm that correct bearings are used. GI

MA

SEM973F LC
6. Install pistons with connecting rods.
a. Install them into corresponding cylinders with Tool.
EC
I Be careful not to scratch cylinder wall with the connecting
rod.
I Arrange so that front mark on piston head faces toward FE
engine front.

CL

SEM620-B
MT
b. A plastic zone tightening method is used for tightening con-
necting rod bolts and nuts. Check the old bolts for deformation AT
before re-using them.
I Ensure that the connecting rod nut can be screwed
smoothly as far as the bolt thread end. AX
I If this is not possible, use slide calipers to measure the
outside diameter of the narrowest thread part of the bolt
at 16 mm (0.63 in) from the thread end. Replace the con- SU
necting rod bolt and nut, if under the limit.
Standard: 7.90 - 8.00 mm (0.3110 - 0.3150 in)
BR
SEM956E Limit: 7.75 mm (0.3051 in)
c. Install connecting rod caps.
I Lubricate threads and seat surfaces with new engine oil.
ST
Tighten connecting rod bearing cap nuts to the specified
torque. RS
Connecting rod bearing nut:
(1) Tighten nuts to 19 to 21 N·m (1.9 to 2.1 kg-m, 14
to 15 ft-lb). BT
(2) Turn nuts 90 to 95 degrees clockwise with angle
wrench.
HA
SEM953E

7. Measure connecting rod side clearance. SC

Connecting rod side clearance:
Standard
0.20 - 0.35 mm (0.0079 - 0.0138 in) EL
Limit
0.40 mm (0.0157 in) IDX
If beyond the limit, replace connecting rod and/or crankshaft.
8. Install rear oil seal retainer.

SEM954E

EM-71
CYLINDER BLOCK
Assembly (Cont’d)
REPLACEMENT OF PILOT BUSHING (M/T) OR PILOT
CONVERTER (A/T) NFEM0028S04
1. Remove pilot bushing or pilot converter using tool or suitable
tool.

SEM005GA

2. Install pilot bushing or pilot converter as shown.

SEM163B

EM-72
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications

General Specifications NFEM0029

Engine VQ20DE VQ30DE GI

Cylinder arrangement V-6

Displacement 3
cm (cu in) 1,995 (121.73) 2,988 (182.33) MA
Bore and stroke mm (in) 76.0 × 73.3 (2.992 × 2.886) 93 × 73.3 (3.66 × 2.886)

Valve arrangement DOHC

Firing order 1-2-3-4-5-6

Compression 2 LC
Number of piston rings
Oil 1

Number of main bearings 4 EC

Compression ratio 9.5 10.0

Compression Pressure FE
NFEM0030
Unit: kPa (bar, kg/cm2, psi)/300 rpm

Standard 1,275 (12.75, 13.0, 185) CL

Compression pressure Minimum 981 (9.81, 10.0, 142)

Differential limit between cylinders 98 (0.98, 1.0, 14) MT

Cylinder number
AT

AX

SU

SEM713A BR

Cylinder Head NFEM0031

ST
Unit: mm (in)

Standard Limit
RS
Head surface distortion Less than 0.03 (0.0012) 0.1 (0.004)

BT

HA

SC

EL
SEM949E
IDX

EM-73
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve

Valve NFEM0032
VALVE NFEM0032S01
Unit: mm (in)

SEM188

Engine VQ20DE VQ30DE

Intake 29.0 - 29.3 (1.142 - 1.154) 36.0 - 36.3 (1.417 - 1.429)

Valve head diameter “D”
Exhaust 23.9 - 24.2 (0.941 - 0.953) 31.2 - 31.5 (1.228 - 1.240)

Intake 99.44 - 99.94 (3.9150 - 3.9346) 97.32 - 97.82 (3.8315 - 3.8512)

Valve length “L”
Exhaust 96.97 - 97.47 (3.8177 - 3.8374) 94.85 - 95.35 (3.7342 - 3.7539)

Intake 5.965 - 5.980 (0.2348 - 0.2354)

Valve stem diameter “d”
Exhaust 5.945 - 5.960 (0.2341 - 0.2346)

Intake
Valve seat angle “α” 45°15′ - 45°45′
Exhaust

Intake 0.95 - 1.25 (0.0374 - 0.0492)

Valve margin “T”
Exhaust 1.15 - 1.45 (0.0453 - 0.0571)

Valve margin “T” limit More than 0.5 (0.020)

Valve stem end surface grinding limit Less than 0.2 (0.008)

Intake 0.26 - 0.34 (0.010 - 0.013)

Valve clearance (Cold)
Exhaust 0.29 - 0.37 (0.011 - 0.015)

VALVE CLEARANCE NFEM0032S02

Unit: mm (in)

Cold Hot* (reference data)

Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016)

Exhaust 0.29 - 0.37 (0.011 - 0.015) 0.308 - 0.432 (0.012 - 0.017)

*: Approximately 80°C (176°F)

EM-74
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve (Cont’d)
AVAILABLE SHIMS =NFEM0032S03

Engine VQ20DE VQ30DE

GI
ID mark Thickness mm (in)

210 2.10 (0.0827) —

MA
212 2.12 (0.0835) —

214 2.14 (0.0843) —

216 2.16 (0.0850) —

218 2.18 (0.0858) — LC

220 2.20 (0.0866) —

221 2.21 (0.0870) — EC

222 2.22 (0.0874) —

223 2.23 (0.0878) — FE

224 2.24 (0.0882) —

225 2.25 (0.0886) — CL

226 2.26 (0.0890) —

227 2.27 (0.0894) — MT

228 2.28 (0.0898) —

229 2.29 (0.0902) — AT

230 2.30 (0.0906) —

231 2.31 (0.0909) — AX

232 2.32 (0.0913)

233 2.33 (0.0917) SU

234 2.34 (0.0921)

235 2.35 (0.0925) BR

236 2.36 (0.0929)

237 2.37 (0.0933) ST

238 2.38 (0.0937)

239 2.39 (0.0941) RS

240 2.40 (0.0945)

241 2.41 (0.0949) BT

242 2.42 (0.0953)

243 2.43 (0.0957) HA

244 2.44 (0.0961)

245 2.45 (0.0965) SC

246 2.46 (0.0969)

247 2.47 (0.0972) EL

248 2.48 (0.0976)

249 2.49 (0.0980) IDX

250 2.50 (0.0984)

251 2.51 (0.0988)

252 2.52 (0.0992)

EM-75
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve (Cont’d)

Engine VQ20DE VQ30DE

ID mark Thickness mm (in)

253 2.53 (0.0996)

254 2.54 (0.1000)

255 2.55 (0.1004)

256 2.56 (0.1008)

257 2.57 (0.1012)

258 2.58 (0.1016)

259 2.59 (0.1020)

260 2.60 (0.1024)

261 2.61 (0.1028)

262 2.62 (0.1031)

263 2.63 (0.1035)

264 2.64 (0.1039)

265 2.65 (0.1043)

266 2.66 (0.1047)

267 — 2.67 (0.1051)

268 2.68 (0.1055)

269 — 2.69 (0.1059)

270 2.70 (0.1063)

271 — 2.71 (0.1067)

272 2.72 (0.1071)

273 — 2.73 (0.1075)

274 — 2.74 (0.1079)

275 — 2.75 (0.1083)

276 — 2.76 (0.1087)

277 — 2.77 (0.1091)

278 — 2.78 (0.1094)

279 — 2.79 (0.1098)

280 — 2.80 (0.1102)

281 — 2.81 (0.1106)

282 — 2.82 (0.1110)

283 — 2.83 (0.1114)

284 — 2.84 (0.1118)

285 — 2.85 (0.1122)

286 — 2.86 (0.1126)

287 — 2.87 (0.1130)

288 — 2.88 (0.1134)

289 — 2.89 (0.1138)

290 — 2.90 (0.1142)

291 — 2.91 (0.1146)

EM-76
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve (Cont’d)

Engine VQ20DE VQ30DE

ID mark Thickness mm (in) GI

292 — 2.92 (0.1150)

293 — 2.93 (0.1154) MA

294 — 2.94 (0.1157)

295 — 2.95 (0.1161)

—: Not available

LC

EC

FE

CL
SEM966E
MT
VALVE SPRING NFEM0032S04

Engine VQ20DE VQ30DE AT

Free height mm (in) 53.14 (2.0921) 47.10 (1.8543)

Pressure Standard 167 (17, 37) at 37.0 (1.457) 202 (20.6, 45.4) at 37.0 (1.457) AX
N (kg, lb) at height mm (in)
Limit 298 (30.4, 67.0) at 29.25 (1.1516) 436 (44.5, 98.1) at 28.2 (1.110)

Out-of-square mm (in) Less than 2.3 (0.091) Less than 2.1 (0.083) SU
VALVE LIFTER NFEM0032S05
Unit: mm (in) BR
Engine VQ20DE VQ30DE

Valve lifter outer diameter 29.965 - 29.975 (1.1797 - 1.1801) 34.960 - 34.975 (1.3764 - 1.3770) ST
IN 30.015 - 30.036 (1.1817 - 1.1825)
Lifter guide inner diameter 35.000 - 35.021 (1.3780 - 1.3788)
EX 30.003 - 30.024 (1.1812 - 1.1820) RS
IN 0.040 - 0.071 (0.0016 - 0.0028)
Clearance between lifter and lifter guide 0.025 - 0.061 (0.0010 - 0.0024)
EX 0.028 - 0.059 (0.0011 - 0.0023) BT

HA

SC

EL

IDX

EM-77
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve (Cont’d)
VALVE GUIDE =NFEM0032S06
Unit: mm (in)

SEM950E

Standard Service

Outer diameter 10.023 - 10.034 (0.3946 - 0.3950) 10.223 - 10.234 (0.4025 - 0.4029)
Valve guide
Inner diameter (Finished size) 6.000 - 6.018 (0.2362 - 0.2369)

Cylinder head valve guide hole diameter 9.975 - 9.996 (0.3927 - 0.3935) 10.175 - 10.196 (0.4006 - 0.4014)

Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023)

Standard Max. tolerance

Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.08 (0.0031)

Stem to guide clearance
Exhaust 0.040 - 0.073 (0.0016 - 0.0029) 0.1 (0.004)

Intake — 0.24 (0.0094)

Valve deflection limit
Exhaust — 0.28 (0.0110)

Projection length “L” 12.6 - 12.8 (0.496 - 0.504)

EM-78
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Seat

Valve Seat =NFEM0033

Unit: mm (in)
GI

MA

LC

EC

FE

CL

MT

AT

AX
SEM179F
SU
VQ20DE NFEM0033S03
Unit: mm (in) BR
Standard Service

In. 30.000 - 30.016 (1.1811 - 1.1817) 30.500 - 30.516 (1.2008 - 1.2014) ST

Cylinder head seat recess diameter (D)
Ex. 25.000 - 25.016 (0.9843 - 0.9849) 25.500 - 25.516 (1.004 - 1.0046)

In. 0.064 - 0.096 (0.0025 - 0.0038) RS

Valve seat interference fit
Ex. 0.064 - 0.096 (0.0025 - 0.0038)

In. 30.080 - 30.096 (1.1842 - 1.1849) 30.580 - 30.596 (1.2039 - 1.2046) BT

Valve seat outer diameter (d)
Ex. 25.080 - 25.096 (0.9874 - 0.9880) 25.580 - 25.596 (1.0071 - 1.0077)

In. 6.2 - 6.3 (0.244 - 0.248) 5.55 - 5.65 (0.2185 - 0.2224) HA

Height (h)
Ex. 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)

Depth (H) 5.9 - 6.1 (0.232 - 0.240) SC

VQ30DE NFEM0033S04
Unit: mm (in) EL
Standard Service

In. 37.000 - 37.016 (1.4567 - 1.4573) 37.500 - 37.516 (1.4764 - 1.4770)

IDX
Cylinder head seat recess diameter (D)
Ex. 32.200 - 32.216 (1.2677 - 1.2683) 32.700 - 32.716 (1.2874 - 1.2880)

EM-79
SERVICE DATA AND SPECIFICATIONS (SDS)
Valve Seat (Cont’d)

Standard Service

In. 0.081 - 0.113 (0.0032 - 0.0044)

Valve seat interference fit
Ex. 0.064 - 0.096 (0.0025 - 0.0038)

In. 37.097 - 37.113 (1.4605 - 1.4611) 37.597 - 37.613 (1.4802 - 1.4808)

Valve seat outer diameter (d)
Ex. 32.280 - 32.296 (1.2709 - 1.2715) 32.780 - 32.796 (1.2905 - 1.2912)

In. 5.9 - 6.0 (0.232 - 0.236) 5.05 - 5.15 (0.1988 - 0.2028)

Height (h)
Ex. 5.9 - 6.0 (0.232 - 0.236) 4.95 - 5.05 (0.1949 - 0.1988)

Depth (H) 5.9 - 6.1 (0.232 - 0.240)

Camshaft and Camshaft Bearing NFEM0034

Unit: mm (in)

Standard Limit

No. 1
0.045 - 0.086 (0.0018 - 0.0034)
Camshaft journal to bearing clearance 0.15 (0.0059)
No. 2, 3, 4
0.035 - 0.076 (0.0014 - 0.0030)

No. 1
26.000 - 26.021 (1.0236 - 1.0244)
Inner diameter of camshaft bearing —
No. 2, 3, 4
23.500 - 23.521 (0.9252 - 0.9260)

No. 1
25.935 - 25.955 (1.0211 - 1.0218)
Outer diameter of camshaft journal —
No. 2, 3, 4
23.445 - 23.465 (0.9230 - 0.9238)

Camshaft runout [TIR*] Less than 0.02 (0.0008) 0.05 (0.0020)

Camshaft sprocket runout [TIR*] Less than 0.15 (0.0059) —

Camshaft end play 0.115 - 0.188 (0.0045 - 0.0074) 0.24 (0.0094)

EM671

Engine VQ20DE VQ30DE

Intake 43.355 - 43.545 (1.7069 - 1.7144) 43.940 - 44.130 (1.7299 - 1.7374)

Cam height “A”
Exhaust 43.405 - 43.595 (1.7089 - 1.7163) 44.465 - 44.655 (1.7506 - 1.7581)

Wear limit of cam height 0.2 (0.008)

*: Total indicator reading

EM-80
SERVICE DATA AND SPECIFICATIONS (SDS)
Camshaft and Camshaft Bearing (Cont’d)

Valve timing

GI

MA

LC
EM120

Unit: degree EC
a b c d e f

VQ20DE 232 224 3 41 3 49 FE

VQ30DE 232 224 3 41 3 49

CL
Cylinder Block NFEM0035
Unit: mm (in)
MT

AT

AX

SU
SEM022EA
BR
VQ20DE VQ30DE
Limit
Standard
ST
Surface flatness Less than 0.03 (0.0012) 0.1 (0.004)

Grade No. 1 76.000 - 76.010 (2.9921 - 2.9925) 93.000 - 93.010 (3.6614 - 3.6618)
Cylinder bore inner
RS
Grade No. 2 76.011 - 76.020 (2.9926 - 2.9929) 93.011 - 93.020 (3.6618 - 3.6622) 0.20 (0.0079)
diameter
Grade No. 3 76.021 - 76.030 (2.9929 - 2.9933) 93.021 - 93.030 (3.6622 - 3.6626)
BT
Out-of-round (X − Y) Less than 0.015 (0.0006) —

Taper (A − B − C) Less than 0.015 (0.0006) —

HA

SC

EL

IDX

EM-81
SERVICE DATA AND SPECIFICATIONS (SDS)
Cylinder Block (Cont’d)

Grade No. A 63.993 - 63.994 (2.5194 - 2.5194)

Grade No. B 63.994 - 63.995 (2.5194 - 2.5195)

Grade No. C 63.995 - 63.996 (2.5195 - 2.5195)

Grade No. D 63.996 - 63.997 (2.5195 - 2.5196)

Grade No. E 63.997 - 63.998 (2.5196 - 2.5196)

Grade No. F 63.998 - 63.999 (2.5196 - 2.5196)

Grade No. G 63.999 - 64.000 (2.5196 - 2.5197)

Grade No. H 64.000 - 64.001 (2.5197 - 2.5197)

Grade No. J 64.001 - 64.002 (2.5197 - 2.5198)

Grade No. K 64.002 - 64.003 (2.5198 - 2.5198)

Grade No. L 64.003 - 64.004 (2.5198 - 2.5198)

Main journal inner Grade No. M 64.004 - 64.005 (2.5198 - 2.5199)

—
diameter
Grade No. N 64.005 - 64.006 (2.5199 - 2.5199)

Grade No. P 64.006 - 64.007 (2.5199 - 2.5200)

Grade No. R 64.007 - 64.008 (2.5200 - 2.5200)

Grade No. S 64.008 - 64.009 (2.5200 - 2.5200)

Grade No. T 64.009 - 64.010 (2.5200 - 2.5201)

Grade No. U 64.010 - 64.011 (2.5201 - 2.5201)

Grade No. V 64.011 - 64.012 (2.5201 - 2.5202)

Grade No. W 64.012 - 64.013 (2.5202 - 2.5202)

Grade No. X 64.013 - 64.014 (2.5202 - 2.5202)

Grade No. Y 64.014 - 64.015 (2.5202 - 2.5203)

Grade No. 4 64.015 - 64.016 (2.5203 - 2.5203)

Grade No. 7 64.016 - 64.017 (2.5203 - 2.5203)

Difference in inner diameter between cylinders Less than 0.03 (0.0012) —

EM-82
SERVICE DATA AND SPECIFICATIONS (SDS)
Piston, Piston Ring and Piston Pin

Piston, Piston Ring and Piston Pin =NFEM0036

AVAILABLE PISTON NFEM0036S01
Unit: mm (in)
GI

MA

LC

EC
SEM882E

Engine VQ20DE VQ30DE FE

Grade No. 1 75.980 - 75.990 (2.9913 - 2.9917) 92.979 - 92.988 (3.6606 - 3.6609)

Grade No. 2 75.990 - 76.000 (2.9917 - 2.9921) 92.988 - 93.000 (3.6609 - 3.6614) CL
Piston skirt diameter “A” Standard
Grade No. 3 76.000 - 76.010 (2.9921 - 2.9925) 93.000 - 93.009 (3.6614 - 3.6618)

0.20 (0.0079) oversize (Ser-

76.180 - 76.210 (2.992 - 3.0004) 93.179 - 93.209 (3.6685 - 3.6696) MT
vice)

“a” dimension 45.4 (1.787)

AT
Grade No. 0 21.993 - 21.999 (0.8659 - 0.8661)
Piston pin hole diameter
Grade No. 1 21.999 - 22.005 (0.8661 - 0.8663)
AX
Piston clearance to cylinder block 0.010 - 0.030 (0.0004 - 0.0012) 0.010 - 0.032 (0.0004 - 0.0013)

PISTON RING NFEM0036S02

SU
Unit: mm (in)

Standard Limit
BR
Engine VQ20DE VQ30DE VQ20DE VQ30DE

0.045 - 0.080 0.040 - 0.080

Top
(0.0018 - 0.0031) (0.0016 - 0.0031)
0.11 (0.0043) ST
Side clearance
2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039)

Oil ring 0.015 - 0.185 (0.0006 - 0.0073) —

RS
0.18 - 0.28 0.22 - 0.32
Top 0.51 (0.0201) 0.55 (0.0217)
(0.0071 - 0.0110) (0.0087 - 0.0126) BT
End gap 0.30 - 0.45 0.32 - 0.47
2nd 0.65 (0.0256) 0.85 (0.0335)
(0.0118 - 0.0177) (0.0126 - 0.0185)

Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.95 (0.0374)

HA

PISTON PIN NFEM0036S03 SC

Unit: mm (in)

Grade No. 0 21.989 - 21.995 (0.8657 - 0.8659)

Piston pin outer diameter EL
Grade No. 1 21.995 - 22.001 (0.8659 - 0.8662)

Interference fit of piston pin to piston 0.002 - 0.006 (0.0001 - 0.0002)

IDX
Piston pin to connecting rod bushing clear- Standard 0.005 - 0.017 (0.0002 - 0.0007)
ance Limit 0.030 (0.0012)

*: Values measured at ambient temperature of 20°C (68°F)

EM-83
SERVICE DATA AND SPECIFICATIONS (SDS)
Connecting Rod

Connecting Rod NFEM0037

Unit: mm (in)

Center distance 147.60 - 147.70 (5.8110 - 5.8149)

Bend [per 100 (3.94)] Limit 0.15 (0.0059)

Torsion [per 100 (3.94)] Limit 0.30 (0.0118)

Connecting rod small end inner diameter 23.980 - 24.000 (0.9441 - 0.9449)

Grade No. 0 22.000 - 22.006 (0.8661 - 0.8664)

Piston pin bushing inner diameter*
Grade No. 1 22.006 - 22.012 (0.8664 - 0.8666)

Connecting rod big end inner diameter 48.000 - 48.013 (1.8898 - 1.8903)

Standard 0.20 - 0.35 (0.0079 - 0.0138)

Side clearance
Limit 0.40 (0.0157)

*: After installing in connecting rod

Crankshaft NFEM0038
Unit: mm (in)

Grade No. A 59.975 - 59.974 (2.3612 - 2.3612)

Grade No. B 59.974 - 59.973 (2.3612 - 2.3611)
Grade No. C 59.973 - 59.972 (2.3611 - 2.3611)
Grade No. D 59.972 - 59.971 (2.3611 - 2.3611)
Grade No. E 59.971 - 59.970 (2.3611 - 2.3610)
Grade No. F 59.970 - 59.969 (2.3610 - 2.3610)
Grade No. G 59.969 - 59.968 (2.3610 - 2.3609)
Grade No. H 59.968 - 59.967 (2.3609 - 2.3609)
Grade No. J 59.967 - 59.966 (2.3609 - 2.3609)
Grade No. K 59.966 - 59.965 (2.3609 - 2.3608)
Grade No. L 59.965 - 59.964 (2.3608 - 2.3608)
Grade No. M 59.964 - 59.963 (2.3608 - 2.3607)
Main journal dia. “Dm” grade
Grade No. N 59.963 - 59.962 (2.3607 - 2.3607)
Grade No. P 59.962 - 59.961 (2.3607 - 2.3607)
Grade No. R 59.961 - 59.960 (2.3607 - 2.3606)
Grade No. S 59.960 - 59.959 (2.3606 - 2.3606)
Grade No. T 59.959 - 59.958 (2.3606 - 2.3605)
Grade No. U 59.958 - 59.957 (2.3605 - 2.3605)
Grade No. V 59.957 - 59.956 (2.3605 - 2.3605)
Grade No. W 59.956 - 59.955 (2.3605 - 2.3604)
Grade No. X 59.955 - 59.954 (2.3604 - 2.3604)
Grade No. Y 59.954 - 59.953 (2.3604 - 2.3603)
Grade No. 4 59.953 - 59.952 (2.3603 - 2.3603)
Grade No. 7 59.952 - 59.951 (2.3603 - 2.3603)

Grade No. 0 44.968 - 44.974 (1.7704 - 1.7706)

Pin journal dia. “Dp” Grade No. 1 44.962 - 44.968 (1.7702 - 1.7704)

Grade No. 2 44.956 - 44.962 (1.7699 - 1.7702)

Center distance “r” 36.61 - 36.69 (1.4413 - 1.4445)

Out-of-round (X − Y) Standard Less than 0.002 (0.0001)

Taper (A − B) Standard Less than 0.002 (0.0001)

Runout [TIR] Limit Less than 0.10 (0.0039)

Standard 0.10 - 0.25 (0.0039 - 0.0098)

Free end play
Limit 0.30 (0.0118)

EM-84
SERVICE DATA AND SPECIFICATIONS (SDS)
Crankshaft (Cont’d)

GI

MA

SEM645 EM715
LC

EC

FE

CL

MT

AT

AX

SU

BR

ST

RS

BT

HA

SC

EL

IDX

EM-85
SERVICE DATA AND SPECIFICATIONS (SDS)
Available Main Bearing

Available Main Bearing =NFEM0039

SEM175F

Width “W” Identification color

Grade number Thickness “T” mm (in) Remarks
mm (in) (UPR/LWR)

0 2.000 - 2.003 (0.0787 - 0.0789) Black

1 2.003 - 2.006 (0.0789 - 0.0790) Brown

2 2.006 - 2.009 (0.0790 - 0.0791) Green

3 2.009 - 2.012 (0.0791 - 0.0792) Yellow Grade is the same for

upper and lower bearings.
4 2.012 - 2.015 (0.0792 - 0.0793) Blue

5 2.015 - 2.018 (0.0793 - 0.0794) Pink

6 2.018 - 2.021 (0.0794 - 0.0796) Purple

7 2.021 - 2.024 (0.0796 - 0.0797) White

UPP 2.003 - 2.006 (0.0789 - 0.0790)

01 Brown/Black
LWR 2.000 - 2.003 (0.0787 - 0.0789)

UPR 2.006 - 2.009 (0.0790 - 0.0791) 19.9 - 20.1

12 Green/Brown
(0.783 - 0.791)
LWR 2.003 - 2.006 (0.0789 - 0.0790)

UPR 2.009 - 2.012 (0.0791 - 0.0792)

23 Yellow/Green
LWR 2.006 - 2.009 (0.0790 - 0.0791)

UPR 2.012 - 2.015 (0.0792 - 0.0793)

Grade is different for upper
34 Blue/Yellow
LWR 2.009 - 2.012 (0.0791 - 0.0792) and lower bearings.

UPR 2.015 - 2.018 (0.0793 - 0.0794)

45 Pink/Blue
LWR 2.012 - 2.015 (0.0792 - 0.0793)

UPR 2.018 - 2.021 (0.0794 - 0.0796)

56 Purple/Pink
LWR 2.015 - 2.018 (0.0793 - 0.0794)

UPR 2.021 - 2.024 (0.0796 - 0.0797)

67 White/Purple
LWR 2.018 - 2.021 (0.0794 - 0.0796)

UNDERSIZE NFEM0039S01
Unit: mm (in)

Thickness Main journal diameter “Dm”

Grind so that bearing clearance is the specified

0.25 (0.0098) 2.132 - 2.140 (0.0839 - 0.0843)
value.

EM-86
SERVICE DATA AND SPECIFICATIONS (SDS)
Available Connecting Rod Bearing

Available Connecting Rod Bearing NFEM0040

CONNECTING ROD BEARING NFEM0040S01
GI
Grade number Thickness “T” mm (in) Identification color (mark)

0 1.500 - 1.503 (0.0591 - 0.0592) Black

MA
1 1.503 - 1.506 (0.0592 - 0.0593) Brown

2 1.506 - 1.509 (0.0593 - 0.0594) Green

UNDERSIZE NFEM0040S02
Unit: mm (in) LC
Thickness Crank pin journal diameter “Dp”

0.25 (0.0098) 1.626 - 1.634 (0.0640 - 0.0643)

Grind so that bearing clearance is the specified EC
value.

Miscellaneous Components NFEM0041

FE
Unit: mm (in)

Flywheel runout [TIR]* Less than 0.15 (0.0059)

CL
Drive plate runout [TIR]* Less than 0.15 (0.0059)

*: Total indicator reading MT

BEARING CLEARANCE NFEM0041S01
Unit: mm (in)
AT
Standard 0.012 - 0.030 (0.0005 - 0.0012)
Main bearing clearance
Limit 0.065 (0.0026)
AX
Standard 0.020 - 0.045 (0.0008 - 0.0018)
Connecting rod bearing clearance
Limit 0.070 (0.0028)
SU

BR

ST

RS

BT

HA

SC

EL

IDX

EM-87
NOTES