NISSAN X-TRAIL 2005 Service Workshop Manual

TERMINOLOGY
GI-49
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Exhaust gas recirculation control-BPT
valveEGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid
valveEGRC-solenoid valve EGR control solenoid valve
Exhaust gas recirculation temperature sen-
sor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
read only memoryFEEPROM ***
Flash erasable programmable read only
memoryFEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
valve*** PRVR control solenoid valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
valveIACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
noid valveIACV-idle up control solenoid valve Idle up control solenoid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection controlNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

GI-50
TERMINOLOGY

Nonvolatile random access memory NVRAM ***
On board diagnostic system OBD system Self-diagnosis
Open loop OL Open loop
Oxidation catalyst OC Catalyst
Oxidation catalytic converter system OC system ***
Oxygen sensor O2S Exhaust gas sensor
Park position switch *** Park switch
Park/neutral position switch PNP switchPark/neutral switch
Inhibitor switch
Neutral position switch
Periodic trap oxidizer system PTOX system ***
Positive crankcase ventilation PCV Positive crankcase ventilation
Positive crankcase ventilation valve PCV valve PCV valve
Powertrain control module PCM ***
Programmable read only memory PROM ***
Pulsed secondary air injection control sole-
noid valvePAIRC solenoid valve AIV control solenoid valve
Pulsed secondary air injection system PAIR system Air induction valve (AIV) control
Pulsed secondary air injection valve PAIR valve Air induction valve
Random access memory RAM ***
Read only memory ROM ***
Scan tool ST ***
Secondary air injection pump AIR pump ***
Secondary air injection system AIR system ***
Sequential multiport fuel injection system SFI system Sequential fuel injection
Service reminder indicator SRI ***
Simultaneous multiport fuel injection sys-
tem*** Simultaneous fuel injection
Smoke puff limiter system SPL system ***
Supercharger SC ***
Supercharger bypass SCB ***
System readiness test SRT ***
Thermal vacuum valve TVV Thermal vacuum valve
Three way catalyst TWC Catalyst
Three way catalytic converter system TWC system ***
Three way + oxidation catalyst TWC + OC Catalyst
Three way + oxidation catalytic converter
systemTWC + OC system ***
Throttle body TBThrottle chamber
SPI body
Throttle body fuel injection system TBI system Fuel injection control
Throttle position TP Throttle position
Throttle position sensor TPS Throttle sensor
Throttle position switch TP switch Throttle switch
Torque converter clutch solenoid valve TCC solenoid valveLock-up cancel solenoid
Lock-up solenoid NEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

TERMINOLOGY
GI-51
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***: Not applicableTransmission control module TCM A/T control unit
Turbocharger TC Turbocharger
Vehicle speed sensor VSS Vehicle speed sensor
Volume air flow sensor VAFS Air flow meter
Warm up oxidation catalyst WU-OC Catalyst
Warm up oxidation catalytic converter sys-
temWU-OC system ***
Warm up three way catalyst WU-TWC Catalyst
Warm up three way catalytic converter sys-
temWU-TWC system ***
Wide open throttle position switch WOTP switch Full switchNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM

GI-52
TERMINOLOGY

EM-1
ENGINE MECHANICAL
B ENGINE
CONTENTS
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SECTION EM
A
EM

ENGINE MECHANICAL
QR
PRECAUTIONS .......................................................... 5
Precautions for Drain Engine Coolant ...................... 5
Precautions for Disconnecting Fuel Piping .............. 5
Precautions for Removal and Disassembly ............. 5
Precautions for Inspection, Repair and Replace-
ment ......................................................................... 5
Precautions for Assembly and Installation ............... 5
Parts Requiring Angle Tightening ............................. 5
Precautions for Liquid Gasket .................................. 6
REMOVAL OF LIQUID GASKET .......................... 6
LIQUID GASKET APPLICATION PROCEDURE ..... 6
PREPARATION ........................................................... 7
Special Service Tools ............................................... 7
Commercial Service Tools ........................................ 9
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ...............................................11
NVH Troubleshooting — Engine Noise ................... 11
Use the Chart Below to Help You Find the Cause
of the Symptom. ..................................................... 12
DRIVE BELTS ........................................................... 13
Checking Drive Belts .............................................. 13
Tension Adjustment ................................................ 13
Removal and Installation ........................................ 13
REMOVAL ........................................................... 13
INSTALLATION ................................................... 14
Removal and Installation of Drive Belt Auto-Ten-
sioner ..................................................................... 14
REMOVAL ........................................................... 14
INSTALLATION ................................................... 15
AIR CLEANER AND AIR DUCT ............................... 16
Removal and Installation ........................................ 16
REMOVAL ........................................................... 16
INSTALLATION ................................................... 17
Changing Air Cleaner Filter .................................... 17
REMOVAL ........................................................... 17
INSTALLATION ................................................... 17
INTAKE MANIFOLD ................................................. 18
Removal and Installation (QR20DE) ...................... 18
REMOVAL ........................................................... 18INSTALLATION ................................................... 19
INSPECTION AFTER INSTALLATION ................ 20
Removal and Installation (QR25DE) ...................... 21
REMOVAL ........................................................... 21
INSPECTION AFTER REMOVAL ....................... 23
INSTALLATION ................................................... 23
INSPECTION AFTER INSTALLATION ................ 24
EXHAUST MANIFOLD AND THREE WAY CATA-
LYST .......................................................................... 25
Removal and Installation ........................................ 25
REMOVAL ........................................................... 25
INSPECTION AFTER REMOVAL ....................... 26
INSTALLATION ................................................... 26
OIL PAN AND OIL STRAINER ................................. 27
Removal and Installation ........................................ 27
REMOVAL ........................................................... 27
INSPECTION AFTER REMOVAL ....................... 29
INSTALLATION ................................................... 29
INSPECTION AFTER INSTALLATION ................ 30
IGNITION COIL ......................................................... 31
Removal and Installation ........................................ 31
REMOVAL ........................................................... 31
INSTALLATION ................................................... 31
SPARK PLUG ........................................................... 32
Removal and Installation ........................................ 32
REMOVAL ........................................................... 32
INSPECTION AFTER REMOVAL (EXCEPT
RUSSIA) .............................................................. 32
INSPECTION AFTER REMOVAL (FOR RUS-
SIA) ..................................................................... 33
INSTALLATION ................................................... 33
FUEL INJECTOR AND FUEL TUBE ........................ 34
Removal and Installation (QR20DE) ...................... 34
REMOVAL ........................................................... 34
INSTALLATION ................................................... 36
INSPECTION AFTER INSTALLATION ................ 38
Removal and Installation (QR25DE) ...................... 39
REMOVAL ........................................................... 39
INSTALLATION ................................................... 41
INSPECTION AFTER INSTALLATION ................ 43

EM-2 ROCKER COVER ..................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSTALLATION .................................................... 45
TIMING CHAIN .......................................................... 46
Removal and Installation ........................................ 46
REMOVAL ........................................................... 46
INSPECTION AFTER REMOVAL ........................ 50
INSTALLATION .................................................... 51
INSPECTION AFTER INSTALLATION ................ 55
CAMSHAFT ............................................................... 56
Removal and Installation ........................................ 56
REMOVAL ........................................................... 56
INSPECTION AFTER REMOVAL ........................ 58
INSTALLATION .................................................... 61
Valve Clearance ...................................................... 64
INSPECTION ....................................................... 64
ADJUSTMENT .................................................... 65
OIL SEAL .................................................................. 67
Removal and Installation of Valve Oil Seal ............. 67
REMOVAL ........................................................... 67
INSTALLATION .................................................... 67
Removal and Installation of Front Oil Seal ............. 67
REMOVAL ........................................................... 67
INSTALLATION .................................................... 68
Removal and Installation of Rear Oil Seal .............. 68
REMOVAL ........................................................... 68
INSTALLATION .................................................... 68
CYLINDER HEAD ..................................................... 70
On-Vehicle Service ................................................. 70
CHECKING COMPRESSION PRESSURE ......... 70
Removal and Installation ........................................ 71
REMOVAL ........................................................... 71
INSPECTION AFTER REMOVAL ........................ 72
INSTALLATION .................................................... 73
INSPECTION AFTER INSTALLATION ................ 73
Disassembly and Assembly .................................... 74
DISASSEMBLY ................................................... 74
ASSEMBLY ......................................................... 75
Inspection After Disassembly ................................. 77
VALVE DIMENSIONS .......................................... 77
VALVE GUIDE CLEARANCE .............................. 77
VALVE GUIDE REPLACEMENT ......................... 77
VALVE SEAT CONTACT ..................................... 79
VALVE SEAT REPLACEMENT ........................... 79
VALVE SPRING SQUARENESS ......................... 80
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 80
ENGINE ASSEMBLY ................................................ 81
Removal and Installation (2WD Models) ................ 81
REMOVAL ........................................................... 82
INSTALLATION .................................................... 83
INSPECTION AFTER INSTALLATION ................ 84
Removal and Installation (4WD Models) ................ 85
REMOVAL ........................................................... 85
INSTALLATION .................................................... 88
INSPECTION AFTER INSTALLATION ................ 88CYLINDER BLOCK ................................................... 89
Disassembly and Assembly .................................... 89
DISASSEMBLY .................................................... 90
ASSEMBLY .......................................................... 94
How to Select Piston and Bearing .......................... 99
DESCRIPTION .................................................... 99
HOW TO SELECT PISTON ...............................100
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................100
HOW TO SELECT MAIN BEARING ..................102
Inspection After Disassembly ................................107
CRANKSHAFT END PLAY ................................107
CONNECTING ROD SIDE CLEARANCE .........107
PISTON TO PISTON PIN OIL CLEARANCE .....107
PISTON RING SIDE CLEARANCE ...................108
PISTON RING END GAP ..................................108
CONNECTING ROD BEND AND TORSION .....109
CONNECTING ROD BIG END DIAMETER ......109
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................109
CYLINDER BLOCK DISTORTION ....................110
MAIN BEARING HOUSING INNER DIAMETER . 111
PISTON TO CYLINDER BORE CLEARANCE .. 111
CRANKSHAFT MAIN JOURNAL DIAMETER ...112
CRANKSHAFT PIN JOURNAL DIAMETER ......113
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ...............................................................113
CRANKSHAFT RUNOUT ..................................113
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................113
MAIN BEARING OIL CLEARANCE ...................114
MAIN BEARING CRUSH HEIGHT ....................115
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................115
LOWER CYLINDER BLOCK MOUNTING BOLT
OUTER DIAMETER ...........................................115
CONNECTING ROD BOLT OUTER DIAMETER .115
FLYWHEEL DEFLECTION (M/T MODELS) ......116
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ...........................................................116
SERVICE DATA AND SPECIFICATIONS (SDS) ....117
Standard and Limit ................................................117
GENERAL SPECIFICATIONS ...........................117
DRIVE BELT ......................................................117
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................117
SPARK PLUG ....................................................117
CYLINDER HEAD ..............................................117
VALVE ................................................................118
CAMSHAFT AND CAMSHAFT BEARING .........121
CYLINDER BLOCK ............................................122
PISTON, PISTON RING AND PISTON PIN ......123
CONNECTING ROD ..........................................124
CRANKSHAFT ...................................................124
MAIN BEARING .................................................126
CONNECTING ROD BEARING .........................127
Tightening Torque .................................................127

EM-3
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EMA

YD22DDTi
PRECAUTIONS ...................................................... 130
Precautions for Draining Engine Coolant ............. 130
Precautions for Disconnecting Fuel Piping .......... 130
Precautions for Removal and Disassembly ......... 130
Precautions for Inspection, Repair and Replace-
ment ..................................................................... 130
Precautions for Assembly and Installation ........... 130
Parts Requiring Angle Tightening ......................... 130
Precautions For Liquid Gasket ............................. 131
REMOVAL OF LIQUID GASKET ...................... 131
LIQUID GASKET APPLICATION PROCEDURE . 131
PREPARATION ....................................................... 132
Special Service Tools ........................................... 132
Commercial Service Tools .................................... 136
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING ............................................ 138
NVH Troubleshooting — Engine Noise ................ 138
Use the Chart Below to Help You Find the Cause
of the Symptom. ................................................... 139
DRIVE BELTS ......................................................... 140
Checking Drive Belts ............................................ 140
Tension Adjustment .............................................. 140
A/C COMPRESSOR BELT ............................... 141
ALTERNATOR AND WATER PUMP BELT ....... 141
Removal and Installation ...................................... 141
REMOVAL ......................................................... 141
INSTALLATION ................................................. 141
AIR CLEANER AND AIR DUCT ............................. 142
Removal and Installation ...................................... 142
REMOVAL ......................................................... 142
INSTALLATION ................................................. 142
CHANGING AIR CLEANER FILTER ................. 143
CHARGE AIR COOLER ......................................... 144
Removal and Installation ...................................... 144
REMOVAL ......................................................... 144
INSPECTION AFTER REMOVAL ..................... 144
INSTALLATION ................................................. 144
INTAKE MANIFOLD ............................................... 146
Removal and Installation ...................................... 146
REMOVAL ......................................................... 146
INSPECTION AFTER REMOVAL ..................... 147
INSTALLATION ................................................. 147
INSPECTION AFTER INSTALLATION ............. 148
CATALYST .............................................................. 149
Removal and Installation ...................................... 149
REMOVAL ......................................................... 149
INSTALLATION ................................................. 150
EXHAUST MANIFOLD AND TURBOCHARGER .. 151
Removal and Installation ...................................... 151
REMOVAL ......................................................... 151
INSTALLATION ................................................. 152
INSPECTION AFTER INSTALLATION ............. 152
Disassembly and Assembly ................................. 153
DISASSEMBLY ................................................. 153
ASSEMBLY ....................................................... 153INSPECTION AFTER DISASSEMBLY ..............154
Turbocharger ........................................................154
ROTOR SHAFT CLEARANCE ..........................154
ROTOR SHAFT END PLAY ..............................155
TURBINE WHEEL .............................................155
COMPRESSOR WHEEL ...................................155
TURBOCHARGER BOOST CONTROL ACTU-
ATOR .................................................................155
TROUBLE DIAGNOSIS OF TURBOCHARGER .156
OIL PAN AND OIL STRAINER ...............................157
Removal and Installation ......................................157
REMOVAL .........................................................157
INSPECTION AFTER REMOVAL .....................159
INSTALLATION .................................................159
INSPECTION AFTER INSTALLATION ..............161
GLOW PLUG ..........................................................162
Removal and Installation ......................................162
REMOVAL .........................................................162
INSTALLATION .................................................162
VACUUM PUMP ......................................................163
Removal and Installation ......................................163
INSPECTION BEFORE REMOVAL ..................163
REMOVAL .........................................................163
INSTALLATION .................................................164
INSPECTION AFTER INSTALLATION ..............165
Disassembly and Assembly ..................................165
DISASSEMBLY .................................................165
ASSEMBLY .......................................................166
INJECTION TUBE AND FUEL INJECTOR ............167
Removal and Installation ......................................167
REMOVAL .........................................................167
INSTALLATION .................................................169
INSPECTION AFTER INSTALLATION ..............170
FUEL PUMP ............................................................171
Removal and Installation ......................................171
REMOVAL .........................................................171
INSPECTION AFTER REMOVAL .....................175
INSTALLATION .................................................175
ROCKER COVER ...................................................178
Removal and Installation ......................................178
REMOVAL .........................................................178
INSTALLATION .................................................179
INSPECTION AFTER INSTALLATION ..............179
CAMSHAFT ............................................................180
Removal and Installation ......................................180
REMOVAL .........................................................180
INSPECTION AFTER REMOVAL .....................181
INSTALLATION .................................................184
Valve Clearance ...................................................185
INSPECTION ....................................................185
ADJUSTMENTS ................................................187
OIL SEAL ................................................................190
Removal and Installation of Valve Oil Seal ...........190
REMOVAL .........................................................190
INSTALLATION .................................................190
Removal and Installation of Front Oil Seal ...........191
REMOVAL .........................................................191

EM-4 INSTALLATION ..................................................191
Removal and Installation of Rear Oil Seal ............192
REMOVAL .........................................................192
INSTALLATION ..................................................192
SECONDARY TIMING CHAIN ................................193
Removal and Installation ......................................193
REMOVAL .........................................................193
INSPECTION AFTER REMOVAL ......................195
INSTALLATION ..................................................195
PRIMARY TIMING CHAIN ......................................198
Removal and Installation ......................................198
REMOVAL .........................................................200
INSPECTION AFTER REMOVAL ......................203
INSTALLATION ..................................................203
CYLINDER HEAD ...................................................209
On-Vehicle Service ...............................................209
CHECKING COMPRESSION PRESSURE .......209
Removal and Installation ......................................210
REMOVAL .........................................................210
INSPECTION AFTER REMOVAL ......................211
INSTALLATION ..................................................212
INSPECTION AFTER INSTALLATION ..............214
Disassembly and Assembly ..................................215
DISASSEMBLY .................................................215
ASSEMBLY .......................................................216
INSPECTION AFTER DISASSEMBLY ..............217
ENGINE ASSEMBLY ..............................................222
Removal and Installation (2WD Models) ..............222
REMOVAL .........................................................223
INSTALLATION ..................................................224
INSPECTION AFTER INSTALLATION ..............225
Removal and Installation (4WD Models) ..............226
REMOVAL .........................................................227
INSTALLATION ..................................................229
INSPECTION AFTER INSTALLATION ..............229
CYLINDER BLOCK .................................................230
Disassembly and Assembly ..................................230
DISASSEMBLY .................................................231
ASSEMBLY .......................................................235
How to Select Piston and Bearing ........................241
DESCRIPTION ..................................................241
HOW TO SELECT PISTON ...............................242
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................242HOW TO SELECT MAIN BEARING ..................244
Inspection After Disassembly ................................245
CRANKSHAFT END PLAY ................................245
CONNECTING ROD SIDE CLEARANCE .........246
PISTON TO PISTON PIN CLEARANCE ...........246
PISTON RING SIDE CLEARANCE ...................247
PISTON RING END GAP ..................................247
CONNECTING ROD BEND AND TORSION .....248
CONNECTING ROD BIG END INNER DIAME-
TER ....................................................................248
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................248
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ..................................................................249
MAIN BEARING HOUSING INNER DIAMETER .249
PISTON TO CYLINDER BORE CLEARANCE ..250
CRANKSHAFT MAIN JOURNAL DIAMETER ...251
CRANKSHAFT PIN JOURNAL DIAMETER ......251
CRANKSHAFT OUT-OF-ROUND AND TAPER .251
CRANKSHAFT RUNOUT ..................................252
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................252
MAIN BEARING OIL CLEARANCE ...................253
CRUSH HEIGHT OF MAIN BEARING ..............253
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................253
MAIN BEARING CAP BOLT DEFORMATION ...254
CONNECTING ROD BOLT DEFORMATION ....254
OIL JET ..............................................................254
OIL JET RELIEF VALVE ....................................254
FLYWHEEL DEFLECTION ................................255
MOVEMENT AMOUNT OF FLYWHEEL ...........255
SERVICE DATA AND SPECIFICATIONS (SDS) ....256
Standard and Limit ................................................256
GENERAL SPECIFICATIONS ...........................256
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................256
DRIVE BELTS ....................................................256
CAMSHAFT .......................................................257
CYLINDER HEAD ..............................................259
VALVE ................................................................259
CYLINDER BLOCK ............................................262
PISTON, PISTON RING AND PISTON PIN ......263
CONNECTING ROD ..........................................264
CRANKSHAFT ...................................................264
AVAILABLE MAIN BEARING .............................265
AVAILABLE CONNECTING ROD BEARING .....265
Tightening Torque .................................................266

PRECAUTIONS
EM-5
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[QR]PRECAUTIONSPFP:00001
Precautions for Drain Engine CoolantEBS00KN0
Drain engine coolant when engine is cooled.
Precautions for Disconnecting Fuel PipingEBS00KN1

Before starting work, make sure no fire or spark producing items are in the work area.

Release fuel pressure before disassembly.

After disconnecting pipes, plug openings to stop fuel leakage.
Precautions for Removal and DisassemblyEBS00KN2

When instructed to use special service tools, use the specified tools. Always be careful to work safely,
avoid forceful or uninstructed operations.

Exercise maximum care to avoid damage to mating or sliding surfaces.

Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.

Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.

When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally
opposite, and so on. If the order of loosening is specified, do exactly as specified.
Precautions for Inspection, Repair and ReplacementEBS00KN3
Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and
replace if necessary.
Precautions for Assembly and InstallationEBS00MRZ

Use torque wrench to tighten bolts or nuts to specification.

When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the
ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is speci-
fied, do exactly as specified.

Replace with new gasket, packing, oil seal or O-ring.

Dowel pins are used for several parts alignment. When replacing and reassembling with dowel pins, make
sure that dowel pins are installed in the original portion.

Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction
and blockage.

Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust.
Before assembly, oil sliding surfaces well.

Release air within route when refilling after draining coolant.

Before starting engine, apply fuel pressure to fuel lines with turning ignition switch “ON” (with engine
stopped). Then make sure there are no leaks at fuel line connections.

After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and
exhaust systems for leakage.
Parts Requiring Angle TighteningEBS00KN5

Use an angle wrench (special service tool: KV10112100) for the final tightening of the following engine
parts.
–Cylinder head bolts
–Lower cylinder block bolts
–Connecting rod cap bolts
–Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle
tightening)
–Balancer unit

Do not use a torque value for final tightening.

The torque value for these parts are for a preliminary step.

Ensure thread and seat surfaces are clean and coated with engine oil.

EM-6
[QR]
PRECAUTIONS

Precautions for Liquid GasketEBS00MRW
REMOVAL OF LIQUID GASKET

After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter (special service tool) and remove the
old liquid gasket sealing.
CAUTION:
Be careful not to damage the mating surfaces.

Tap seal cutter to insert it (1), and then slide it (2) by tapping on
the side as shown in the figure.

In areas where seal cutter is difficult to use, use plastic hammer
to lightly tap the areas where the liquid gasket is applied.
CAUTION:
If for some unavoidable reason tool such as screwdriver is
used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the liq-
uid gasket application surface and the mating surface.

Remove the liquid gasket completely from the groove of the
liquid gasket application surface, mounting bolts and bolt
holes.
2. Wipe the liquid gasket application surface and the mating sur-
face with white gasoline (lighting and heating use) to remove
adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to the tube presser (special service
tool).
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.

If there is a groove for the liquid gasket application, apply the
liquid gasket to the groove.

As for the bolt holes, normally apply the liquid gasket inside
the holes. Occasionally, it should be applied outside the
holes. Make sure to read the text of service manual.

Within five minutes of liquid gasket application, install the mat-
ing component.

If the liquid gasket protrudes, wipe it off immediately.

Do not retighten mounting bolts or nut after the installation.

Wait 30 minutes or more after installation before refilling
engine oil and engine coolant.
CAUTION:
If there are instructions in this manual, observe them.
PBIC0275E
PBIC0003E
PBIC2160E
SEM159F