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1. MAIN BEARING Unit mm in Oil hole Ae Oil groove AS Lower cylinder block side PBIC2969E Grade number Thickness Width Identification color Remarks 0 2 500 2 503 0 0984 0 0985 Black 1 2 503 2 506 0 0985 0 0987 Brown 2 2 506 2 509 0 0987 0 0988 Green 3 2 509 2 512 0 0988 0 0989 Yellow Grade is the same for upper and lower 4 2 512 2 515 0 0989 0 0990 Blue bearings 5 2 515 2 518 0 0990 0 0991 Pink 6 2 518 2 521 0 0991 0 0993 Purple 7 2 521 2 524 0 0993 0 0994 White ag UPR 2 503 2 506 0 0985 0 0987 Brown LWR 2 500 2 503 0 0984 0 0985 Black 23 UPR 2 506 2 509 0 0987 0 0988 19 9 20 1 Green LWR 2 503 2 506 0 0985 0 0987 0 783 0 791 Brown Bi UPR 2 509 2 512 0 0988 0 0989 Yellow LWR 2 506 2 509 0 0987 0 0988 Green UPR 2 512 2 515 0 0989 0 0990 Blue Grade and color are 34 different for upper LWR 2 509 2 512 0 0988 0 0989 Yellow and lower bearings e UPR 2 515 2 518 0 0990 0 0991 Pink LWR 2 512 2 515 0 0989 0 0990 Blue a UPR 2 518 2 521 0 0991 0 0993 Purple LWR 2 515 2 518 0 0990 0 0991 Pink S UPR 2 521 2 524 0 0993 0 0994 White LWR 2 518 2 521 0 0991 0 0993 Purple UNDERSIZE Revision 2007 November EM 148 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Unit mm
2. i Intake 34 6 1 362 Diameter d1 Exhaust 27 7 1 091 d Intake 35 9 36 4 1 413 1 433 Diameter d2 Exhaust 29 3 29 8 1 154 1 173 Intake 60 Angle a1 Exhaust 60 Intake 88 45 90 15 Angle a2 Exhaust 88 45 90 15 Intake 120 Angle a3 Exhaust 120 S Intake 1 0 1 4 0 039 0 055 Contacting width WI ne Exhaust 1 2 1 6 0 047 0 063 Gaga Intake 5 9 6 0 0 232 0 236 5 05 5 15 0 1988 0 2028 eight h 9 Exhaust 5 9 6 0 0 232 0 236 4 95 5 05 0 1949 0 1988 Depth H 6 0 0 236 zl Diameter made by intersection point of conic angles a1 and a2 2 Diameter made by intersection point of conic angles a2 and a3 3 Machining data VALVE SPRING Items Standard Free height 43 85 mm 1 7264 in Installation height 37 00 mm 1 4567 in Installation load 166 188 N 16 9 19 2 kg 37 42 Ib Height during valve open 26 8 mm 1 055 in Load with valve open 502 566 N 51 2 57 7 kg 113 127 Ib Squareness Cylinder Block CYLINDER BLOCK 1 9 mm 0 075 in INFOID 0000000003139161 Unit mm in JPBIA1050GB Standard Less than 0 03 0 0012 Surface flatness Limit 0 1 0 004 Main bearing housing inner diameter Standard 69 993 70 017 2 7556 2 7566 EM 144 Revision 2007 November 2008 EX35
3. MAIN BEARING GRADE TABLE ALL JOURNALS Main bearing grade table All journals Refer to EM 148 Main Bearing UNDERSIZE BEARING USAGE GUIDE e When the specified main bearing oil clearance is not obtained with standard size main bearings use under size US bearing e When using undersize US bearing measure the main bearing inner diameter with bearing installed and grind main journal so that the main bearing oil clearance satisfies the standard Revision 2007 November EM 137 2008 EX35 HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt CAUTION In grinding crankshaft main journal to use undersize bearings keep the fillet R A 1 5 1 7 mm 0 059 0 067 in JPBIA0216ZZ Bearing undersize table Refer to EM 148 Main Bearing Revision 2007 November EM 138 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS General Specification GENERAL SPECIFICATIONS Cylinder arrangement INFOID 0000000003139154 V 6 Displacement cm cu in 3 498 213 45 Bore and stroke mm in 95 5 x 81 4 3 760 x 3 205 Valve arrangement DOHC Firing order 1 2 3 4 5 6 Number of piston rings oe S Oil 1 Number of main bearings 4 Compression ratio 10 6 Standard 1 275 13 0 185 Compression pressure Mini
4. Re bored size calculation D A B C where A Piston skirt diameter as measured B Piston to cylinder bore clearance standard value C Honing allowance 0 02 mm 0 0008 in D Bored diameter 2 Install lower cylinder block and tighten to the specified torque Otherwise cylinder bores may be distorted in final assembly 3 Cut cylinder bores Revision 2007 November EM 128 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt NOTE e When any cylinder needs boring all other cylinders must also be bored e 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 4 Hone cylinders to obtain the specified piston to cylinder bore clearance 5 Measure finished cylinder bore for the out of round and taper NOTE Measurement should be done after cylinder bore cools down CRANKSHAFT MAIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft main journals with a micrometer Standard Refer to EM 144 Cylinder Block e H out of the standard measure the main bearing oil clearance Then use undersize bearing Refer to EM 136 Main Bearing CRANKSHAFT PIN JOURNAL DIAMETER e Measure the outer diameter of crankshaft pin journal with a micrometer A Standard Refer to EM 144 Cylinder Block e If out of the standard measure the connecting rod bearing oil clearance Then use undersize bearing Refer to EM 134 Connecting Rod Bearing
5. The following are procedures for checking fluids leakage lubricates leakage e Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside chain tensioner drops after removal installation slack in guide may generate a pounding noise during and just after the engine start However this does not indicate an unusualness Noise will stop after hydraulic pressure rises Revision 2007 November EM 65 2008 EX35 lt ON VEHICLE REPAIR gt TIMING CHAIN e Warm up engine thoroughly to check there is no leakage of fuel or any oil fluids including engine oil and engine coolant e Bleed air from lines and hoses of applicable lines such as in cooling system e After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage L
6. cscsesseeeseeeees 15 Revision 2007 November EM 1 2008 EX35 FUEL INJECTOR AND FUEL TUBE 37 ENGINE UNIT cisssesctoiccttinieccasedacetesdiensactetectiveaess 91 Exploded View ccccesssccceeeesseeeeeeeseeeeeteeseeeeeeees 37 RI ue EE 91 Removal and Installation eeen 37 ASSOMDIY E 91 INSPECTION segrar EE huceetitee A 42 REAR TIMING CHAIN CASE csssssseeeeeeees 92 OIL PAN LOWER ccccesseeeeeeeeeeensseeseeeeeeeees 43 Exploded View cccccesseesseseeeeeeeeeseeseeeeeeeeeeeeeeaes 92 Exploded View 2WD 43 Disassembly oani i O 93 Exploded View AWD 44 E ue EE 94 Removal and Installation s is 44 IMS PO ue NEE 46 OIL PAN UPPER AND OIL STRAINER 97 IGNITION COIL SPARK PLUG AND ROCK SW GEESS GAEREN Se ER GOVER sninu A n 47 r SAP OEO NIE eE a aa ec EROR VEW eiea a N A 47 ee s Removal and Installation ea e ie hee ache 47 2WD INSPECTION 000 eee eee ienereaiiect residien 99 AWD E 99 Eege errereen AWD Exploded View ccccccccsssssssesesevessssssesesseee 100 eA and Installation CR Ee E 51 AWD Disassembly and Assembly 4 100 Pa Ge 65 AWD SINS POCUION enteo eer e nA TAT 103 CAMSHAFT 67 CYLINDER HEAD a c2cesstscisscesstseceeecetsvescsnne dead 104 Eeer eaea oera oded VIB aoei doina Gi Removal and Installation eeen 67 SEH ANG RSSOMIDIY anja nit nents ue Sa veer 7 IMS PSCUON EE 111 CYLINDER BLOCK eege Eeer 114 ONL EE 76 Ee e VALVE OIL SEAL s ccccsssesesssss
7. e Lubricate with new engine oil to piston 1 and piston ring 2 and then insert piston ring until middle of cylinder with piston and mea sure the piston ring end gap with a feeler gauge B A Press C Measuring point Standard and limit Refer to EM 144 Cylinder Block e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit rebore cylinder and use oversize piston and piston rings CONNECTING ROD BEND AND TORSION e Check with a connecting rod aligner JPBIA0220ZZ A Bend B Torsion C Feeler gauge EUA Bend limit p i Refer to EM 144 Cylinder Block Ma SS Torsion limit O e If it exceeds the limit replace connecting rod assembly JPBIA0221ZZ CONNECTING ROD BIG END DIAMETER Revision 2007 November EM 125 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt e Install connecting rod bearing cap without installing connecting rod bearing and tightening connecting rod bolts to the specified torque Refer to EM 115 Disassembly and Assembly for the tightening procedure 1 Connecting rod e Measure the inner diameter of connecting rod big end with an inside micrometer Standard Refer to EM 144 Cylinder Block JPBIA0222ZZ e If out of the standard replace connecting rod assembly CONNECTING ROD BUSHING OIL CLEARANCE Connecting Rod Bushing Inner Diameter Measure the inner diameter of connecting rod bu
8. for the tightening proce dure e Measure inner diameter A of camshaft bracket with a bore gauge Standard Refer to EM 140 Camshaft PBIC1645E CAMSHAFT JOURNAL OIL CLEARANCE e Oil clearance Camshaft bracket inner diameter Camshaft journal diameter Revision 2007 November EM 72 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt Standard and limit Refer to EM 140 Camshaft If the calculated value exceeds the limit replace either or both camshaft and cylinder head NOTE Camshaft brackets cannot be replaced as single parts because there are machined together with cylinder head Replace whole cylinder head assembly Camshaft End Play e Install a dial indicator in thrust direction on front end of camshaft Measure the end play of a dial indicator when camshaft is moved forward backward in direction to axis Standard and limit Refer to EM 140 Camshaft e Measure the following parts if out of the limit Dimension A for camshaft No 1 journal Standard 27 500 27 548 mm 1 0827 1 0846 in Dimension B for cylinder head No 1 journal bearing Standard 27 360 27 385 mm 1 0772 1 0781 in e Refer to the standards above and then replace camshaft and or cylinder head KBIA2404J Camshaft Sprocket Runout 1 Put V block on precise flat table and support No 2 and 4 journals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocke
9. Difference in inner diameter between cylinders Standard AVAILABLE PISTON Less than 0 03 0 0012 Unit mm in SEM882E Items Standard Oversize Service 0 2 0 008 Grade No 1 95 480 95 490 3 7590 3 7594 Grade No 2 95 490 95 500 3 7594 3 7598 Piston skirt diameter A Grade No 3 95 500 95 510 3 7598 3 7602 Service 95 680 95 710 3 7669 3 7681 Items Standard Limit a dimension 38 8 1 528 Grade No 21 993 21 999 0 8659 0 8661 Piston pin hole diameter Grade No 21 999 22 005 0 8661 0 8663 Piston to cylinder bore clearance Revision 2007 November 0 010 0 030 0 0004 0 0012 EM 145 0 08 0 0031 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS PISTON RING Unit mm in Items Standard Limit Top 0 040 0 080 0 0016 0 0031 0 11 0 0043 Side clearance 2nd 0 030 0 070 0 0012 0 0028 0 10 0 0039 Oil ring 0 055 0 155 0 0022 0 0061 Top 0 23 0 33 0 0091 0 0130 0 42 0 0165 End gap 2nd 0 33 0 48 0 0130 0 0189 0 57 0 0224 Oil rail ring 0 17 0 47 0 0067 0 0185 0 63 0 0248 PISTON PIN Unit mm in Items Standard Limit Grade No 0 21 989 21 995 0 8657 0 8659 Piston pin outer diameter Grade No 1 21 995 22 001 0 8659 0 8662 Piston to piston pin
10. Engine front CAUTION e Be careful not to damage front oil seal by interference with front end of crankshaft e Attaching should be done within 5 minutes after liquid gasket application Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case e Tighten mounting bolts to the specified torque in numerical order as shown in the figure e There are two types of mounting bolts Refer to the following for locating bolts w N JPBIA0058ZZ M10 bolts 1 2 3 4 5 6 7 O 55 0 N m 5 6 kg m 41 ft lb M6 bolts Except the above O 12 7 N m 1 3 kg m 9 ft Ib f After all bolts are tightened retighten them to the specified torque in numerical order shown in the figure CAUTION Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan upper g Install two mounting bolts in front of oil pan upper in numerical order shown in the figure JPBIA0046ZZ lt Engine front Tightening torque Refer to EM 97 2WD Exploded View JPBIA0047ZZ 11 Install valve timing control covers bank 1 and bank 2 as follows Revision 2007 November EM 63 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt a Install new seal rings 1 in shaft grooves A Bank2 CAUTION When replacing seal ring replace all rings with new one JPBIAOO60ZZ To check the joint between dowel pins and dowel pin holes check the looseness in th
11. GO 19 6 2 0 14 ol 2 5 0 26 A Op Li ge SC 1 PCV hose 2 Clamp 4 Spark plug 5 PCV valve 7 Rocker cover gasket bank 1 8 Rocker cover bank 1 Camshaft position sensor PHASE 10 bank 1 us sensor bank 1 13 oleae eh a control position 14 Rocker cover gasket bank 2 16 PCV hose 17 Oil filler cap A To intake manifold collector B Refer to EM 47 D To air duct Refer to Gl 4 Components for symbols in the figure Removal and Installation REMOVAL Exhaust valve timing control position INFOID 0000000003 139089 7 0 0 71 62 JPBIA1622GB 3 Ignition coil 6 O ring O ring 12 Camshaft position sensor PHASE bank 2 15 Rocker cover bank 2 18 PCV hose C Camshaft bracket side INFOID 0000000003139090 1 Remove engine cover with power tool Refer to EM 25 Exploded View Remove air duct RH and LH Refer to EM 27 Exploded View 2 3 Remove electric throttle control actuator Refer to EM 29 Exploded View 4 Remove ignition coil Refer to EM 47 Removal and Installation EM 16 Revision 2007 November 2008 EX35 SPARK PLUG lt ON VEHICLE MAINTENANCE gt 5 Remove spark plug with a spark plug wrench commercial ser vice tool a 14 mm 0 55 in JPBIA0030ZZ INSTALLATION Installation is the reverse order of removal n S pect i O n INFOID 0000000003139091 INSPECTION AFTER REMOVAL Use the standard type spark plug for
12. OIL PAN UPPER AND OIL STRAINER lt DISASSEMBLY AND ASSEMBLY gt e Install axle pipe 1 to oil pan upper from axle pipe flange side left side using a suitable drift A outer diameter 43 to 57 mm 1 69 to 2 24 in CAUTION Insert it with care to prevent O ring from sliding 2 Install oil pan upper as follows a Use a scraper A to remove old liquid gasket from mating sur faces CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket e Also remove old liquid gasket from mating surface of lower cyl inder block e Remove old liquid gasket from the bolt holes and threads b Install new O rings 2 on the bottom of lower cylinder block 1 and oil pump 3 lt x Engine front c Apply a continuous bead of liquid gasket with the tube presser commercial service tool to the cylinder block mating surface of oil pan upper to a limited portion as shown in the figure a 64 0 5 0 mm 0 157 0 197 in lt Engine front Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION e For bolt holes with A marks 7 locations apply liquid gasket outside the holes e Attaching should be done within 5 minutes after coating d Install oil pan upper CAUTION Install avoiding misalignment of O rings JPBIA0388ZZ Revision 2007 November EM 102 2008 EX35 OIL PAN UPPER AND OIL STRAINER lt DISAS
13. lt Engine front JPBIA0172ZZ 3 Remove cylinder head gaskets 4 Remove valve lifter e Identify installation positions and store them without mixing them up 5 Remove valve collet e Compress valve spring with the valve spring compressor SST KV10116200 J 26336 A A the attachment SST KV10115900 J26336 20 C and the adapter SST KV10109220 B Remove valve collet with a magnet hand CAUTION When working take care not to damage valve lifter holes weaned X a pen JPBIA0180ZZ 6 Remove valve spring retainer valve spring and valve spring seat 7 Push valve stem to combustion chamber side and remove valve e Identify installation positions and store them without mixing them up 8 Remove valve oil seal using the valve oil seal puller SST KV10107902 J38959 A JPBIAO177ZZ 9 Remove valve seat if valve seat must be replaced Revision 2007 November EM 105 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt e 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 Refer to EM 142 Cylinder Head CAUTION Prevent to scratch cylinder head by excessive boring 10 Remove valve guide if valve guide must be replaced a To remove valve guide heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIA0184ZZ b Drive
14. 0 020 Valve stem end surface grinding limit 0 2 0 008 VALVE GUIDE Unit mm in SEM950E Items Standard Oversize Service 0 2 0 008 Outer diameter 10 023 10 034 0 3946 0 3950 10 223 10 234 0 4025 0 4029 Valve guide Sg 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 Items Standard Limit Intake 0 020 0 053 0 0008 0 0021 0 08 0 0031 Valve guide clearance Exhaust 0 030 0 056 0 0012 0 0022 0 09 0 0035 Projection length L 12 6 12 8 0 496 0 504 VALVE SEAT Unit mm in PBIC2745E Items Standard Oversize Service 0 5 0 02 i Intake 38 000 38 016 1 4961 1 4967 38 500 38 516 1 5157 1 5164 Cylinder head seat recess diameter D Exhaust 31 600 31 616 1 2441 1 2447 32 100 32 116 1 2638 1 2644 Intake 38 097 38 113 1 4999 1 5005 38 597 38 613 1 5196 1 5202 Valve seat outer diameter d Exhaust 31 680 31 696 1 2472 1 2479 32 180 32 196 1 2669 1 2676 Intake 0 081 0 113 0 0032 0 0044 Valve seat interference fit Exhaust 0 064 0 096 0 0025 0 0038 Revision 2007 November EM 143 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS
15. 2 25 Front oil seal 26 Crankshaft pulley 27 Crankshaft pulley bolt Intake valve timing control solenoid 28 valve bank 1 29 Power steering oil pump bracket 30 Idler pulley bracket 31 Alternator bracket 32 Water outlet front 33 Front timing chain case 34 Rear timing chain case 35 O ring 36 O ring 37 O ring A Refer to EM 94 B Refer to EM 51 C Oil filter Refer to GI 4 Components for symbols in the figure D i sassem bly INFOID 0000000003139135 Remove front timing chain case and timing chain Refer to EM 50 Exploded View Remove water pump Refer to CO 18 Exploded View Remove oil pan upper Refer to EM 97 2WD Exploded View 2WD models or EM 100 AWD Exploded View AWD models Remove rear timing chain case as follows Loosen and remove mounting bolts in reverse order as shown in the figure Cut liquid gasket using the seal cutter SST KV10111100 J37228 and remove rear timing chain case JPBIAO089ZZ CAUTION e Never remove plate metal cover 1 of oil passage e After removal handle rear timing chain case carefully so it does not tilt cant or warp under a load JPBIAO088ZZ Revision 2007 November EM 93 2008 EX35 REAR TIMING CHAIN CASE lt DISASSEMBLY AND ASSEMBLY gt 5 Remove O rings 1 from cylinder block lt Engine front R 9 Nee lt aS Y OC Q C JPBIA0090ZZ 6 Remove timing chain tensioners secondary from cylinder head as fol
16. 2WD Exploded View 2WD models or EM 83 AWD Exploded View AWD models 2 Remove the parts that may restrict installation of engine to widely use engine stand NOTE The procedure is described assuming that you use a widely use engine stand holding the surface to which transmission is installed e Remove drive plate with power tool Fix crankshaft with a ring gear stopper SST KV10118600 J 48641 and remove mounting bolts e Loosen mounting bolts in diagonal order e Check for deformation or damage drive plate CAUTION e Never disassemble drive plate e Never place drive plate with signal plate facing down e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becoming magnetized 3 Remove pilot converter using the pilot bushing puller SST ST16610001 J 23907 A as necessary JPBIA0193ZZ 4 Lift the engine with hoist to install it onto the widely use engine stand CAUTION Use an engine stand that has a load capacity 220 kg 485 Ib or more large enough for supporting the engine weight If the load capacity of the stand is not adequate remove the following parts beforehand to reduce the potential risk of overturning the stand Remove intake manifold collector Refer to EM 29 Exploded View Remove intake manifold Refer to EM 32 Exploded View Remove fuel injector and fuel tube assembly Refer to EM 37 Exploded View Remove ignition coi
17. 4 23 445 23 465 0 9230 0 9238 Camshaft end play 0 115 0 188 0 0045 0 0074 0 24 0 0094 Intake 45 865 46 055 1 8057 1 8132 0 2 0 008 Camshaft cam height A Exhaust 45 875 46 065 1 8061 1 8136 0 2 0 008 Camshaft runout TIR Less than 0 02 0 0008 0 05 0 0020 Camshaft sprocket runout TIR E 0 15 0 0059 A SEM671 1 Cam wear limit Revision 2007 November EM 140 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS 2 Total indicator reading VALVE LIFTER Items Standard Unit mm in Valve lifter outer diameter 33 980 33 990 1 3378 1 3382 Valve lifter hole diameter 34 000 34 016 1 3386 1 3392 Valve lifter clearance VALVE CLEARANCE 0 010 0 036 0 0004 0 0014 Unit mm in Items 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 AVAILABLE VALVE LIFTER Unit mm in Identification stamped mark Thickness 788 7 88 0 3102 790 7 90 0 3110 792 7 92 0 3118 794 7 94 0 3126 796 7 96 0 3134 798 7 98 0 3142 800 8 00 0 3150 802 8 02 0 3157 804 8 04 0 3165 806 8 06 0 3173 808 8 08 0 3181 810 8 10 0 3189 812 8 12 0 3197 814
18. 69 997 2 7557 2 7558 69 997 69 998 2 7558 2 7558 69 998 69 999 2 7558 2 7559 70 001 70 002 2 7559 2 7560 70 003 70 004 2 7560 2 7561 70 004 70 005 2 7561 2 7561 NIN 70 005 70 006 2 7561 2 7561 NJ N 70 006 70 007 2 7561 2 7562 gja wlale ENESES ww AIRIAIA w o IRISI 70 009 70 010 2 7563 2 7563 70 011 70 012 2 7563 2 7564 70 016 70 017 2 7565 2 7566 69 995 69 996 2 7557 2 7557 OCH No ole l Djo oje OJO ojo Axle diameter O N NIN 64 975 64 974 2 5581 2 5580 0 2 12 3 3 0 01 1 121 64 974 64 973 2 5580 2 5580 0 0 01 01 11 12 12 1 64 973 64 972 2 5580 2 5579 o 01 01 01 1 1 1 12 12 12 2 2 2 23 23 64 972 64 971 2 5579 2 5579 o1 01 o1 1 1 4 12 12 12 2 2 2 23 23 23 3 3 3 3 64 970 64 969 2 5579 2 5578 01 1 34 34 34 4 2 2 2 23 3 64 969 64 968 2 5578 2 5578 1 1 1 12 2 2 2 23 23 3 3 34 34 34 4 4 3 34 34 a44 4 4 64 967 64 966 2 5578 2 5577 1 12 12 12 2 232312313 34 34 34 4 4 4 45 SCHER ES ls A EA a 2 2 afalafe rm ISIS ES wjolo NIYII co Jo PSPS 123 bal BRIS oja o 64 968 64 967 2 5578 2 5578 1 1 12 12 2 2 2a 23 23 64 966 64 965 2 5577 2 5577 12 12 12 2 23 23 23 3 3 3434 4 4 4 45 45 64 965 64 964 2 5577 2 5576 12 12 2 2 2 23 23 23 3 3 3 34 34
19. JPBIA0011ZZ 4 Disconnect vacuum hose PCV hose and EVAP hose from intake manifold collector 5 Remove EVAP canister purge volume control solenoid valve and EVAP tube assembly from intake mani fold collector 6 Loosen mounting bolts and nuts with power tool in the reverse order as shown in the figure to remove intake manifold collector lt Engine front INSTALLATION Note the following and install in the reverse order of removal INTAKE MANIFOLD COLLECTOR e If stud bolts were removed install them and tighten to the specified torque below 10 8 N m 1 1 kg m 8 ft lb e Tighten mounting bolts and nuts in numerical order as shown in the figure lt 2 Engine front Ta Ta an Tan a a n maa aa E 4 CH 1 4 WATER HOSE e Insert hose by 27 to 32 mm 1 06 to 1 26 in from connector end e Clamp hose at location of 3 to 7 mm 0 12 to 0 28 in from hose end ELECTRIC THROTTLE CONTROL ACTUATOR BANK 1 AND BANK 2 Revision 2007 November EM 30 2008 EX35 INTAKE MANIFOLD COLLECTOR lt ON VEHICLE REPAIR gt e Tighten in numerical order as shown in the figure NOTE e The figure shows the electric throttle control actuator bank 1 viewed from the air duct side e Viewed from the air duct side order of tightening mounting bolts of electric throttle control actuator bank 2 is the same as that of the electric throttle control actuator bank 1 Perform the Throttle Valve Closed Position Learning whe
20. KV10115900 J26336 20 C the adapter SST KV10109220 B Remove valve collet with a magnet hand CAUTION When working take care not to damage valve lifter holes AY el 1 1 i i H H i SI We Ss JPBIAO180ZZ 5 Remove valve spring retainer and valve spring 6 Remove valve oil seal using the valve oil seal puller SST KV10107902 J38959 A JPBIAO177ZZ INSTALLATION 1 Apply new engine oil on new valve oil seal joint and seal lip 2 Using the valve oil seal drift SST KV10115600 J38958 A press fit valve seal to height b shown in the figure NOTE Dimension Height measured before valve spring seat installa tion Intake and exhaust 14 3 14 9 mm 0 563 0 587 in JPBIAO178ZZ 3 Install in the reverse order of removal after this step FRONT OIL SEAL FRONT OIL SEAL Removal and Installation EE REMOVAL Revision 2007 November EM 76 2008 EX35 OIL SEAL lt ON VEHICLE REPAIR gt 1 Remove the following parts e Engine undercover with power tool e Drive belt Refer to EM 13 Exploded View e Crankshaft pulley Refer to EM 50 Exploded View 2 Remove front oil seal using a suitable tool CAUTION Be careful not to damage front timing chain case and crank shaft PBIC2931E INSTALLATION 1 Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal 2 Install front oil seal e Install front oil seal so that each seal
21. Refer to CO 16 Exploded View 5 Discharge refrigerant from A C circuit Refer to HA 26 Collection and Charge 6 Remove radiator hoses upper and lower Refer to CO 13 Exploded View Engine Room LH 1 Disconnect heater hose from vehicle side and fit a plug onto hose end to prevent engine coolant leakage 2 Disconnect A C piping from A C compressor and temporarily fasten it on vehicle with a rope Refer to HA 39 Exploded View 3 Disconnect brake booster vacuum hose 4 Disconnect ground cable Engine Room RH 1 Disconnect battery positive cable at vehicle side and temporarily fasten it on engine 2 Disconnect all clips and connector of the engine room harness from engine back side 3 Disconnect fuel feed hose with damper and EVAP hose Refer to EM 37 Exploded View CAUTION Fit plugs onto disconnected hoses to prevent fuel leakage 4 Remove reservoir tank of power steering oil pump and piping from vehicle and temporarily secure them on engine Refer to ST 25 2WD Exploded View CAUTION When temporarily securing keep the reservoir tank upright to avoid a fluid leakage Vehicle Inside Follow procedure below to disconnect engine room harness connectors at passenger room side and tempo rarily secure them on engine 1 Remove passenger side kicking plate and dash side finisher Refer to INT 20 Exploded View 2 Disconnect engine room harness connectors at unit sides TCM ECM and other 3 Disengage
22. SERVICE DATA AND SPECIFICATIONS SDS Unit mm in Taper Difference between A and B Out of round Difference between X and Y SEM645 SBIA0535E Grade No A 64 975 64 974 2 5581 2 5580 Grade No B 64 974 64 973 2 5580 2 5580 Grade No C 64 973 64 972 2 5580 2 5579 Grade No D 64 972 64 971 2 5579 2 5579 Grade No E 64 971 64 970 2 5579 2 5579 Grade No F 64 970 64 969 2 5579 2 5578 Grade No G 64 969 64 968 2 5578 2 5578 Grade No H 64 968 64 967 2 5578 2 5578 Grade No J 64 967 64 966 2 5578 2 5577 Grade No K 64 966 64 965 2 5577 2 5577 Grade No L 64 965 64 964 2 5577 2 5576 senh e E Grade No M 64 964 64 963 2 5576 2 5576 Main journal diameter Dm grade Standard Grade No N 64 963 64 962 2 5576 2 5576 Grade No P 64 962 64 961 2 5576 2 5575 Grade No R 64 961 64 960 2 5575 2 5575 Grade No S 64 960 64 959 2 5575 2 5574 Grade No T 64 959 64 958 2 5574 2 5574 Grade No U 64 958 64 957 2 5574 2 5574 Grade No V 64 957 64 956 2 5574 2 5573 Grade No W 64 956 64 955 2 5573 2 5573 Grade No X 64 955 64 954 2 5573 2 5572 Grade No Y 64 954 64 953 2 5572 2 5572 Grade No 4 64 953 64 952 2 5572 2 5572 Grade No 7 64 952 64 951 2 5572 2 5571 Grade No A 53 974 53 973 2 1250 2 1249 Grade No B 53
23. SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Grade No 1 95 500 95 510 3 7598 3 7602 Standard Grade No 2 95 510 95 520 3 7602 3 7606 Cylinder bore Inner diameter Grade No 3 95 520 95 530 3 7606 3 7610 Wear limit 0 2 0 008 Out of round 0 015 0 0006 Limit Taper 0 010 0 0004 Grade No A 69 993 69 994 2 7556 2 7557 Grade No B 69 994 69 995 2 7557 2 7557 Grade No C 69 995 69 996 2 7557 2 7557 Grade No D 69 996 69 997 2 7557 2 7558 Grade No E 69 997 69 998 2 7558 2 7558 Grade No F 69 998 69 999 2 7558 2 7559 Grade No G 69 999 70 000 2 7559 2 7559 Grade No H 70 000 70 001 2 7559 2 7559 Grade No J 70 001 70 002 2 7559 2 7560 Grade No K 70 002 70 003 2 7560 2 7560 Grade No L 70 003 70 004 2 7560 2 7561 Main bearing housing inner diameter grade Without bearing e 7 eg r Ge i E Grade No P 70 006 70 007 2 7561 2 7562 Grade No R 70 007 70 008 2 7562 2 7562 Grade No S 70 008 70 009 2 7562 2 7563 Grade No T 70 009 70 010 2 7563 2 7563 Grade No U 70 010 70 011 2 7563 2 7563 Grade No V 70 011 70 012 2 7563 2 7564 Grade No W 70 012 70 013 2 7564 2 7564 Grade No X 70 013 70 014 2 7564 2 7565 Grade No Y 70 014 70 015 2 7565 2 7565 Grade No 4 70 015 70 016 2 7565 2 7565 Grade No 7 70 016 70 017 2 7565 2 7566
24. 5 A C compressor 6 Idler pulley 7 Drive belt 8 Idler pulley A Possible use range B Range when new drive belt is installed C Indicator D ViewD C h ecki n d INFOID 0000000003139084 WARNING Be sure to perform the this step when engine is stopped e Check that the indicator C notch on fixed side of drive belt auto tensioner is within the possible use range A NOTE e Check the drive belt auto tensioner indication when the engine is cold e When new drive belt is installed the indicator notch on fixed side should be within the range B in the fig ure e Visually check entire drive belt for wear damage or cracks e If the indicator notch on fixed side is out of the possible use range or belt is damaged replace drive belt Tension Adjustment INFOID 0000000009136085 Refer to EM 139 Drive Belt Re moval and Installation INFOID 0000000003139086 REMOVAL 1 Remove engine undercover with power tool Revision 2007 November EM 13 2008 EX35 DRIVE BELT lt ON VEHICLE MAINTENANCE gt 2 While securely holding the square hole A in pulley center of auto tensioner 1 with a spinner handle move spinner handle in the direction of arrow loosening direction of drive belt 4m Loosening direction of drive belt CAUTION Never place hand in a location where pinching may occur if the holding tool accidentally comes off 3 Under the above condition insert a metallic bar of approximately 6 mm 0 24 in in diamet
25. 61 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt 10 e Apply new engine oil to both oil seal lip A and dust seal lip B lt Engine inside dem Engine outside e Install it so that each seal lip is oriented as shown in the figure JPBIA0054ZZ e Using a suitable drift outer diameter 60 mm 2 36 in A press fit oil seal until it becomes flush with front timing chain case end face e Check the garter spring is in position and seal lip is not inverted Install front timing chain case as follows e Check O rings stay in place during installation to rear timing chain case Apply a continuous bead of liquid gasket with the tube presser commercial service tool to front timing chain case back side as shown in the figure Protrusion 03 4 4 4 mm 0 134 0 173 in 02 6 3 6 mm 0 102 0 142 in e 4 0 5 6 mm 0 157 0 220 in aow Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants JPBIA1138ZZ Revision 2007 November EM 62 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt b Apply liquid gasket to top surface of oil pan upper as shown in the figure A 4 0 5 0 mm 0 157 0 197 in Use Genuine RTV silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants JPBIA0056ZZ c Assemble front timing chain case Front timing chain case Oil pan upper Cylinder block lt
26. View 3 Drain engine coolant from radiator Refer to CO 7 Draining CAUTION e Perform this step when engine is cold e Never spill engine coolant on drive belt 4 Remove the following parts e Radiator reservoir tank Refer to CO 13 Exploded View e Engine cover Refer to EM 25 Exploded View e Front road wheel and tires power tool e Engine undercover power tool e Front cross bar Refer to FSU 37 Exploded View Cowl top cover Refer to EXT 22 Exploded View e Air duct and air cleaner case assembly RH and LH Refer to EM 27 Exploded View e Cooling fan assembly Refer to CO 16 Exploded View 5 Discharge refrigerant from A C circuit Refer to HA 26 Collection and Charge 6 Remove radiator hoses upper and lower Refer to CO 13 Exploded View Engine Room LH 1 Disconnect heater hose from vehicle side and fit a plug onto hose end to prevent engine coolant leakage 2 Disconnect A C piping from A C compressor and temporarily fasten it on vehicle with a rope Refer to HA 39 Exploded View 3 Disconnect brake booster vacuum hose 4 Disconnect ground cables Revision 2007 November EM 84 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt Engine Room RH 1 Disconnect battery positive cable vehicle side and temporarily fasten it on engine 2 Disconnect all clips and connectors of the engine room harness from engine back side 3 Disconnect fuel feed hose with damper and EVAP
27. at connection points Run engine to check for unusual noise and vibration Warm up engine thoroughly to check there is no leakage of fuel exhaust gases or any oil fluids including engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc AWD AWD Exploded View INFOID 0000000003 139128 DI 49 0 5 0 36 5 49 0 6 0 36 DI 49 0 5 0 36 Sa 0 49 0 5 0 36 DI 49 0 5 0 36 T S 2 1 15 EM 83 92 5 9 4 68 DI 49 0 5 0 36 L is 92 5 9 4 68 Revision 2007 November 2008 EX35 EM ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt Engine mounting bracket RH low 1 Engine mounting bracket RH 2 er 3 Dynamic damper 4 Washer 5 Engine mounting insulator RH 6 Engine mounting bracket LH 7 Engine mounting insulator LH 8 Heat insulator 9 Rear engine mounting member 10 Engine mounting insulator rear A Front m
28. bank 1 2 Air fuel ratio sensor 1 bank 1 3 Exhaust manifold cover upper 4 Exhaust manifold bank 1 5 Exhaust manifold cover lower 6 Gasket 7 Ring gasket 8 Three way catalyst bank 1 9 Gasket 10 Heated oxygen sensor 2 bank 2 11 Gasket 12 Three way catalyst bank 2 13 Ring gasket 14 Exhaust manifold bank 2 15 Exhaust manifold cover lower 16 Gasket 17 Air fuel ratio sensor 1 bank 2 18 Exhaust manifold cover upper Refer to GI 4 Components for symbols in the figure Re m oval a nd n stal lat i O n INFOID 0000000003139105 REMOVAL WARNING Perform the work when the exhaust and cooling system have completely cooled down NOTE When removing bank 1 side parts only step 2 5 and 7 are unnecessary 1 NOa PP bah Remove engine undercover with power tool Drain engine coolant Refer to CO 7 Draining Remove engine cover with power tool Refer to EM 25 Exploded View Remove air cleaner case and air duct RH and LH Refer to EM 27 Exploded View Remove heater pipe and water hose Refer to CO 23 Exploded View Remove exhaust front tube and three way catalysts bank 1 and bank 2 Refer to EX 5 Exploded View Disconnect steering lower joint at power steering gear assembly side and release steering lower shaft Revision 2007 November EM 34 2008 EX35 EXHAUST MANIFOLD lt ON VEHICLE REPAIR gt 8 Disconnect air fuel ratio sensor 1 harness connectors bank 1 and bank 2 and remove h
29. figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure lt x Engine front e No 3 cylinder at compression TDC Measuring position bank 1 A No 1 CYL No 3 CYL No 5 CYL No 3 cylinder at com EXH C x B pression TDC INT D x E Measuring position bank 2 H No 2 CYL No 4 CYL No 6 CYL No 3 cylinder at com INT D x F pression TDC EXH C x G JPBIAO167ZZ d Rotate crankshaft 240 degrees clockwise when viewed from engine front to align No 5 cylinder at TDC of compression stroke NOTE Mark a position 240 degrees b from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure Use the hexagonal part as a guide 1 Crankshaft pulley A Paint mark Revision 2007 November EM 20 2008 EX35 CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt e By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure lt Engine front e No 5 cylinder at compression TDC Measuring position bank 1 A No 1 CYL No 3 CYL No 5 CYL No 5 cylinder at EXH C x B compression TDC INT D x E Measuring position bank 2 H No 2 CYL No 4 CYL No 6 CYL No 5 cylinder at INT D x F compression TDC EXH C x G 3 Perform a
30. hose Refer to EM 37 Exploded View CAUTION EM Fit plugs onto disconnected hoses to prevent fuel leakage 4 Remove reservoir tank of power steering oil pump and piping from vehicle and temporarily secure them on engine Refer to ST 52 AWD Exploded View CAUTION When temporarily securing keep the reservoir tank upright to avoid a fluid leakage Vehicle Inside Follow procedure below to disconnect engine room harness connectors at passenger room side and tempo rarily secure them on engine 1 Remove passenger side kicking plate and dash side finisher Refer to INT 20 Exploded View 2 Disconnect engine room harness connectors at unit sides TCM ECM and other 3 Disengage intermediate fixing point Pull out engine room harnesses to engine room side and temporarily secure them on engine CAUTION e When pulling out harnesses take care not to damage harnesses and connectors e After temporarily securing cover connectors with vinyl or similar material to protect against for eign material adhesion Vehicle Underbody 1 Remove A T fluid cooler hoses and power steering oil pump oil cooler hoses e Install plug to avoid leakage of A T fluid and power steering fluid 2 Disconnect heated oxygen sensor 2 harness Refer to EX 6 Removal and Installation Remove three way catalyst and exhaust front tube Refer to EX 5 Exploded View Disconnect steering lower joint at power steering gear assembly side and release steering lower
31. in Items Thickness Main journal diameter 0 25 0 0098 2 633 2 641 0 1037 0 1040 Grind so that bearing clearance is the specified value MAIN BEARING OIL CLEARANCE Unit mm in Items Standard Limit Main bearing oil clearance 0 035 0 045 0 0014 0 0018 0 065 0 0026 Actual clearance Co n n ecti n d Rod Bear n d INFOID 0000000003139163 CONNECTING ROD BEARING Unit mm in Grade number Thickness Identification color mark 0 1 497 1 500 0 0589 0 0591 Black 1 1 500 1 503 0 0591 0 0592 Brown 2 1 503 1 506 0 0592 0 0593 Green 3 1 506 1 509 0 0593 0 0594 Yellow 4 1 509 1 512 0 0594 0 0595 Blue UNDERSIZE Unit mm in Items Thickness Crank pin journal diameter 0 25 0 0098 1 626 1 634 0 0640 0 0643 Grind so that bearing clearance is the specified value CONNECTING ROD BEARING OIL CLEARANCE Unit mm in Items Standard Limit Connecting rod bearing oil clearance 0 040 0 053 0 0016 0 0021 0 070 0 0028 Actual clearance Revision 2007 November EM 149 2008 EX35
32. of piston pin hole with an inside micrometer A Standard Refer to EM 144 Cylinder Block JPBIA0217ZZ Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer A Standard Refer to EM 144 Cylinder Block JPBIA0218ZZ Piston to Piston Pin Oil Clearance Piston to piston pin oil clearance Piston pin hole diameter Piston pin outer diameter Standard Refer to EM 144 Cylinder Block e If the calculated value is out of the standard replace piston and piston pin assembly e When replacing piston and piston pin assembly refer to EM 133 Description NOTE e Piston is available together with piston pin as assembly e Piston pin piston pin hole grade is provided only for the parts installed at the plant For service parts no piston pin grades can be selected Only 0 grade is available PISTON RING SIDE CLEARANCE EM 124 2008 EX35 Revision 2007 November CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt e Measure the side clearance of piston ring 1 and piston ring groove with a feeler gauge C A NG B Ok Standard and limit Refer to EM 144 Cylinder Block e If the measured value exceeds the limit replace piston ring and measure again If it still exceeds the limit replace piston also JPBIA0219ZZ PISTON RING END GAP e Check that the cylinder bore inner diameter is within the specification Refer to EM 115 Disassembly and Assembly
33. oil clearance 0 002 0 006 0 0001 0 0002 Connecting rod bushing oil clearance CONNECTING ROD Items 0 005 0 017 0 0002 0 0007 Standard 0 030 0 0012 Unit mm in Limit Center distance 144 15 144 25 5 68 5 68 Bend per 100 3 94 0 15 0 0059 Torsion per 100 3 94 0 30 0 0118 Grade No 0 22 000 22 006 0 8661 0 8664 Connecting rod bushing inner diameter Grade No 1 22 006 22 012 0 8664 0 8666 Grade No A 57 000 57 001 2 2441 2 2441 Grade No B 57 001 57 002 2 2441 2 2442 Grade No C 57 002 57 008 2 2442 2 2442 Grade No D 57 003 57 004 2 2442 2 2442 Grade No E 57 004 57 005 2 2442 2 2443 Grade No F 57 005 57 006 2 2443 2 2443 oe rod big end diameter Without Grade No G 57 006 57 007 2 2443 2 2444 Grade No H 57 007 57 008 2 2444 2 2444 Grade No J 57 008 57 009 2 2444 2 2444 Grade No K 57 009 57 010 2 2444 2 2445 Grade No L 57 010 57 011 2 2445 2 2445 Grade No M 57 011 57 012 2 2445 2 2446 Grade No N 57 012 57 013 2 2446 2 2446 Items Standard Limit Side clearance After installing in connecting rod CRANKSHAFT Revision 2007 November 0 20 0 35 0 0079 0 0138 EM 146 0 40 0 0157 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt
34. out valve guide with a press under a 20 kN 2 ton 2 2 US ton 2 0 Imp ton pressure or a hammer and the valve guide drift commercial service tool WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned 11 Remove spark plug tube as necessary e Using a pliers pull spark plug tube out of cylinder head CAUTION e Take care not to damage cylinder head e Once removed spark plug tube will be deformed and cannot be reused Never remove it unless absolutely necessary ASSEMBLY 1 If valve guide is removed in step 10 DISASSEMBLY install it Replace with oversized 0 2 mm 0 008 in valve guide a Using the valve guide reamer commercial service tool A ream cylinder head valve guide hole Valve guide hole diameter for service parts Intake and exhaust Refer to EM 142 Cylinder Head Revision 2007 November EM 106 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt b Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIAO184ZZ c Using the valve guide drift commercial service tool press valve guide from camshaft side to the dimensions as shown in the fig ure Projection A Intake and exhaust Refer to EM 142 Cylinder Head WARNING Cylinder head contains heat When working wear protec tive equipment to avoid getting burned JPBIAO186ZZ d Using the valve guide reamer commercial servic
35. procedure Liquid gasket application point View F End surface of camshaft bracket No 1 4 mm 0 16 in 2 5 3 5 mm 0 098 0 138 in 5 mm 0 20 in 10 mm 0 39 in lt Engine front o Oo E mn Ze Use Genuine RTV silicone sealant or equivalent Refer toG 15 Recommended Chemical Products and Sealants a Refer to figure E to apply liquid gasket to joint part of camshaft bracket No 1 1 and cylinder head b Refer to figure H to apply liquid gasket in 90 degrees to figure JPBIA0274ZZ 2 Install rocker cover gasket to rocker cover 3 Install rocker cover e Check if rocker cover gasket is not dropped from the installation groove of rocker cover 4 Tighten bolts in two steps separately in numerical order as shown in the figure lt Engine front W 1st step 2 0 N m 0 2 kg m 18 in Ib o 2nd step 8 3 N m 0 85 kg m 73 in Ib JPBIA0040ZZ 5 Install in the reverse order of removal after this step Revision 2007 November EM 49 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt TIMING CHAIN Exp loded View INFOID 0000000003139116 SEC 120 130 135 150 210 aa G ey 0 15 7 1 6 12 61 3 Gs 3 45 61 3 o 6 3 45 Ze H 9 6 0 98 85 ne Di 28 0 2 9 21 A elo e Pa 0 98 85 JPBIA1926GB 1 Timing chain secondary 2 Camshaft sprocket EXH 3 O ring 4 Timing chain secondary 5 Camshaf
36. shaft Refer to ST 23 Exploded View Remove rear propeller shaft Refer to DLN 89 Exploded View Remove front drive shaft both side Refer to FAX 23 Exploded View Disconnect harness connector from transmission assembly and transfer assembly Disengage A T control rod at control device assembly side Then temporarily secure it on the transmis sion assembly so that it does not sag Refer to TM 158 AWD Exploded View 9 Remove rear plate cover from oil pan upper Then remove bolts fixing drive plate to torque converter Refer to EM 100 AWD Exploded View 10 Remove bolts fixing the transmission assembly to lower rear side of oil pan upper Refer to EM 100 AWD Exploded View 11 Remove front stabilizer connecting rod from transverse link Refer to FSU 32 Exploded View 12 Remove lower ends of left and right steering knuckle from transverse link Refer to ST 34 AWD Exploded View 13 Separate steering outer sockets from steering knuckle Refer to ST 34 AWD Exploded View 14 Remove transverse links mounting bolts at suspension member side Refer to FSU 32 Exploded View Pw ONO Removal Work Revision 2007 November EM 85 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt 1 w Use a manual lift table caddy commercial service tool or equiv alently rigid tool such as a transmission jack Securely support bottom of suspension member and transmission CAUTIO
37. side e Crankshaft key should line up with the bank 1 cylinder center line as shown in the figure JPBIAO174ZZ Revision 2007 November EM 109 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt 11 Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure with cylin der head bolts wrench commercial service tool A Bank B Bank2 lt Engine front CAUTION e If cylinder head bolts re used check their outer diameters before installation Refer to EM 111 Inspection e Before installing cylinder head inspect cylinder head dis tortion Refer to EM 111 Inspection a Apply new engine oil to threads and seat surfaces of cylinder head bolts b Tighten all cylinder head bolts 105 N m 11 kg m 77 ft lb c Completely loosen all cylinder head bolts 0 N m 0 kg m 0 ft Ib CAUTION In step c loosen bolts in reverse order of that indicated in the figure d Tighten all cylinder head bolts JPBIA0172ZZ 40 0 N m 4 1 kg m 30 ft Ib e Turn all cylinder head bolts 95 degrees clockwise angle tightening CAUTION Check the tightening angle by using the angle wrench SST KV10112100 BT8653 A A Never make judgment by visual inspection e Check tightening angle indicated on the angle wrench indica tor plate f Turn all cylinder head bolts 95 degrees clockwise again angle tightening 12 After installi
38. spring seat 7 Valve guide 8 Cylinder head bolt 9 Spark plug 10 Spark plug tube 11 Cylinder head bank 1 12 Valve seat EXH 13 Valve INT 14 Valve EXH 15 Valve seat EXH 16 Cylinder head gasket bank 1 17 Cylinder head gasket bank 2 18 Cylinder head bank 2 19 Engine rear lower slinger A Refer to EM 104 EXD Apply high strength thread locking sealant or equivalent Refer to Gl 4 Components for symbols not described on the above Disassembly and Assembly INFO1D 0000000003139145 DISASSEMBLY 1 Remove the following parts Intake manifold collector Refer to EM 29 Exploded View Rocker cover and spark plug Refer to EM 47 Exploded View Fuel tube and fuel injector assembly Refer to EM 37 Exploded View Intake manifold Refer to EM 32 Exploded View Exhaust manifold Refer to EM 34 Exploded View Water inlet and thermostat assembly Refer to CO 21 Exploded View Water outlets front and rear water pipe and heater pipe Refer to CO 23 Exploded View e Timing chain Refer to EM 50 Exploded View Revision 2007 November EM 104 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt e Rear timing chain case Refer to EM 92 Exploded View e Camshaft Refer to EM 67 Exploded View 2 Remove cylinder head e Loosen cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench commercial service tool and power tool A Bank 1 B Bank2
39. tightening bolts is the same for bank 1 and bank 2 JPBIA1960ZZ 7 Inspect and adjust the valve clearance Refer to EM 18 Inspection and Adjustment 8 Install in the reverse order of removal after this step n S pect i Oo n INFOID 0000000003139121 INSPECTION AFTER REMOVAL Camshaft Runout Revision 2007 November EM 71 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt 1 Put V block on precise flat table and support No 2 and 4 jour nals of camshaft CAUTION Never support No 1 journal on the side of camshaft sprocket because it has a different diameter from the other three locations 2 Seta dial indicator vertically to No 3 journal 3 Turn camshaft to one direction with hands and measure the camshaft runout on a dial indicator Total indicator reading Standard and limit Refer to EM 140 Camshaft _ _ 4 If it exceeds the limit replace camshaft Camshaft Cam Height 1 Measure the camshaft cam height with a micrometer Standard cam height Intake and exhaust Cam wear limit Refer to EM 140 Camshaft 2 If wear exceeds the limit replace camshaft Refer to EM 140 Camshaft EMQ0072D Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER e Measure the outer diameter of camshaft journal with a micrometer A Standard Refer to EM 140 Camshaft CAMSHAFT BRACKET INNER DIAMETER e Tighten camshaft bracket bolt with the specified torque Refer to INSTALLATION
40. to CO 13 Exploded View 5 Remove air duct and air cleaner case assembly RH and LH Refer to EM 27 Exploded View 6 Remove engine undercover with power tool 7 Drain engine coolant from radiator Refer to CO 7 Draining CAUTION e Perform this step when the engine is cold e Never spill engine coolant on drive belt 8 Remove radiator hose upper and lower Refer to CO 13 Exploded View 9 Drain engine oil Refer to LU 8 Draining CAUTION e Perform this step when the engine is cold e Never spill engine oil on drive belt 10 Remove drive belt Refer to EM 13 Exploded View 11 Remove radiator cooling fan assembly Refer to CO 16 Exploded View 12 Separate engine harnesses removing their brackets from front timing chain case 13 Remove intake manifold collector Refer to EM 29 Exploded View 14 Remove intake manifold Refer to EM 32 Exploded View 15 Remove fuel sub tube mounting bolt Refer to EM 37 Exploded View 16 Remove oil level gauge and oil level gauge guide 17 Remove A C compressor from bracket with piping connected and temporarily secure it aside Refer to HA 39 Exploded View 18 Remove power steering oil pump from bracket with piping connected and temporarily secure it aside Refer to ST 45 Exploded View 19 Remove power steering oil pump bracket Refer to ST 45 Exploded View 20 Remove idler pulley auto tensioner and bracket 21 Remove alternator and alternator
41. 00003470880 Ignition coil O ring O ring Camshaft position sensor PHASE bank 2 Rocker cover bank 2 PCV hose Camshaft bracket side INFOID 0000000003139115 2008 EX35 IGNITION COIL SPARK PLUG AND ROCKER COVER lt ON VEHICLE REPAIR gt 3 Remove camshaft position sensor PHASE and exhaust valve timing control position sensor bank 1 and bank 2 A Keep off any magnetic materials CAUTION e Handle carefully to avoid dropping and shocks e Never disassemble e Never allow metal powder to adhere to magnetic part at sensor tip e Never place sensors in a location where they are exposed x to magnetism S JPBIA0454ZZ 4 Remove PCV valve and O ring from rocker cover if necessary Remove oil filler cap from rocker cover if necessary 6 Remove ignition coil CAUTION Never shock ignition coil 7 Remove harness clips on the rocker cover 8 Loosen mounting bolts with power tool in reverse order shown in the figure a lt Engine front JPBIA0040ZZ 9 Remove rocker cover gasket from rocker cover 10 Use scraper to remove all traces of liquid gasket from cylinder head and camshaft bracket No 1 CAUTION Never scratch or damage the mating surface when cleaning off old liquid gasket INSTALLATION Revision 2007 November EM 48 2008 EX35 IGNITION COIL SPARK PLUG AND ROCKER COVER lt ON VEHICLE REPAIR gt 1 Apply liquid gasket to the position shown in the figure with the following
42. 0111100 J37228 by tapping on the side of tool with a hammer Remove oil pan lower JPBIA0276ZZ INSTALLATION 1 Install oil pan lower as follows a Use scraper A to remove old liquid gasket from mating sur faces e Remove old liquid gasket from the bolt holes and thread CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket JPBIA0025ZZ b Apply a continuous bead of liquid gasket with the tube presser commercial service tool to the oil pan lower as shown in the figure lt Engine front a 4 0 5 0 mm 0 157 0 197 in Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION JPBIA1556ZZ Attaching should be done within 5 minutes after coating c Install oil pan lower Revision 2007 November EM 45 2008 EX35 OIL PAN LOWER lt ON VEHICLE REPAIR gt e Tighten mounting bolts in numerical order as shown in the fig ure lt Engine front JPBIA0021ZZ Install oil pan drain plug e Refer to the figure of components of former page for installation direction of drain plug washer Refer to EM 43 Exploded View 2WD 2WD models and EM 44 Exploded View AWD AWD models Install in the reverse order of removal after this step NOTE At least 30 minutes after oil pan is installed pour engine oil In spection INFOID 0000000003139113 INSPECTION AFTER REMOVAL Clean oil s
43. 2 Exploded View Remove camshaft Refer to EM 67 Exploded View 10 Remove cylinder head Refer to EM 104 Exploded View AS se m b y INFOID 0000000003139133 Assembly in the reverse order of disassembly Revision 2007 November EM 91 2008 EX35 REAR TIMING CHAIN CASE lt DISASSEMBLY AND ASSEMBLY gt REAR TIMING CHAIN CASE Exploded View SEC 120 130 135 150 210 gyno as Dez Loes 7 DE E 6 3 45 Ka z Y TY G0 E 9 61 3 eg Ee d S 6 3 45 9 7 eg 9 6 0 98 85 ne 28 0 2 9 21 9 6 0 98 85 INFOID 0000000003567096 JPBIA1926GB 1 Timing chain secondary 2 Camshaft sprocket EXH 3 O ring 4 Timing chain secondary 5 Camshaft sprocket EXH 6 Internal chain guide 7 Timing chain primary 8 Camshaft sprocket INT 9 Timing chain tensioner primary Revision 2007 November EM 92 2008 EX35 REAR TIMING CHAIN CASE lt DISASSEMBLY AND ASSEMBLY gt 10 Slack guide 11 Crankshaft sprocket 12 Camshaft sprocket INT 13 Valve ming control Cover Gasket 14 Seal ring 15 Valve timing control cover bank 1 bank 1 F Exhaust valve timing control sole 16 O ring 17 noid valve bank 1 18 Oil level gauge e Intake valve timing control solenoid 19 Oil level gauge guide 20 O ring 21 valve bank 2 22 Valve timing control cover bank 2 23 Exhaust valve timing control sole 24 Valve timing control cover gasket bank noid valve bank 2
44. 34 4 44 45 45 45 5 5 5 64 964 64 963 2 5576 2 5576 12 2 2 2 23 23 23 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 64 963 64 962 2 5576 2 5576 2 2 2 23 23 23 3 3 3 3434134 4 4 4 45 45 45 5 5 5 56 50 56 64 962 64 961 2 5576 2 5575 2 2 23231233 3 3 34 34 al 4 4 4 45 45 45 5 5 5 56 56 50 6 64 961 64 960 2 5575 2 5575 2 23 23 23 3 3 3 34 34 34 4 4 4 45 45145 5 Tele 56 56 56 ele 64 959 64 958 2 5574 2 5574 2a 23 3 3 3 34 34 3a 4 4 4 45 45 45 5 5 5 56 56 56 6 6 64 958 64 957 2 5574 2 5574 23 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 64 957 64 956 2 5574 2 5573 3 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 64 956 64 955 2 5573 2 5573 3 3 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 64 955 64 954 2 5573 2 5572 3 Salade 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 7 64 954 64 953 2 5572 2 5572 34 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 7 64 953 64 952 2 5572 2 5572 34 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 67 67 67 7 7 7 64 952 64 951 2 5572 2 5571 34 4 4 4 45 45 45 5 5 5 56 56 56 6 6 6 67 67 67 7 7 7 JPBIA0264ZZ wo A A A on ojo AMBAlalala ol oioloelz ala SIE
45. 590 3 7594 3 7594 3 7598 3 7598 3 7602 NOTE e Piston is available together with piston pin as assembly e Piston pin piston pin hole grade is provided only for the parts installed at the plant For service parts no pis ton pin grades can be selected Only 0 grade is available e No second grade mark is available on piston Co n n ecti n d Rod Beari n d INFOID 0000000003139152 WHEN NEW CONNECTING ROD AND CRANKSHAFT ARE USED 1 Apply connecting rod big end diameter grade stamped D on connecting rod side face to the row in the CONNECTING ROD BEARING SELECTION TABLE Sample codes Bearing stopper groove Small end diameter grade Weight grade Cylinder No Management code Front mark JPBIA0208ZZ Com Dm OD gt Management code 2 Apply crankshaft pin journal diameter grade stamped on crank shaft front side to the column in the CONNECTING ROD BEARING SELECTION TABLE Journal diameter grade No 1 r ANE VFN Journal diameter grade No 2 1 ABO Journal diameter grade No 3 OPOMNI NA Journal diameter grade No 4 4 Pin diameter grade No Pin diameter grade No JPBIA0269ZZ Pin diameter grade No 2 3 Pin diameter grade No 4 Pin diameter grade No 5 Com m D OD ry Revision 2007 November EM 134 2008 EX35 HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt J Pin diameter grade No 6 K Identific
46. 8 14 0 3205 816 8 16 0 3213 818 8 18 0 3220 820 8 20 0 3228 822 8 22 0 3236 824 8 24 0 3244 826 8 26 0 3252 828 8 28 0 3260 830 8 30 0 3268 832 8 32 0 3276 834 8 34 0 3283 836 8 36 0 3291 838 8 38 0 3299 Revision 2007 November EM 141 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Identification stamped mark Thickness 840 8 40 0 3307 Cylinder Head CYLINDER HEAD Items a Stamped mark Valve lifter thickness Standard INFOID 0000000003 139160 Unit mm in Limit Head surface distortion Less than 0 03 0 0012 0 1 0 004 Normal cylinder head height H 126 3 126 5 4 97 4 98 VALVE DIMENSIONS T Margin thickness SES rm D Unit mm in 36 6 36 9 1 441 1 453 Intake Valve head diameter D Exhaust 30 2 30 5 1 189 1 201 Intake 97 13 3 8240 Valve length L Exhaust 94 67 3 7272 Intake 5 965 5 980 0 2348 0 2354 Valve stem diameter d Exhaust 5 962 5 970 0 2347 0 2350 Revision 2007 November EM 142 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Intake Valve seat angle a 45 15 45 45 Exhaust Intake 1 1 0 043 Valve margin T Exhaust 1 3 0 051 EM Valve margin T limit 0 5
47. 973 53 972 2 1249 2 1249 Grade No C 53 972 53 971 2 1249 2 1248 Grade No D 53 971 53 970 2 1248 2 1248 Grade No E 53 970 53 969 2 1248 2 1248 Grade No F 53 969 53 968 2 1248 2 1247 Grade No G 53 968 53 967 2 1247 2 1247 Grade No H 53 967 53 966 2 1247 2 1246 o i Grade No J 53 966 53 965 2 1246 2 1246 Pin journal diameter Dp grade Standard Grade No K 53 965 53 964 2 1246 2 1246 Grade No L 53 964 53 963 2 1246 2 1245 Grade No M 53 963 53 962 2 1245 2 1245 Grade No N 53 962 53 961 2 1245 2 1244 Grade No P 53 961 53 960 2 1244 2 1244 Grade No R 53 960 53 959 2 1244 2 1244 Grade No S 53 959 53 958 2 1244 2 1243 Grade No T 53 958 53 957 2 1243 2 1243 Grade No U 53 957 53 956 2 1243 2 1242 Center distance r 40 66 40 74 1 6008 1 6039 Revision 2007 November EM 147 2008 EX35 lt SERVICE DATA AND SPECIFICATIONS SDS SERVICE DATA AND SPECIFICATIONS SDS Taper Difference between A and B eo 0 0025 0 0001 imi Out of round Difference between X and Y 0 0025 0 0001 Standard Less than 0 05 0 0020 Crankshaft runout TIR Limit 0 10 0 0039 Standard 0 10 0 25 0 0039 0 0098 Crankshaft end play Limit 0 30 0 0118 Main Bearing Total indicator reading INFOID 0000000003 139162
48. AUTION FLAMMABLE sign in the workshop e Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher e Never smoke while servicing fuel system Keep open flames and sparks away from the work area e Never drain engine coolant when the engine is hot to avoid the danger of being scalded Release fuel pressure Refer to EC 538 Inspection Disconnect battery cable from the negative terminal Refer to PG 103 Exploded View Remove engine cover with power tool Refer to EM 25 Exploded View Remove air cleaner case and air duct RH and LH Refer to EM 27 Exploded View Pow NS Revision 2007 November EM 37 2008 EX35 FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt 5 Remove intake manifold collector Refer to EM 29 Exploded View 6 Remove fuel feed hose with damper 1 from fuel sub tube 2 and remove harness bracket 3 lt Engine front NOTE There is no fuel return route CAUTION e While hoses are disconnected plug them to prevent fuel from draining e Never separate damper and hose 7 When separating fuel feed hose with damper and centralized under floor piping connection disconnect quick connector as follows a Remove quick connector cap 2 from quick connector connec tion on right member side b Disconnect fuel feed hose with damper 1 from bracket hose clamp JPBIA0254ZZ c Pushin retainer tabs 2 d Draw and pull out quick connec
49. Check again for normal contact Refer to VALVE SEAT CONTACT Install new valve oil seals as follows Apply new engine oil on valve oil seal joint and seal lip Install with the valve oil seal drift SST KV10115600 J 38958 A to match dimension in the figure Tp wo Height b Without valve spring seat installed Intake and exhaust 14 3 14 9 mm 0 563 0 587 in JPBIAO178ZZ 4 Install valve spring seat 5 Install valve NOTE Larger diameter valves are for intake side 6 Install valve spring uneven pitch type Revision 2007 November EM 108 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt e Install narrow pitch end to cylinder head side valve spring seat side Wide pitch Narrow pitch Paint mark ee aes Cylinder head side Paint mark color Yellowish green JPBIAO179ZZ 7 Install valve spring retainer 8 Install valve collet e Compress valve spring with the valve spring compressor SST KV10116200 J26336 A A the attachment SST KV10115900 J26336 20 C and the adapter SST KV10116200 B Install valve collet with a magnet hand CAUTION When working take care not to damage valve lifter holes e Tap valve stem edge lightly with plastic hammer after installa tion to check its installed condition JPBIAO180ZZ Install new cylinder head gaskets 10 Turn crankshaft until No 1 piston is set at TDC 1 Crankshaft key lt Bank 1
50. EM 50 Exploded View e After all bolts are tightened tighten No 1 bolt to the specified torque again JPBIA0041ZZ Revision 2007 November EM 64 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt 12 Install oil pan lower Refer to EM 43 Exploded View 2WD 2WD models or EM 44 Exploded View AWD AWD models 13 Install rocker covers bank 1 and bank 2 Refer to EM 47 Exploded View 14 Install crankshaft pulley as follows a Fix crankshaft using the ring gear stopper SST KV10118600 J 48641 EM b Install crankshaft pulley taking care not to damage front oil seal e When press fitting crankshaft pulley with plastic hammer tap on its center portion not circumference c Tighten crankshaft pulley bolt 44 1 N m 4 5 kg m 33 ft lb d Place a matching mark A on crankshaft pulley 2 aligning with the matching mark C of crankshaft pulley bolt 1 Tighten the bolt 90 degrees one marks b e Rotate crankshaft pulley in normal direction clockwise when viewed from front to confirm it turns smoothly 15 For the following operations perform steps in the reverse order of removal n spect i O n INFOID 0000000003139118 INSPECTION AFTER REMOVAL Timing Chain Check for cracks and any excessive wear at link plates and roller links of timing chain Replace timing chain as necessary A Crack B Wear JPBIA0091ZZ INSPECTION AFTER INSTALLATION Inspection for Leakage
51. ENGINE SECTION E M ENGINE MECHANICAL SYMPTOM DIAGNOSIS cceeeceeeeeeeeees 3 Removal and Installation cccccccscsecsecseeteceeees 15 NOISE VIBRATION AND HARSHNESS SPARK PLUG a dE AA T 16 NVH TROUBLESHOOTING csccsssscsseneens 3 Exploded View BEE 16 NVH Troubleshooting i Engine Noise AER 3 Removal and Installation Se See TETT 16 Use the Chart Below to Help You Find the C Inspection Seale ta sora ala ARNAR E e EE 17 ause Of the Symptom ccceccecceeseeeeeeeentteeeeesenes 3 CAMSHAFT VALVE CLEARANCE 18 PRECAUTION occcccccccccccccccecccccececcceeeececeeeececee 5 Inspection and Adjustment s es 18 PRECAUTIONS sssssssssssssesssseesrsseessseesssneesssnees 5 COMPRESSION PRESSURE ssu sn1s1111121111 23 Precaution for Procedure without Cowl Top Cover 5 Inspection EEATT LET EEATT TETT ITATTA TETT 23 Precaution for Supplemental Restraint System x E enn eGo E ON VEHICLE REPAIR nassssesoeeneeenneeeneennnee 25 SONER eaer a ea AS ee 5 ENGINE COVER heecocececccccecececeeecceesceeseeeeeeeeeeeeee 25 Precaution Necessary for Steering Wheel Rota Exploded Ven o n 25 tion after Battery Disconnect en 5 Removal and Installation 0c cesses 25 Draining Engine Coolant sseseeseeeseeeeereeseeene 6 Disconnecting Fuel Piping cceseeeeeeeees 6 DRIVE BELT AUTO TENSIONER AND IDLER Removal and Disassembly GM IN CN E 26 Inspection Repair and Replacement 0 1010211 6
52. Exploded View When installing engine mounting bracket RH and LH on cylinder block tighten two upper bolts shown as B in the figure first Then tighten two lower bolts shown as C in the figure 3 Engine mounting bracket LH A Right side G Left side Install engine mounting bracket RH lower 2 as follows Temporarily tighten mounting bolts shown as D E and F in the figure Tighten mounting bolts to the specified torque with following mounting surfaces touched Engine mounting bracket RH 1 to engine mounting bracket RH lower shown as and in figure Front final drive to engine mounting bracket RH lower shown as in figure Check all engine mounting insulators are seated properly then tighten mounting nuts JPBIAO163ZZ Tighten rear engine mounting member bolts in numerical order as shown in the figure lt Vehicle front JPBIA0407ZZ AW D n S p ecti O n INFOID 0000000003139130 INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage and exhaust gases leakage Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Revision 2007 November EM 87 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt
53. Exploded VieW c cccscccssccsscccssecsseecseeeseeeceeesaeeesaes 26 Assembly and Installation ccccscecceeteereenees 6 Removal and Installation cccccccccsccsecsseeesseeesaes 26 Parts Requiring Angle Tightening neeese 6 Liquid Gasket eege 7 AIR CLEANER AND AIR DUT seen 27 Definitions of Bank NaO cccccceccccececccccecececceeceees 8 Exploded View siusis reiiir eninin iieii 27 Removal and Installation 27 PREPARATION 5ssssswscicesssccscntennatetvccsevearsensesies 9 feet ere 28 PREPARATION cccccccececeeeeeeeseeeeeenseenseensensenens 9 INTAKE MANIFOLD COLLECTOR 29 Special Service Tools c cccceceeeseeeeeeeeeeeseeeeeteeees 9 Exploded VieW 0 eeeeeseeceeeentaeeeeeeeneeeeeeenaeeeeeeeaaaes 29 Commercial Service Tools 0 cccccsscceeeesteeeeeees 10 Removal and Installation 29 ON VEHICLE MAINTENANCE 13 INTAKE MANIFOLD eecceeseseeeeeeeeeeeeeneeeees 32 Exploded View REENEN 32 DRIVE BELT TTT 13 Removal and Installation c ccccccccccccccececccccceueuees 32 Exploded View EEN 13 INSpECHON EE 33 CHECKING E 13 Tension Adjustment ccccccccesseccescecsesteteeeteeeees 13 EXHAUST MANIFOLD esseseeseeeeenseees 34 Removal and Installation 0 cccceceeeeeceeeeeeeeeeeees 13 Exploded VIEW neinar tinaa ann a sdai 34 IMSDECHION a a ege a a a Eed Ee ee 14 Removal and Installation isses 34 lie 36 AIR CLEANER FILTER
54. Exploded View 10 Remove lower ends of left and right steering knuckle from transverse link Refer to ST 25 2WD Exploded View 11 Separate steering outer sockets from steering knuckle Refer to ST 25 2WD Exploded View 12 Remove transverse links mounting bolts at suspension member side Refer to FSU 13 Exploded View Removal Work 1 Use a manual lift table caddy commercial service tool or equiv alently rigid tool such as a transmission jack Securely support bottom of suspension member and the transmission assembly CAUTION Put a piece of wood or something similar as the supporting surface secure a completely stable condition PBICO804E 2 Remove rear engine mounting member bolts Remove front suspension member mounting bolts and nuts Refer to FSU 18 Exploded View 4 Carefully lower jack or raise lift to remove the engine the transmission assembly and front suspension member When performing work observe the following caution CAUTION e Confirm there is no interference with the vehicle e Check that all connection points have been disconnected e Keep in mind the center of vehicle gravity changes If necessary use jack s to support the vehi cle at rear jacking point s to prevent it from falling it off the lift w Separation Work 1 Install engine slingers into front of cylinder head bank 1 and rear of cylinder head bank 2 Engine front slinger Engine rear upper slinger Spa
55. F M3 D mark C EXH B Yes No Green Light 1F 1 blue INT A Yes Green No Light 1E blue INT A Yes Green No Light 1G blue i Ligh EXH B Yes No Green ight 1H blue JPBIA0121ZZ JPBIA1191ZZ e Install camshaft so that dowel pin A on front end face are positioned as shown in the figure No 1 cylinder TDC on its compression stroke 1 Crankshaft key NOTE Though camshaft does not stop at the portion as shown in the figure for the placement of cam nose it is generally accepted camshaft is placed for the same direction of the figure JPBIA0094ZZ Revision 2007 November EM 69 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt 4 Install camshaft brackets No 1 No 2 No 3 No 4 Camshaft brackets bank 1 Exhaust side Intake side Camshaft brackets bank 2 Intake side CG Con m Oo D gt Exhaust side d Engine front e Remove foreign material completely from camshaft bracket backside and from cylinder head installation face e Install camshaft bracket in original position and direction as shown in figure JPBIA0258ZZ e Install camshaft brackets No 2 to 4 aligning the stamp marks A as shown in the figure B Bank 1 C Bank2 lt Engine front NOTE There are no identification marks indicating bank 1 and bank 2 for camshaft bracket No 1 JPBIA0272ZZ e Apply liquid gasket to mating surface of camshaft bracket No 1 as shown
56. J Precaution for Supplemental Restraint System SRS AIR BAG and SEAT BELT P R E T E N S O N E R INFOID 0000000003554243 The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a front seat belt helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision This system includes seat belt switch inputs and dual stage front air bag modules The SRS system uses the seat belt switches to determine the front air bag deployment and may only deploy one front air bag depending on the severity of a collision and whether the front occupants are belted or unbelted Information necessary to service the system safely is included in the SRS AIRBAG and SEAT BELT of this Service Manual WARNING e To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be performed by an authorized NISSAN INFINITI dealer Improper maintenance including incorrect removal and installation of the SRS can lead to personal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the SRS AIRBAG Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses can be identified by yellow and or orange harnesse
57. JPBIA0228ZZ CRANKSHAFT OUT OF ROUND AND TAPER e Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer e Out of round is indicated by the difference in the dimensions between d and c at a and b e Taper is indicated by the difference in the dimensions between Limit Refer to EM 144 Cylinder Block e If the measured value exceeds the limit correct or replace crank shaft e If corrected measure the bearing oil clearance of the corrected main journal and or pin journal Then select the main bearing and JPBIA0229ZZ or connecting rod bearing Refer to EM 136 Main Bearing and or EM 134 Connecting Rod Bearing CRANKSHAFT RUNOUT e Place V block on precise flat table and support the journals on the both end of crankshaft e Place a dial indicator straight up on the No 3 journal e While rotating crankshaft read the movement of the pointer on a dial indicator Total indicator reading Standard and limit Refer to EM 144 Cylinder Block e If it exceeds the limit replace crankshaft SEM346D CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation Revision 2007 November EM 129 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt e Install connecting rod bearings 1 to connecting rod 2 and con necting rod cap and tighten connecting rod bolts to the specified torque Refer to EM 115 Disassembly and Assembly
58. N Put a piece of wood or something similar as the supporting surface secure a completely stable condition PBICO804E Remove rear engine mounting member bolts Remove front suspension member mounting bolts and nuts Refer to FSU 37 Exploded View Carefully lower jack or raise lift to remove the engine transmission assembly transfer front final drive assembly and front suspension member When performing work observe the following caution CAUTION e Confirm there is no interference with the vehicle e Check that all connection points have been disconnected e Keep in mind the center of the vehicle gravity changes If necessary use jack s to support the vehicle at rear jacking point s to prevent it from falling it off the lift Separation Work 1 Gei 5 Install engine slingers into front of cylinder head bank 1 and rear of cylinder head bank 2 Engine front slinger Engine rear upper slinger Spacer Engine rear lower slinger Bank 1 Bank 2 lt 2 Engine front pm bk oO ao JPBIAO157ZZ Slinger bolts Di 28 0 N m 2 9 kg m 21 ft lb e To protect rocker cover against damage caused by tilting of engine slinger insert spacer between cylinder head and engine rear lower slinger 3 in direction shown in the figure 1 Engine rear upper slinger lt 2 Engine front NOTE Spacer 2 is a component part of engine rear upper slinger assembly JPBIAO158ZZ Remove power steer
59. PET P 0 8659 0 8661 0 8661 0 8663 Piston pin outer diameter 21 989 21 995 21 995 22 001 0 8657 0 8659 0 8659 0 8662 After installing in connecting rod CYLINDER BLOCK DISTORTION e Using a scraper remove gasket on the cylinder block surface and also remove engine oil scale carbon or other contamination CAUTION Be careful not to allow gasket flakes to enter engine oil or engine coolant passages e Measure the distortion on the cylinder block upper face at some different points in six directions C D E F G and H with a straightedge A and a feeler gauge B Limit Refer to EM 144 Cylinder Block e If it exceeds the limit replace cylinder block MAIN BEARING HOUSING INNER DIAMETER e Install lower cylinder block 2 without installing main bearings and tighten lower cylinder block bolts to the specified torque Refer to EM 115 Disassembly and Assembly for the tightening proce dure e Measure the inner diameter of main bearing housing with a bore gauge Standard Refer to EM 144 Cylinder Block If out of the standard replace cylinder block 1 and lower cylinder block as assembly NOTE JPBIA0225ZZ Cylinder block cannot be replaced as a single part because it is machined together with lower cylinder block PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore inner Diameter Revision 2007 November EM 127 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt e Usin
60. RATION lt PREPARATION gt Tool number Kent Moore No Description Tool name KV10112100 Tightening bolts for connecting rod bearing BT8653 A cap cylinder head etc in angle Angle wrench NT014 KV10114400 Loosening or tightening air fuel ratio sensor 1 J38365 e a 22 mm 0 87 in Heated oxygen sensor wrench Gii P A JPBIA0397ZZ KV10118600 Removing and installing crankshaft pulley J 48641 Ring gear stopper Ss S JPBIA0409ZZ Commercial Service Tools Ge Kent Moore No Description Tool name p 2 Pressing the tube of liquid gasket Tube presser NT052 oe Loosening bolts and nuts Power tool PBICO190E Removing and installing engine Manual lift table caddy Revision 2007 November GE 2008 EX35 lt PREPARATION gt Kent Moore No Tool name PREPARATION Description J24239 01 Cylinder head bolt wrench Gee JPBIAO398ZZ Loosening and tightening cylinder head bolt and used with the angle wrench SST KV10112100 BT8653 A a 13 mm 0 51 in dia b 12 mm 0 47 in c 10 mm 0 39 in ant 1 Compression gauge 2 Adapter d ZZA0008D Checking compression pressure Keen A Spark plug wrench JPBIAO399ZZ Removing and installing spark plug a 14 mm 0 55 in La Valve seat cutter set NT048 Finishing valve seat dimensions t Piston ring expander NT030 Removing and installing piston ri
61. SEMBLY gt e Insert oil jet dowel pin A into cylinder block dowel pin hole and tighten mounting bolts lt Engine front JPBIAO198ZZ Install main bearings and thrust bearings as follows CAUTION Be careful not to drop main bearing and to scratch the surface Remove dust dirt and engine oil on bearing mating surfaces of cylinder block and lower cylinder block Install thrust bearings 1 to the both sides of the No 3 journal housing on cylinder block A No 1 B No C No 3 D No 4 F Thrust bearing installation position lt q Engine front e Install thrust bearings with the oil groove E facing crankshaft arm outside Install main bearings paying attention to the direction A Cylinder block side D Lower cylinder block side lt Engine front e Main bearing with oil hole B and groove C goes on cylinder block The one without them goes on lower cylinder block e Before installing main bearings apply engine oil to the bearing surface inside Do not apply engine oil to the back surface but thoroughly clean it e When installing align main bearing stopper protrusion to cut out of cylinder block and lower cylinder block e Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned JPBIA0200ZZ Install crankshaft to cylinder block e While turning crankshaft by hand check that it turns smoothly Install lower cylinder block NOTE Lower cylind
62. SEMBLY AND ASSEMBLY gt e Tighten mounting bolts in numerical order as shown in the fig ure lt Engine front e There are three types of mounting bolts Refer to the following for locating bolts M8 x 25 mm 0 98 in 3 6 8 9 11 12 14 15 16 M8 x 50 mm 1 97in 2 M8 x 90 mm 3 54 in 1 4 5 7 10 13 JPBIA0022ZZ 3 Install oil strainer to oil pump Install oil pan lower Refer to EM 44 Exploded View AWD 5 Install oil pan drain plug e Refer to the figure of components of former page for installation direction of drain plug washer Refer to EM 44 Exploded View AWD 6 Install in the reverse order of removal after this step NOTE At least 30 minutes after oil pan is installed pour engine oil AW D S n S p ecti O n INFOID 0000000003139142 a INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSPECTION AFTER INSTALLATION Check the engine oil level and adjust engine oil Refer to LU 6 Inspection Start engine and check there is no leakage of engine oil Stop engine and wait for 10 minutes Check the engine oil level again Refer to LU 6 Inspection gt ONS Revision 2007 November EM 103 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt CYLINDER HEAD Exp loded View INFOID 0000000003 139143 SEC 111 130 220 DI 28 0 2 9 21 JPBIA1826GB 1 Valve lifter 2 Valve collet 3 Valve spring retainer 4 Valve spring 5 Valve oil seal 6 Valve
63. Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points e Run engine to check for unusual noise and vibration e Warm up engine thoroughly to check there is no leakage of fuel exhaust gases or any oil fluids including engine oil and engine coolant e Bleed air from lines and hoses of applicable lines such as in cooling system e After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2007 November EM 88 2008 EX35 ENGINE STAND SETTING lt DISASSEMBLY AND ASSEMBLY gt DISASSEMBLY AND ASSEMBLY ENGINE STAND SETTING Setti n g INFOID 0000000003139131 NOTE Explained here is how to disassemble with engine stand supporting transmission surface When using differ ent type of engine stand note with difference in steps and etc 1 Remove the engine assembly from the vehicle Refer to EM 79
64. ace and the mating sur face with white gasoline lighting and heating use to remove adhering moisture grease and foreign materials JPBIA0052ZZ 3 Attach liquid gasket tube to the tube presser commercial ser vice tool Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants 4 Apply liquid gasket without breaks to the specified location with the specified dimensions e If there is a groove for liquid gasket application apply liquid gasket to the groove e As for bolt holes B normally apply liquid gasket inside the holes Occasionally it should be applied outside the holes Check to read the text of this manual A Groove lt Inside e Within five minutes of liquid gasket application install the mat ing component e If liquid gasket protrudes wipe it off immediately e Do not retighten mounting bolts or nuts after the installation e After 30 minutes or more have passed from the installation fill engine oil and engine coolant CAUTION If there are specific instructions in this manual observe them JPBIA0010ZZ Revision 2007 November EM 7 2008 EX35 PRECAUTIONS lt PRECAUTION gt Definitions of Bank Names INFOID 0000000003130080 e In this manual each bank name is defined as follows A Bank 1 The conventional right bank B Bank 2 The conventional left bank lt 2 Engine front e For cylinder numbers and bank l
65. aligned tighten camshaft sprocket mounting bolts e Secure camshaft using a wrench at the hexagonal portion to tighten mounting bolts d Pull stopper pins 2 out from timing chain tensioners second ary 1 A Bank1 B Bank2 JPBIA0087ZZ Install timing chain primary as follows a Install crankshaft sprocket 1 A Matching mark Front side lt Engine front e Check the matching marks on crankshaft sprocket face the front of the engine JPBIA1108ZZ b Install timing chain primary Revision 2007 November EM 59 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt e Install timing chain primary so the matching mark punched B on camshaft sprocket INT 1 is aligned with the yellow link A on timing chain while the matching mark notched C on crankshaft sprocket 2 is aligned with the orange link D one on timing chain as shown in the figure 3 Water pump When it is difficult to align matching marks of timing chain pri mary with each sprocket gradually turn camshaft using wrench on the hexagonal portion to align it with the matching marks During alignment be careful to prevent dislocation of matching mark alignments of timing chains secondary JPBIA1601ZZ 5 Install internal chain guide 1 slack guide 2 JPBIAO086ZZ CAUTION Revision 2007 November EM 60 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt Never overtighten slack guide mounting bo
66. allation 4 Remove mass air flow sensor from air cleaner case as necessary CAUTION Handle mass air flow sensor with the following cares e Never shock mass air flow sensor e Never disassemble mass air flow sensor Revision 2007 November EM 27 2008 EX35 AIR CLEANER AND AIR DUCT lt ON VEHICLE REPAIR gt e Never touch mass air flow sensor INSTALLATION Note the following and install in the reverse order of removal Inspection INFOID 0000000003 139098 INSPECTION AFTER REMOVAL Inspect air duct and resonator assembly for crack or tear e If anything found replace air duct and resonator assembly Revision 2007 November EM 28 2008 EX35 INTAKE MANIFOLD COLLECTOR lt ON VEHICLE REPAIR gt INTAKE MANIFOLD COLLECTOR E X p od ed V i ew INFOID 0000000003139099 i 0 92 80 9 8 43 0 86 75 e Se lt L R AL SEC 140 163 223 19 6 2 0 14 SS D E 11 0 1 1 8 ey ee 9 0 E o _ e EVAP canister purge control solenoid 1 2 Clamp 3 EVAP hose valve 4 _EVAP hose 5 Clamp 6 Water hose 7 water hose 8 Electric throttle control actuator 9 Gasket bank1 10 Intake manifold collector 11 Gasket 12 Water hose Electric throttle control actuator 13 Water hose 14 bank2 15 EVAP hose 16 Water hose 17 EVAP tube assembly 18 EVAP hose A To vacuum pipe B To brake booster C To heater pipe D To water outlet rear Refer to Gl 4 Components for symbols in the figure Removal
67. and Installation INFOID 0000000003139100 REMOVAL WARNING Never drain engine coolant when the engine is hot to avoid the danger of being scalded 1 Remove engine cover with power tool Refer to EM 25 Exploded View 2 Remove air cleaner case and air duct RH and LH Refer to EM 27 Exploded View 3 Remove electric throttle control actuator as follows a Drain engine coolant or when water hoses are disconnected attach plug to prevent engine coolant leak age Revision 2007 November EM 29 2008 EX35 INTAKE MANIFOLD COLLECTOR lt ON VEHICLE REPAIR gt CAUTION e Perform this step when engine is cold e Never spill engine coolant on drive belt b Disconnect water hoses from electric throttle control actuator When engine coolant is not drained from radiator attach plug to water hoses to prevent engine coolant leakage c Disconnect harness connector d Loosen mounting bolts in reverse order as shown in the figure NOTE e When removing only intake manifold collector move electric throttle control actuator without disconnecting the water hose e The figure shows the electric throttle control actuator bank 1 viewed from the air duct side e Viewed from the air duct side order of loosening mounting bolts of electric throttle control actuator bank 2 is the same as that of the electric throttle control actuator bank 1 CAUTION Handle carefully to avoid any shock to electric throttle con trol actuator
68. anually turn crankshaft pulley a few turns Check that the valve clearances for cold engine are within the specifications by referring to the specified values Refer to EM 18 Inspection and Adjustment Install all removal parts in the reverse order of removal 11 Warm up the engine and check for unusual noise and vibration EM 22 2008 EX35 COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt COMPRESSION PRESSURE n S pect i O n INFOID 0000000003139093 Te 2 3 AUO OL Warm up engine thoroughly Then stop it Release fuel pressure Refer to EC 538 Inspection Disconnect fuel pump fuse 1 from IPDM E R 2 to avoid fuel x injection during measurement fa ere HOT ee varie Lk Ay Oe JMBIA0021ZZ Remove engine cover with power tool Refer to EM 25 Exploded View Remove ignition coil and spark plug from each cylinder Refer to EM 16 Exploded View Connect engine tachometer not required in use of CONSULT III Install compression gauge with an adapter commercial service tool onto spark plug hole PBICO900E e Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm 0 79 in in diameter Otherwise it may be caught by cylinder head during removal a 20mm 0 79 in JPBIAO171ZZ With accelerator pedal fully depressed turn ignition switch to START for cranking When the gauge pointer stabilizes read the compression pressure and the en
69. are not covered by the engine section refer to the applicable sections e Always use the support point specified for lifting e Use either 2 pole lift type or separate type lift as best you can If board on type is used for unavoid able reasons support at rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity Revision 2007 November EM 79 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt e For supporting points for lifting and jacking point at rear axle refer to GI 29 Garage Jack and Safety Stand and 2 Pole Lift REMOVAL Outline At first remove the engine and the transmission assembly with front suspension member downward Then separate the engine from transmission Preparation 1 Release fuel pressure Refer to EC 538 Inspection 2 Disconnect both battery cables Refer to PG 103 Exploded View 3 Drain engine coolant from radiator Refer to CO 7 Draining CAUTION e Perform this step when engine is cold e Never spill engine coolant on drive belt 4 Remove the following parts e Radiator reservoir tank Refer to CO 13 Exploded View e Engine cover Refer to EM 25 Exploded View e Front road wheel and tires power tool e Engine undercover power tool e Cowl top cover Refer to EXT 22 Exploded View e Air duct and air cleaner case assembly RH and LH Refer to EM 27 Exploded View e Cooling fan assembly
70. ark Refer to Gl 4 Components for symbols in the figure AWD Removal and Installation Geen WARNING e Situate the vehicle on a flat and solid surface e Place chocks at front and back of rear wheels e For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG CAUTION Always be careful to work safely avoid forceful or uninstructed operations e Never start working until exhaust system and engine coolant are cool enough e If items or work required are not covered by the engine section refer to the applicable sections e Always use the support point specified for lifting e Use either 2 pole lift type or separate type lift as best you can If board on type is used for unavoid able reasons support at rear axle jacking point with transmission jack or similar tool before starting work in preparation for the backward shift of center of gravity e For supporting points for lifting and jacking point at rear axle refer to GI 29 Garage Jack and Safety Stand and 2 Pole Lift REMOVAL Outline At first remove the engine the transmission assembly the transfer assembly and the front final drive assem bly with front suspension member downward Then separate the engine the transmission assembly the trans fer and the front final drive assembly Preparation 1 Release fuel pressure Refer to EC 538 Inspection 2 Disconnect both battery terminals Refer to PG 103 Exploded
71. arness clip 9 Using the heated oxygen sensor wrench SST KV10114400 J38365 C remove air fuel ratio sensor 1 bank 1 and bank 2 A Bank2 B Bank 1 CAUTION e Be careful not to damage air fuel ratio sensor 1 e Discard any air fuel ratio sensor 1 which has been dropped onto a hard surface such as a concrete floor Replace with a new sensor 10 Remove exhaust manifold cover upper bank 1 and bank 2 11 Loosen mounting nuts in the reverse order as shown in the fig ure to remove exhaust manifold A Bank 1 B Bank2 lt Engine front NOTE Disregard the numerical order No 7 and 8 in removal JPBIA0017ZZ 12 Remove gaskets CAUTION Cover engine openings to avoid entry of foreign materials INSTALLATION Note the following and install in the reverse order of removal EXHAUST MANIFOLD GASKET e Install exhaust manifold gasket in direction shown in the figure Follow same procedure for both banks Bank 1 Triangle press Bank 2 Engine front AOD EXHAUST MANIFOLD Revision 2007 November EM 35 2008 EX35 EXHAUST MANIFOLD lt ON VEHICLE REPAIR gt e If stud bolts were removed install them and tighten to the specified torque below Tightening torque Refer to EM 34 Exploded View e Install exhaust manifold and tighten mounting nuts in numerical order as shown in the figure A Bank 1 B Bank 2 lt Engine front NOTE Tighten nuts No 1 and 2 in two ste
72. arts of drive belt engine mounting insulator etc Wipe engine oil off immediately if it is splashed 5 Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head e Remove oil filter and then clean it Refer to EM 50 Exploded View e Clean oil groove between oil strainer and intake valve timing control solenoid valve Refer to LU 2 Engine Lubrication System 6 Remove components between intake valve timing control solenoid valve and camshaft sprocket INT and then check each oil groove for clogging e Clean oil groove if necessary Refer to LU 2 Engine Lubrication System 7 After inspection install removed parts in the reverse order JPBIA0410ZZ Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration NOTE If hydraulic pressure inside timing chain tensioner drops after r
73. ation 3 Read the symbol at the cross point of selected row and column in the CONNECTING ROD BEARING SELECTION TABLE 4 Apply the symbol obtained to the CONNECTING ROD BEARING GRADE TABLE to select connecting EM rod bearing WHEN CONNECTING ROD AND CRANKSHAFT ARE REUSED 1 Measure the connecting rod big end diameter Refer to EM 144 Cylinder Block 2 Check that the connecting rod big end diameter is within the standard value 3 Measure the crankshaft pin journal diameter Refer to EM 144 Cylinder Block 4 Determine the grade of crankshaft pin diameter grade by corresponding to the measured dimension in Crankshaft pin journal diameter column of CONNECTING ROD BEARING SELECTION TABLE 5 Select connecting rod bearing of the same grade CONNECTING ROD BEARING SELECTION TABLE B C H J K L M N Connecting rod big end eise SE E EE EE Unit mm in 5 Ie sl oe be el se be se be be ae ell EK sil feel WH becca H saa lent aca lea D NPENIENININITNINT NIT NTN ITN ITN YN Crankshaft v lelalalalolo el tll oleole pin journal E EE EE a aa ES diameter ailailalailalalalalalalala ai Unit mm in claloa l wloln jolalol ualo x oO1 o o o o o l o o O ri ri rir Qe re el e e2 e e e e2 e e e ee ee eS 1O O O O e Bee e e ee ef el O TINIOITILHOLSO RI DID oO rIn S OoTo el alol OGIO lolo e r 1 Mark Axle diameter ojojojajalaojajaojaja
74. ayout refer to the illustration Bank1 The bank side including cylinder No 1 odd numbered cylinder side Bank 2 The other bank side of the above JPBIA 13522 even numbered cylinder side Revision 2007 November EM 8 2008 EX35 lt PREPARATION gt PREPARATION PREPARATION Special Service Tools PREPARATION INFOID 0000000003139081 The actual shapes of Kent Moore tools may differ from those of special service tools illustrated here Tool number Kent Moore No Description Tool name KV10116200 Disassembling valve mechanism J26336 A Part 1 is a component of KV10116200 Valve spring compressor 1 KV10115900 J26336 20 Attachment 2 KV10109220 Adapter PBIC1650E J26336 A but Part 2 is not so KV10107902 J38959 Valve oil seal puller NTO11 Replacing valve oil seal KV10115600 J 38958 Valve oil seal drift JPBIAO396ZZ Installing valve oil seal Use side A G a 20 0 79 dia d 8 0 31 dia b 13 0 51 dia e 10 7 0 421 c 10 3 0 406 dia f 5 0 20 H side B Unit mm in EM03470000 J8037 Piston ring compressor Installing piston assembly into cylinder bore ST16610001 J23907 Pilot bushing puller NT045 Removing pilot converter KV10111100 J37228 Seal cutter Revision 2007 November NT046 EM 9 Removing oil pan lower and upper front and rear timing chain case etc 2008 EX35 PREPA
75. bracket Refer to CHG 25 2WD Exploded View 2WD models or CHG 27 AWD Exploded View AWD models 22 Remove water outlet front and water piping Refer to CO 23 Exploded View 23 Remove valve timing control covers bank 1 and bank 2 and gasket as follows Revision 2007 November EM 51 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt a Disconnect valve timing control harness connector b Loosen mounting bolts in reverse order as shown in the figure A Bank 1 B Bank C Dowel pin hole CAUTION Shaft is internally jointed with camshaft sprocket INT cen ter hole When removing keep it horizontal until it is com pletely disconnected JPBIA0041ZZ c Shaft is engaged with intake side camshaft sprocket center hole on inside pull straight out so as not to tilt until the joint is disengaged e The mating surface of magnet retarder 2 may be fitted with the exhaust side camshaft sprocket via the engine oil Open valve timing control cover 1 carefully e If the mating surface of magnet retarder is fitted with the cam shaft sprocket open the cover within the range that the load is not applied to the harness And then remove it so as to pre vent magnet retarder from dropping CAUTION e Be careful not to damage magnet retarder e When carrying valve timing control cover face the mag net retarder side up to prevent the cover from falling from magnet retarder e Never remove magnet retarder fr
76. cceeeee 89 Connecting Rod Bearing cccccseceeeeeeeeseeees 149 Setting BE 89 EM 2 Revision 2007 November 2008 EX35 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt SYMPTOM DIAGNOSIS NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING NVH Troubleshooting Engine Noise E Camshaft bearing noise Tappet noise Timing chain and chain tensioner nois Drive belt noise Stick Slipping Drive belt noise Stick Slipping Main bearing noise JPBIA0001GB Use the Chart Below to Help You Find the Cause of the SyMptoM imromoooo000008130089 1 Locate the area where noise occurs Revision 2007 November EM 3 2008 EX35 NOISE VIBRATION AND HARSHNESS NVH TROUBLESHOOTING lt SYMPTOM DIAGNOSIS gt 2 Confirm the type of noise 3 Specify the operating condition of the engine 4 Check specified noise source If necessary repair or replace these parts Operating condition of engine Location Type of Before After When f Source of Refer of noise noise warm warm ll start When When While noise Peer tem ence page g idling racing driving up up ing Top an Ticking or C A A B Tappet Valve clearance EM 18 gine clicking noise Rocker cover Camshaft Camshaft runout EM 140 Cylinder Rattle C A A B C bearing Camshaft journal oil EM 140 head noise
77. cer Engine rear lower slinger Bank 1 Bank 2 lt 2 Engine front wrron A JPBIAO157ZZ Slinger bolts DI 28 0 N m 2 9 kg m 21 ft lb Revision 2007 November EM 81 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt e To protect rocker cover against damage caused by tilting of engine slinger insert spacer between cylinder head and engine rear lower slinger 3 in direction shown in the figure 1 Engine rear upper slinger lt I Engine front NOTE Spacer 2 is a component part of engine rear upper slinger assembly JPBIAO158ZZ 2 Remove power steering oil pump from engine side Refer to ST 45 Exploded View Remove engine mounting insulators RH and LH under side nuts with power tool 4 Lift with hoist and separate the engine and the transmission assembly from front suspension member CAUTION e Before and during this lifting always check that any harnesses are left connected e Never damage to and oil grease smearing or spills onto engine mounting insulator Remove alternator Refer to CHG 25 2WD Exploded View Remove starter motor Refer to STR 15 Exploded View Separate the engine from the transmission assembly Refer to TM 192 2WD Exploded View Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool INSTALLATION Note the following and install in the reverse order of removal e Do not allow engine mounting insulato
78. clearance Piston to piston pin oil EM 144 Slap or A _ B B _ Piston pin clearance knock noise Connecting rod bushing EM 144 oil clearance Piston to cylinder bore EM 144 Crank clearance shaft pul Piston ring side clear EM 144 ley i a R E E S S S GE ae Cylinder H H Piston ring end gap EM 144 block Connecting rod bend EM 144 Side of and torsion pa oe Connect Connecting rod bushing EM 144 pan ing rod oil clearance Knock A S S B S B bearing Connecting rod bearing EM 149 noise oil clearance Mainibear Main bearing oil clear EM 148 Knock A B A B C EEN ance 9 Crankshaft runout EM 144 Timing Front of chain and Timing chain cracks EM 65 engine Tapping or A A _ B B B timing and wear Timing ticking chain ten Timing chain tensioner EM 51 chain case sioner operation noise Squeak cin ing or fizz A B B C or slip Drive belt deflection in e b 9 ping EM 13 Front of i Drive belt Idler pulley bearing op engine Creaking A B A B A B Slipping eration Squall Water CO 18 Sek A B B A B pump Water pump operation Exploded noise View A Closely related B Related C Sometimes related Not related EM 4 Revision 2007 November 2008 EX35 PRECAUTIONS lt PRECAUTION gt PRECAUTION PRECAUTIONS Precaution for Procedure without Cowl Top Cover INFOID 0000000003554244 When performing the procedure after removing cowl top cover cover the lower end of windshield with urethane etc PIIB3706
79. djustment if the measured value is out of the standard Refer to ADJUSTMENT ADJUSTMENT e Perform adjustment depending on selected head thickness of valve lifter 1 Measure the valve clearance Refer to INSPECTION Remove camshaft Refer to EM 67 Removal and Installation Remove valve lifters at the locations that are out of the standard Measure the center thickness of the removed valve lifters with a micrometer A AN JPBIA0169ZZ 5 Use the equation below to calculate valve lifter thickness for replacement Valve lifter thickness calculation t t1 C1 C2 t Valve lifter thickness to be replaced t1 Removed valve lifter thickness C1 Measured valve clearance C2 Standard valve clearance Intake 0 30 mm 0 012 in Exhaust 0 33 mm 0 013 in Revision 2007 November EM 21 2008 EX35 CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt oOo ON Revision 2007 November e Thickness of new valve lifter can be identified by stamp marks on the reverse side inside the cylinder Stamp mark 788 indicates 7 88 mm 0 3102 in in thickness A Stamp B _ Thickness of valve lifter JPBIAO170ZZ Available thickness of valve lifter 27 sizes with range 7 88 to 8 40 mm 0 3102 to 0 3307 in in steps of 0 02 mm 0 0008 in when manufactured at factory Refer to EM 140 Camshaft Install selected valve lifter Install camshaft Refer to EM 67 Removal and Installation M
80. e Perform this inspection only when DTC P0011 is detected in self diagnostic results of CONSULT III and it is directed according to inspection procedure of EC section Refer to EC 100 Diagnosis Description e Check when engine is cold so as to prevent burns from the splashing engine oil 1 Check engine oil level Refer to LU 6 Inspection 2 Perform the following procedure so as to prevent the engine from being unintentionally started while checking a Release the fuel pressure Refer to EC 538 Inspection Revision 2007 November EM 74 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt b Disconnect ignition coil and injector harness connectors Refer to EM 47 Exploded View and EM 37 Exploded View 3 Remove intake valve timing control solenoid valve Refer to EM 50 Exploded View 4 Crank engine and then check that engine oil comes out from intake valve timing control solenoid valve hole A End crank after checking 1 Valve timing control cover bank 1 lt 2 Engine front WARNING Be careful not to touch rotating parts drive belt idler pul ley and crankshaft pulley etc CAUTION e Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination e Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle Especially be careful no to apply engine oil to rubber p
81. e Using a suitable drift A press fit until the height of rear oil seal is level with the mounting surface Suitable drift outer diameter 100 mm 3 94 in inner diameter 85 mm 3 35 in CAUTION e Be careful not to damage crankshaft and cylinder block e Press fit straight and avoid causing burrs or tilting oil seal JPBIA0153ZZ 2 Install in the reverse order of removal after this step Revision 2007 November EM 78 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt REMOVAL AND INSTALLATION ENGINE ASSEMBLY mp 2WD S Exploded View INFOID 0000000003139125 SEC 112 0 92 5 9 4 68 0 49 0 5 0 36 0 92 5 9 4 68 0 49 0 5 0 36 1 Engine mounting bracket RH 2 Engine mounting insulator RH 3 Engine mounting bracket LH 4 Engine mounting insulator LH 5 Rear engine mounting member 6 Engine mounting insulator rear 7 Dynamic damper A Front mark Refer to Gl 4 Components for symbols in the figure 2WD Removal and Installation ie Guennadoncontaetee WARNING e Situate the vehicle on a flat and solid surface e Place chocks at front and back of rear wheels e For engines not equipped with engine slingers attach proper slingers and bolts described in PARTS CATALOG CAUTION e Always be careful to work safely avoid forceful or uninstructed operations e Never start working until exhaust system and engine coolant are cool enough e If items or work required
82. e axle direction by pushing the circum ferential looseness between dowel pins and dowel pin holes by twisting in the circumferential direction A __ Mating surface of magnet retarder B Moves slightly CG Not shaken CAUTION Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose Install valve timing control cover with new gasket to front timing chain case 1 Valve timing control cover 2 Magnet retarder CAUTION e Never face the magnet retarder side down to prevent mag net retarder from dropping Check the mating surface of magnet retarder and the drum of exhaust side camshaft sprocket for foreign mate rials Align the center of both shaft holes of the shaft and the intake side camshaft sprocket and then insert them Be careful not to drop the seal ring from the shaft groove When setting the valve timing control cover in position by hand if valve timing control cover is not contacting with the front timing chain case the dowel pin of magnet retarder may not be aligned with the dowel pin holes of cover In this case return to step b Being careful not to move seal ring from the installation groove align dowel pins on front timing chain case with holes to install valve timing control covers Tighten mounting bolts in numerical order as shown in the fig ure A Bank1 B Bank2 C Dowel pin hole Tightening torque Refer to
83. e by pulling straight CAUTION e Be careful with remaining fuel that may go out from fuel tube e Be careful not to damage injector nozzles during removal e Never bump or drop fuel injector e Never disassemble fuel injector JPBIA0036ZZ Install fuel damper 4 as follows Install new O ring 2 to fuel tube 1 as shown When handling new O ring be careful of the following caution CAUTION e Handle O ring with bare hands Never wear gloves e Lubricate O ring with new engine oil e Never clean O ring with solvent e Check that O ring and its mating part are free of foreign material e When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube e Insert new O ring straight into fuel tube Never twist it Install spacer 3 to fuel damper Insert fuel damper straight into fuel tube CAUTION e Insert straight checking sure that the axis is lined up e Never pressure fit with excessive force Reference value 130 N 13 3 kg 29 2 Ib e Insert fuel damper until B is touching A of fuel tube JPBIAO3162Z Tighten bolts evenly in turn e After tightening bolts check that there is no gap between fuel damper cap 5 and fuel tube Install fuel sub tube e When handling new O rings be careful of the following caution CAUTION e Handle O ring with bare
84. e figure Disassembly and Assembly inFo10 0900000008199148 ew EM DISASSEMBLY 1 Remove the following parts e Oil pans lower and upper Refer to EM 97 2WD Exploded View 2WD models or EM 100 AWD Exploded View AWD models e Front and rear timing chain case Refer to EM 50 Exploded View and EM 92 Exploded View e Cylinder head Refer to EM 104 Exploded View 2 Remove knock sensor CAUTION Carefully handle sensor avoiding shocks 3 Remove baffle plate from lower cylinder block 4 Remove piston and connecting rod assembly with the following procedure e Before removing piston and connecting rod assembly check the connecting rod side clearance Refer to EM 144 Cylinder Block CAUTION Be careful not to drop connecting rod bearing and to scratch the surface a Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center Remove connecting rod bearing cap Using a hammer handle or similar tool push piston and connect ing rod assembly out to the cylinder head side CAUTION Be careful not to damage the cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end PBIC2940E 5 Remove connecting rod bearings from connecting rod and connecting rod bearing cap CAUTION e Be careful not to drop connecting rod bearing and to scratch the surface e Identify installation positions and store them without mixing them up 6 Remove pis
85. e following and install in the reverse order of removal INTAKE MANIFOLD e If stud bolts were removed install them and tighten to the specified torque below 10 8 N m 1 1 kg m 8 ft lb Revision 2007 November EM 32 2008 EX35 INTAKE MANIFOLD lt ON VEHICLE REPAIR gt e Tighten all mounting bolts and nuts to the specified torque in two or more steps in numerical order as shown in the figure lt Engine front CAUTION Install intake manifold with the marks put on the intake mani fold and the cylinder head before removal aligned 1st step Ei 7 4 N m 0 75 kg m 5 ft lb 2nd step and after En 25 5 N m 2 6 kg m 19 ft Ib JPBIA0013ZZ n S pect i O n INFOID 0000000003139103 INSPECTION AFTER REMOVAL Surface Distortion e Check the surface distortion of the intake manifold mating surface with a straightedge A and a feeler gauge B Limit Refer to EM 140 Intake Manifold e If it exceeds the limit replace intake manifold JPBIA0015ZZ Revision 2007 November EM 33 2008 EX35 EXHAUST MANIFOLD lt ON VEHICLE REPAIR gt EXHAUST MANIFOLD Exp loded View INFOID 0000000003 139104 SEC 140 208 0 50 0 5 1 37 5 8 OP 45 0 4 6 33 9 j D 25 5 2 6 19 GO G Marus 11 51 3 eg 5 8 0 59 Ss 5 A d A V 2 25 5 2 6 19 we oe e Ze o Kaf 45 0 4 6 33 w 3 fl 5 8 0 59 BE JPBIA1909GB 1 Heated oxygen sensor 2
86. e order of loosening bolts is the same for bank 1 and bank 2 JPBIA1960ZZ Remove camshaft brackets e Mark camshafts camshaft brackets and bolts so they are placed in the same position and direction for installation e Equally loosen camshaft bracket bolts in several steps in reverse order as shown in the figure lt Engine front JPBIA0257ZZ Remove camshaft Remove valve lifter e Identify installation positions and store them without mixing them up Remove timing chain tensioners secondary 1 from cylinder head A Bank 1 B Bank2 e Remove timing chain tensioners secondary with its stopper pin C attached NOTE Stopper pin should be attached when timing chain secondary is removed JPBIAO121ZZ INSTALLATION Install timing chain tensioners Secondary on both sides of cylinder head Revision 2007 November EM 68 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt e Install timing chain tensioners 1 with its stopper pin C attached Bank 1 side A Bank 2 side B Sliding part facing downward Sliding part facing upward 2 Install valve lifter e Install it in the original position 3 Install camshafts e Follow your identification marks made during removal or fol low the identification marks that are present on new camshafts for proper placement and direction lt Engine front i Paint marks aa Bank INT EXH Dowel pin Identification 1 M1 E M2
87. e tool A apply reamer finish to valve guide Standard Refer to EM 142 Intake and exhaust Cylinder Head 2 If valve seat is removed in step 9 DISASSEMBLY install it Replace with oversize 0 5 mm 0 020 in valve seat a Ream cylinder head recess diameter a for service valve seat Oversize Refer to EM 142 Intake and exhaust Cylinder Head e Be sure to ream in circles concentric to valve guide center This will enable valve to fit correctly JPBIAO188ZZ Revision 2007 November EM 107 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt b Heat cylinder head to 110 to 130 C 230 to 266 F by soaking in heated oil A JPBIAO184ZZ c Provide valve seats cooled well with dry ice Force fit valve seat into cylinder head WARNING Cylinder head contains heat When working wear protective equipment to avoid getting burned CAUTION Never directly touching cold valve seats d Using the valve seat cutter set commercial service tool or valve seat grinder finish seat to the specified dimensions Refer to EM 142 Cylinder Head CAUTION When using the valve seat cutter firmly grip cutter handle with both hands Then press on the contacting surface all around the circumference to cut in a single drive Improper pressure on with cutter or cutting many different times may result in stage valve seat j S l Ta SEM934C Using compound grind to adjust valve fitting
88. e wrench SST KV10112100 BT8653 A for the final tightening of the following engine parts Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts e Do not use a torque value for final tightening e The torque value for these parts are for a preliminary step e Ensure thread and seat surfaces are clean and coated with engine oil Revision 2007 November EM 6 2008 EX35 PRECAUTIONS lt PRECAUTION gt Liq u id G asket INFOID 0000000003139079 REMOVAL OF LIQUID GASKET SEALING e After removing mounting bolts and nuts separate the mating sur face using the seal cutter SST KV10111100 J37228 A and remove old liquid gasket sealing CAUTION Be careful not to damage the mating surfaces Tap the seal cutter SST KV10111100 J37228 to insert it B and then slide it C by tapping on the side as shown in the figure In areas where the seal cutter SST KV10111100 J37228 is diffi cult to use use a plastic hammer to lightly tap the parts to remove it CAUTION If for some unavoidable reason tool such as a screwdriver is used be careful not to damage the mating surfaces LIQUID GASKET APPLICATION PROCEDURE 1 Using a scraper A remove old liquid gasket adhering to the liq uid gasket application surface and the mating surface e Remove liquid gasket completely from the groove of the liquid gasket application surface mounting bolts and bolt holes 2 Wipe the liquid gasket application surf
89. each ring with the gap as shown in the figure referring to the piston front mark D Top ring gap Oil ring upper or lower rail gap either of them Second ring and oil ring spacer gap 90 degrees 45 degrees Gm mm CO JPBIA0205ZZ e Check the piston ring side clearance Refer to EM 144 Cylinder Block 11 Install connecting rod bearings to connecting rod and connecting rod bearing cap Revision 2007 November EM 120 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt CAUTION Be careful not to drop connecting rod bearing and to scratch the surface e Before installing connecting rod bearings apply engine oil to the bearing surface inside Do not apply engine oil to the back surface but thoroughly clean it e When installing align connecting rod bearing stopper protru sion B with cutout C of connecting rods and connecting rod bearing caps to install e Ensure the oil hole A on connecting rod and that on the cor responding bearing are aligned JPBIA0206ZZ 12 Install piston and connecting rod assembly to crankshaft e Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center e Apply engine oil sufficiently to the cylinder bore piston and crankshaft pin journal e Match the cylinder position with the cylinder number on connecting rod to install e Be sure that front mark on piston crown is facing front of engine e Using a piston ring compres
90. ead Valve Guide Inner Diameter f e Measure the inner diameter of valve guide with bore gauge Standard Refer to EM 142 Intake and exhaust Cylinder Head JPBIAO183ZZ Valve Guide Clearance f f e Valve guide clearance Valve guide inner diameter Valve stem diameter Valve guide clearance JA Refer to EM 142 Cylinder Head Standard and limit Intake and exhaust e If the calculated value exceeds the limit replace valve and or valve guide When valve guide must be replaced refer to EM 104 Disassembly and Assembly Valve Seat Contact e After confirming that the dimensions of valve guides and valves are within the specifications perform this procedure e Apply prussian blue or white lead onto contacting surface of valve seat to check the condition of the valve contact on the surface e Check if the contact area band is continuous all around the circumference e If not grind to adjust valve fitting and check again If the contacting surface still has NG B conditions even after the recheck replace valve seat Refer to EM 104 Disassembly and Assem bly A OR JPBIAO187ZZ Valve Spring Squareness e Set a try square A along the side of valve spring and rotate spring Measure the maximum clearance between the top of spring and try square B Contact Limit Reiter to EM 142 Cylinder Head e If it exceeds the limit replace valve spring JPBIAO189ZZ Valve S
91. emoval installation slack in the guide may generate a pounding noise during and just after engine start However this is normal Noise will stop after hydraulic pressure rises Warm up engine thoroughly to check there is no leakage of fuel or any oil fluids including engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine oil and engine coolant Refill to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2007 November EM 75 2008 EX35 OIL SEAL lt ON VEHICLE REPAIR gt OIL SEAL VALVE OIL SEAL VALVE OIL SEAL Removal and Installation INFOID 0000000003139122 REMOVAL 1 Remove camshaft relating to valve oil seal to be removed Refer to EM 104 Exploded View 2 Remove valve lifters Refer to EM 67 Exploded View 3 Turn crankshaft until the cylinder requiring new oil seals is at TDC This will prevent valve from dropping into cylinder 4 Remove valve collet e Compress valve spring with the valve spring compressor SST KV10116200 J26336 A A the attachment SST
92. en turn timing chain tensioner primary 1 on the upper mounting bolt so that plunger C is fully expanded NOTE Even if plunger is fully expanded it is not dropped from the body of timing chain tensioner primary c Remove upper mounting bolt and then remove timing chain ten sioner primary JPBIA1537ZZ 33 Remove internal chain guide 1 and slack guide 2 JPBIAO086ZZ 34 Remove timing chain primary and crankshaft sprocket CAUTION After removing timing chain tensioner primary never turn crankshaft and camshaft separately or valves will strike the piston heads 35 Remove timing chain secondary and camshaft sprockets as follows a Attach suitable stopper pin 2 to the timing chain tensioners secondary 1 A Bank B Bank2 NOTE e Use approximately 0 5 mm 0 02 in dia hard metal pin as a stopper pin e For removal of timing chain tensioners Secondary refer to EM 67 Exploded View Removing camshaft bracket No 1 is required JPBIAQ087ZZ b Remove camshaft sprocket mounting bolts INT and EXH Revision 2007 November EM 55 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt e Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts c Remove timing chain secondary together with camshaft sprockets CAUTION e Never loosen the mounting bolts with securing anything other than the camshaft hexagonal portion or with ten sioning the timing chai
93. ened by plastic zone tightening method Whenever the size difference between C and B exceeds the limit replace them with new one Limit C B 0 18 mm 0 0071 in A Measuring point e 48 mm 1 89 in d 11 mm 0 43 in e If reduction of outer diameter appears in a position other than B use it as B point JPBIA0173ZZ Cylinder Head Distortion NOTE When performing this inspection cylinder block distortion should be also checking Refer to EM 144 Cylinder Block 1 Using a scraper wipe off oil scale gasket sealant and carbon deposits from surface of cylinder head CAUTION Never allow gasket fragments to enter engine oil or engine coolant passages 2 At each of several locations on bottom surface of cylinder head measure the distortion in six directions A B C D E and F Limit Refer to EM 142 Cylinder Head e If it exceeds the limit replace cylinder head JPBIAO176ZZ INSPECTION AFTER DISASSEMBLY Valve Dimensions Revision 2007 November EM 111 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt e Check the dimensions of each valve For the dimensions refer to EM 142 Cylinder Head e If dimensions are out of the standard replace valve and check valve seat contact Refer to VALVE SEAT CONTACT Valve Guide Clearance Valve Stem Diameter e Measure the diameter of valve stem with micrometer A Standard Refer to EM 142 Intake and exhaust Cylinder H
94. ep auto tensioner pulley arm locked after drive belt is removed 2 Remove auto tensioner and idler pulley Refer to EM 13 Exploded View e Keep auto tensioner pulley arm locked to install or remove auto tensioner Installation Installation is the reverse order of removal CAUTION If there is damage greater than peeled paint replace drive belt auto tensioner Revision 2007 November EM 26 2008 EX35 AIR CLEANER AND AIR DUCT lt ON VEHICLE REPAIR gt AIR CLEANER AND AIR DUCT E X p od ed V i ew INFOID 0000000003139096 SEC 118 148 165 fe 1 47 0 15 13 Reise P 5 5 0 56 fw 5 5 0 56 49 Y D d fy 5 5 0 56 L SCH L O 5 5 0 56 49 JPBIA1824GB 1 Mass air flow sensor bank 1 2 Air cleaner filter 3 Holder Bracket 5 Resonator RH 6 Bracket Grommet 8 Grommet 9 Air cleaner case RH 10 Clamp 11 Air duct RH 12 PCV hose 13 Air duct LH 14 Mass air flow sensor bank 2 15 Air cleaner case LH 16 Bracket 17 Resonator LH 18 Bracket 19 Clamp 20 PCV hose A eer throttle Control actuator B ee throttle control actuator C To rocker cover bank 2 Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003139097 REMOVAL 1 Disconnect mass air flow sensor harness connector 2 Disconnect PCV hose 3 Remove air cleaner case with mass air flow sensor and air duct disconnecting each joints e Add marks as necessary for easier inst
95. er Refer to EM 43 Exploded View 2WD 4 Install oil pan drain plug e Refer to the figure of components of former page for installation direction of drain plug washer Refer to EM 43 Exploded View 2WD 5 Install in the reverse order of removal after this step NOTE At least 30 minutes after oil pan is installed pour engine oil 2W D n S pe cti O n INFOID 0000000003139139 Si INSPECTION AFTER REMOVAL Clean oil strainer if any object attached INSPECTION AFTER INSTALLATION 1 Check the engine oil level and adjust engine oil Refer to LU 6 Inspection 2 Start engine and check there is no leakage of engine oil 3 Stop engine and wait for 10 minutes 4 Check the engine oil level again Refer to LU 6 Inspection AWD Revision 2007 November EM 99 2008 EX35 OIL PAN UPPER AND OIL STRAINER lt DISASSEMBLY AND ASSEMBLY gt AWD r Exploded View INFOID 0000000003139140 SEC 110 150 213 253 e 0 17 2 1 8 13 e on Dos op Op JPBIA1825GB 1 Oil level gauge 2 Oil level gauge guide 3 O ring 4 O ring 5 Gasket 6 Oil strainer Drain plug 8 Drain plug washer 9 Oil pan lower 10 O ring small 11 Axle pipe 12 O ring large 13 Rear plate cover 14 Oil pan upper A Refer to LU 11 B To oil pump C Oil pan side Refer to Gl 4 Components for symbols in the figure AWD Disassembly and Assembly InFo10 0000000008159141 REMOVAL CAUTION Never drain engine oil when the engine is hot
96. er hexagonal wrench C shown as example in the figure through the holding boss B to lock auto tensioner pulley arm 4 Remove drive belt INSTALLATION Note the following and install in the reverse order of removal CAUTION e Check drive belt is securely installed around all pulleys e Check drive belt is correctly engaged with the pulley groove e Check for engine oil and engine coolant are not adhered drive belt and pulley groove n S pect i O n INFOID 0000000003139087 JPBIA0003ZZ INSPECTION AFTER INSTALLATION e Turn crankshaft pulley clockwise several times to equalize tension between each pulley and then confirm tension of drive belt at indicator notch on fixed side is within the possible use range Refer to EM 13 Exploded View Revision 2007 November EM 14 2008 EX35 AIR CLEANER FILTER lt ON VEHICLE MAINTENANCE gt AIR CLEANER FILTER Removal and Installation INFOID 0000000003 139088 REMOVAL 1 Unhook clips A 1 Holder 2 Air cleaner case 2 Remove holder 3 from air cleaner case 2 and then remove air cleaner filter 1 from holder AS ST JPBIA1598ZZ INSTALLATION Note the following and install in the reverse order of removal e Install the air cleaner filter by aligning the seal with the notch of air cleaner case Revision 2007 November EM 15 2008 EX35 SPARK PLUG lt ON VEHICLE MAINTENANCE gt SPARK PLUG Exploded View SEC 1119118 Je ei erie
97. er block cannot be replaced as a single part because it is machined together with cylinder block Revision 2007 November EM 118 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt e Apply a continuous bead of liquid gasket with the tube presser commercial service tool to lower cylinder block as shown in the figure B _ Apply to end a 04 0 5 0 mm 0 157 0 197 in Use Genuine RTV Silicone Sealant or equivalent Refer to Gl 15 Recommended Chemical Products and Sealants JPBIA1354ZZ Inspect the outer diameter of lower cylinder block bolt Refer to EM 123 Inspection Install lower cylinder block bolts in numerical order as shown in the figure as follows Apply new engine oil to threads and seat surfaces of lower cylinder block bolts Tighten lower cylinder block bolts No 17 to 26 in numerical order as shown in the figure oP ON lt Engine front Dr 25 0 N m 2 6 kg m 18 ft Ib c Repeat step b d Tighten lower cylinder block bolt No 1 to 16 in numerical order as shown in the figure lt Engine front O 35 3 N m 3 6 kg m 26 ft Ib g TA o i ap eng 2 W S 17 OG e Turn lower cylinder block bolt No 1 to 16 90 degrees clockwise angle tightening CAUTION Use the angle wrench SST KV10112100 BT8653 A A to check tightening angle Never make judgment by visual inspection e After installing lower cylinder block bolts check that crankshaft can be rotated s
98. evel Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2007 November EM 66 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt CAMSHAFT Exp loded View INFOID 0000000003139119 SEC 1119130 W aes eet af S ve 1 Camshaft bracket No 3 4 2 Camshaft bracket No 2 3 Seal washer 4 Camshaft bracket No 1 bank 1 5 Dowel pin 6 Camshaft EXH bank 1 7 Camshaft signal plate EXH 8 Camshaft sensor bracket bank 1 9 Dowel pin 10 Camshaft signal plate INT 11 Camshaft INT bank 1 12 Valve lifter 13 een tensioner secondary 14 Cylinder head bank 1 15 ao secondary 16 Cylinder head bank 2 17 Camshaft sensor bracket 18 Camshaft EXH 19 Camshaft signal plate EXH 20 Camshaft signal plate INT 21 Camshaft INT 22 Camshaft bracket No 1 bank 2 A Refer to EM 67 Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003139120 REMOVAL 1 Remove front timing chain case camshaft sprocket and timing chain Refer to EM 50 Exploded View 2 Remove fuel sub tube Refer to EM 37 Exploded View Revision 2007 November EM 67 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt 3 Loosen camshaft sensor bracket bolts in reverse order as shown in the figure lt Engine front NOTE Th
99. for the tightening procedure e Measure the inner diameter of connecting rod bearing with an inside micrometer Oil clearance Connecting rod bearing inner diameter Crank shaft pin journal diameter Standard and limit Refer to EM 149 Connecting Rod Bearing ee e If the calculated value exceeds the limit select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance Refer to EM 133 Description Method of Using Plastigage Remove oil and dust on crankshaft pin journal and the surfaces of each bearing completely e Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes Install connecting rod bearings to connecting rod and connecting rod bearing cap and tighten connecting rod bolts to the specified torque Refer to EM 115 Disassembly and Assembly for the tightening proce dure CAUTION Never rotate crankshaft Remove connecting rod bearing cap and bearings and using the scale on the plastigage bag measure the plastigage width NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation MAIN BEARING OIL CLEARANCE Method by Calculation e Install main bearings 3 to cylinder block 1 and lower cylinder block 2 and tighten lower cylinder block bolts to the specified torq
100. g a bore gauge measure cylinder bore for wear out of round and taper at six different points on each cylinder A and B direc tions at C D and E is in longitudinal direction of engine f 10 mm 0 39 in g 60 mm 2 36 in h 125 mm 4 92 in Standard and limit Refer to EM 144 Cylinder Block If the measured value exceeds the limit or if there are scratches and or seizure on the cylinder inner wall hone or rebore the inner wall Oversize piston is provided When using oversize piston rebore cylinder so that the clearance of the piston to cylinder bore satis fies the standard CAUTION When using oversize piston use oversize pistons for all cylin ders with oversize piston rings Oversize O S 0 2 mm 0 008 in SEM843E Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer A Measure point R f EM 144 W li BI k Standard efer to Cylinder Bloc JPBIA0227ZZ Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter direction B position D Clearance Cylinder bore inner diameter Piston skirt diameter Standard and limit Refer to EM 144 Cylinder Block e If the calculated value exceeds the limit replace piston and piston pin assembly Refer to EM 144 Cylinder Block Re boring Cylinder Bore 1 Cylinder bore size is determined by adding piston to cylinder bore clearance to piston skirt diameter
101. ghtening connecting rod bolts check that crankshaft rotates smoothly e Check the connecting rod side clearance Refer to EM 144 Cylinder Block JPBIAO209ZZ 15 Install baffle plate 16 Install new rear oil seal Refer to EM 77 REAR OIL SEAL Removal and Installation e Apply new engine oil to both oil seal lip and dust seal lip 17 Install pilot converter e With a drift of the following outer diameter press fit as far as it will go Pilot converter Approximately 33 mm 1 30 in PBIC2947E e Press fit pilot converter with its chamfer facing crankshaft as shown in the figure lt Crankshaft side JPBIA0210ZZ Revision 2007 November EM 122 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt 18 Install knock sensors A Bank 1 B Bank 2 lt Engine front e Install knock sensor so that connector faces rear of the engine e After installing knock sensor connect harness connector and lay it out to rear of the engine CAUTION e Never tighten mounting bolts while holding connector e If any impact by dropping is applied to knock sensor replace it with new one NOTE e Check that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor e Check that knock sensor does not interfere with other parts 19 Note the following assemble in the reverse order of disassembly after this step Drive plate e When installing d
102. gine rpm Perform these steps to check each cylinder Compression pressure _ Refer to EM 139 General Specification CAUTION Always use a fully charged battery to obtain the specified engine speed e If the engine speed is out of the specified range check battery liquid for proper gravity Check the engine speed again with normal battery gravity e If compression pressure is below minimum value check valve clearances and parts associated with combustion chamber valve valve seat piston piston ring cylinder bore cylinder head cylinder head gasket After the checking measure compression pressure again Revision 2007 November EM 23 2008 EX35 COMPRESSION PRESSURE lt ON VEHICLE MAINTENANCE gt e If some cylinder has low compression pressure pour small amount of engine oil into the spark plug hole of the cylinder to re check it for compression If the added engine oil improves the compression piston rings may be worn out or damaged Check pis ton rings and replace if necessary If the compression pressure remains at low level despite the addition of engine oil valves may be mal functioning Check valves for damage Replace valve or valve seat accordingly e If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil cylinder head gaskets are leaking In such a case replace cyl inder head gaskets 9 After inspection is completed in
103. grade 1 2 or 3 on rear side of cylinder block and select piston of the same grade Ao Com m D OD gt Identification lt 2 Engine front NOTE Bearing housing grade No 1 Bearing housing grade No 2 Bearing housing grade No 3 Bearing housing grade No 4 Cylinder bore grade No 1 Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No Cylinder bore grade No ao a fF Go PP INFOID 0000000003139151 i VAVDYAVYARY SCH FEVEVYRAVLIV IY N ch LEI AY JPBIA0268ZZ Piston is available with piston pin as a set for the service part Only 0 grade piston pin is available WHEN NEW CYLINDER BLOCK IS REUSED 1 Measure the cylinder bore inner diameter Refer to EM 144 Cylinder Block Revision 2007 November EM 133 2008 EX35 HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt 2 Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the PIS TON SELECTION TABLE A Piston grade number B Front mark CG Piston pin grade number 3 Select piston of the same grade PISTON SELECTION TABLE Unit mm in Grade 1 2 3 Cylinder bore inner diameter 95 500 95 510 95 510 95 520 95 520 95 530 3 7598 3 7602 3 7602 3 7606 3 7606 3 7610 Piston skirt diameter 95 480 95 490 95 490 95 500 95 500 95 510 3 7
104. haft pin so that the connecting rod bearing oil clearance satisfies the standard CAUTION In grinding crankshaft pin to use undersize bearings keep the fillet R A 1 5 1 7 mm 0 059 0 067 in JPBIA0216ZZ Bearing undersize table Refer to EM 149 Connecting Rod Bearing M a i n B ea r i n d INFOID 0000000003 139153 WHEN NEW CYLINDER BLOCK AND CRANKSHAFT ARE USED 1 MAIN BEARING SELECTION TABLE rows correspond to bearing housing grade on rear left side of cylinder block Bearing housing grade No 1 ANVEN NN od ee Bearing housing grade No 2 S r lt p ABC Bearing housing grade No 3 H EE Bearing housing grade No 4 Cylinder bore grade No Cylinder bore grade No 2 Cylinder bore grade No 3 Cylinder bore grade No 4 5 6 JPBIA0268ZZ Cylinder bore grade No Cylinder bore grade No Identification code Ao Ion moov D d Engine front 2 MAIN BEARING SELECTION TABLE columns correspond to journal diameter grade on front side of crankshaft Journal diameter grade No 1 Journal diameter grade No 2 Journal diameter grade No 3 Journal diameter grade No 4 GPO Pin diameter grade No s Pin diameter grade No Pin diameter grade No JPBIA0269ZZ lt 2 3 Pin diameter grade No 4 Pin diameter grade No 5 6 Pin diameter grade No Ao Com mm D OD gt Identification code 3 Select main bearing grade at the point where se
105. hands Never wear gloves Revision 2007 November EM 39 2008 EX35 FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt e Lubricate O ring with new engine oil e Never clean O ring with solvent e Check that O ring and its mating part are free of foreign material e When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube e Insert new O ring straight into fuel tube Never decenter or twist it e Insert fuel sub tube straight into fuel tube e Tighten mounting bolts evenly in turn e After tightening mounting bolts check that there is no gap between flange and fuel tube 3 Install new O rings to fuel injector paying attention to the following CAUTION e Upper and lower O ring are different Be careful not to confuse them Fuel tube side Black Nozzle side Green Handle O ring with bare hands Never wear gloves Lubricate O ring with new engine oil Never clean O ring with solvent Check that O ring and its mating part are free of foreign material e When installing O ring be careful not to scratch it with tool or fingernails Also be careful not to twist or stretch O ring If O ring was stretched while it was being attached never insert it quickly into fuel tube e Insert O ring straight into fuel injector Never decenter or twist it 4 Install fuel i
106. he repair work is completed re connect both battery cables With the brake pedal released turn the push button ignition switch from ACC position to ON position then to LOCK position The steering wheel will lock when the push button ignition switch is turned to LOCK position 6 Perform self diagnosis check of all control units using CONSULT III Draining Engine Coolant INFOID 0000000003139073 Drain engine coolant and engine oil when the engine is cooled Disconnecting Fuel Piping INFOID 0000000003139074 e Before starting work check no fire or spark producing items are in the work area e Release fuel pressure before disconnecting and disassembly e After disconnecting pipes plug openings to stop fuel leakage Removal and Disassembly INFOID 0000000003139075 e When instructed to use SST use specified tools Always be careful to work safely avoid forceful or unin structed operations e Exercise maximum care to avoid damage to mating or sliding surfaces e Dowel pins are used for several parts alignment When replacing and reassembling parts with dowel pins check that dowel pins are installed in the original position e Cover openings of engine system with a tape or equivalent if necessary to seal out foreign materials e Mark and arrange disassembly parts in an organized way for easy troubleshooting and re assembly e When loosening nuts and bolts as a basic rule start with the one furthest outside then the one diagonally opp
107. hickness Determined by match of cylin der block bearing housing grade inner diameter of hous ing and crankshaft journal grade outer diameter of jour nal Between crankshaft and con necting rod Connecting rod bearing Connecting rod bearing grade bearing thickness Combining service grades for connecting rod big end diame ter and crankshaft pin outer di ameter determine connecting rod bearing selection Between cylinder block and pis ton Piston and piston pin assembly Piston is available together with piston pin as assembly Piston grade piston skirt diameter Piston grade cylinder bore grade inner diameter of bore Between piston and connecting rod For the service parts the grade for fitting cannot be selected between piston pin and connecting rod Only 0 grade is available The information at the shipment from the plant is described as a reference e The identification grade stamped on each part is the grade for the dimension measured in new condition This grade cannot apply to reused parts e For reused or repaired parts measure the dimension accurately Determine the grade by comparing the measurement with the values of each selection table e For details of the measurement method of each part the reuse standards and the selection method of the selective fitting parts refer to the text Piston WHEN NEW CYLINDER BLOCK IS USED Check the cylinder bore
108. il and engine coolant Refill to the specified level if necessary Summary of the inspection items Items Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases Leakage Transmission transaxle CVT fluid power steering fluid brake fluid etc Revision 2007 November EM 113 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt CYLINDER BLOCK Exploded View SEC 110 120 226 0 18 1 1 8 13 1 Sub harness 2 Knock sensor 4 Cylinder block heater for Canada 5 Cylinder block 7 Main bearing upper 8 Crankshaft 10 Main bearing lower 11 O ring 13 Baffle plate 14 Lower cylinder block 16 Reinforcement plate 17 Drive plate 19 Oil jet 20 Top ring 22 Oil ring 23 Piston 25 Snap ring 26 Connecting rod 28 Connecting rod bearing cap 29 Connecting rod bolt A Refer to EM 115 B Chamfered Revision 2007 November EM 114 INFOID 0000000003139147 RI 88 0 9 0 65 JPBIA1827GB Crankshaft position sensor Thrust bearing Crankshaft key Lower cylinder block bolt Pilot converter Rear oil seal Second ring Piston pin Connecting rod bearing Front mark 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt lt 3 Crankshaft side Refer to Gl 4 Components for symbols in th
109. ing 5 Connector bolt 7 Plug 8 Oil pressure switch 10 Oil temperature sensor 11 Washer 13 Drain plug 14 Drain plug washer 16 Rear plate cover A Refer to LU 9 B To oil pump Refer to Gl 4 Components for symbols in the figure 2WD Disassembly and Assembly REMOVAL CAUTION INFOID 0000000003139137 em 0 17 2 1 8 13 O ring Oil filter Oil strainer Oil pan upper Oil pan lower Oil pan side INFOID 0000000003139138 Never drain engine oil when the engine is hot to avoid the danger of being scalded 1 Remove oil level gauge oil pressure switch and oil temperature sensor Revision 2007 November EM 97 2008 EX35 OIL PAN UPPER AND OIL STRAINER lt DISASSEMBLY AND ASSEMBLY gt 2 Remove oil pan lower Refer to EM 43 Exploded View 2WD 3 Remove oil strainer 4 Loosen mounting bolts in the reverse order as shown in the fig ure with power tool to remove lt Engine front e Insert the seal cutter SST KV10111100 J37228 between oil pan upper and lower cylinder block Slide seal cutter by tap ping on the side of tool with a hammer Remove oil pan upper CAUTION e Be careful not to damage the mating surfaces e Never insert a screwdriver this will damage the mating surfaces 5 Remove o rings 2 from bottom of lower cylinder block 1 and oil pump 3 lt Engine front INSTALLATION 1 Install oil pan upper as follows a Use a scraper A to remove old liquid ga
110. ing chain secondary NOTE e Figure shows bank 1 rear view e Matching marks for camshaft sprockets are on the back side of camshaft sprockets secondary e There are two types of matching marks circle and oval types They should be used for the bank 1 and bank 2 respectively JPBIA1791ZZ Bank 1 Use circle type Bank2 Use oval type Align dowel pin camshafts with the groove or dowel hole on sprockets and install them On the intake side align dowel pin on camshaft front end with pin groove on the back side of camshaft sprocket and install them On the exhaust side align dowel pin on camshaft front end with pin hole on camshaft sprocket and install them In case that positions of each matching mark and each dowel pin are not fit on matching parts make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent Mounting bolts for camshaft sprockets must be tightened in the next step Tightening them by hand is enough to prevent the dislocation of dowel pins Check the matching marks punched D on each camshaft sprocket are positioned on the matching marks orange link C on timing chain secondary A h B Exhaust side 3 A Intake side M i NOTE d Matching mark punched in the figure is for checking loose at 6 Si this step Revision 2007 November EM 58 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt c After confirming the matching marks are
111. ing oil pump from engine side Refer to ST 45 Exploded View Remove engine mounting insulators RH and LH under side nuts with power tool Lift with hoist and separate the engine the transmission assembly the transfer assembly and the front final drive assembly from front suspension member CAUTION e Before and during this lifting always check if any harnesses are left connected e Never damage to and oil grease smearing or spills onto engine mounting insulator Remove alternator Refer to CHG 27 AWD Exploded View Revision 2007 November EM 86 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt 6 Remove starter motor Refer to STR 15 Exploded View 7 Remove front propeller shaft from the front final drive assembly side Refer to DLN 75 Exploded View 8 Separate the engine from the transmission assembly Refer to TM 195 AWD Exploded View 9 Remove the front final drive assembly from oil pan upper Refer to DLN 106 Exploded View e EK i f EM 10 Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool INSTALLATION Note the following and install in the reverse order of removal Do not allow engine mounting insulator to be damage and careful no engine oil gets on it For a location with a positioning pin insert it securely into hole of mating part For a part with a specified installation orientation refer to component figure in EM 83 AWD
112. intake and exhaust cam nose on No 1 cylinder engine front side of bank 1 are located as shown in the fig ure lt Engine front e If not turn crankshaft one revolution 360 degrees and align as shown in the figure b Use a feeler gauge measure the clearance between valve lifter and camshaft Valve clearance Refer to EM 140 Camshaft INN A SEM139D Revision 2007 November EM 18 2008 EX35 CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt e By referring to the figure measure the valve clearances at locations marked x as shown in the table below locations indicated in the figure lt Engine front e No 1 cylinder at compression TDC Measuring position bank 1 A No 1 CYL No 3 CYL No 5 CYL No 1 cylinder atcom EXH C x B pression TDC INT D x E Measuring position bank 2 H No 2 CYL No 4 CYL No 6 CYL No 1 cylinder atcom NI D x F pression TDC EXH C x G JPBIAO165ZZ c Rotate crankshaft 240 degrees clockwise when viewed from engine front to align No 3 cylinder at TDC its compression stroke NOTE Mark a position 240 degrees b from a corner of the hexagonal part of crankshaft pulley mounting bolt as shown in the figure Use the hexagonal part as a guide 1 Crankshaft pulley A Paint mark Revision 2007 November EM 19 2008 EX35 CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt e By referring to the
113. intermediate fixing point Pull out engine room harnesses to engine room side and temporarily secure them on engine CAUTION e When pulling out harnesses take care not to damage harnesses and connectors e After temporarily securing cover connectors with vinyl or similar material to protect against for eign material adhesion Vehicle Underbody 1 Remove A T fluid cooler hoses and power steering oil pump oil cooler hoses Revision 2007 November EM 80 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt e Install plug to avoid leakage of A T fluid and power steering fluid 2 Disconnect heated oxygen sensor 2 harness Remove three way catalyst and exhaust front tube Refer to EX 5 Exploded View 4 Disconnect steering lower joint at power steering gear assembly side and release steering lower shaft w Refer to ST 23 Exploded View 5 Remove rear propeller shaft Refer to DLN 89 Exploded View 6 Disengage A T control rod at control device assembly side Then temporarily secure it on the transmis sion assembly so that it does not sag Refer to TM 155 2WD Exploded View 7 Remove rear plate cover from oil pan upper Then remove bolts fixing drive plate to torque converter Refer to EM 97 2WD Exploded View 8 Remove transmission joint bolts which pierce at oil pan upper lower rear side Refer to EM 43 Exploded View 2WD Remove front stabilizer connecting rod from transverse link Refer to FSU 17
114. jojoajo NRINITNIN TRIN TRIN TRIN IR IRIN MTMOLTMOITOSMOTMOIMOSMO HO MO MO WM H A 53 974 53 973 2 1250 2 1249 0 fofofofilafifala 1 2 B 53 973 53 972 2 1249 2 1249 DIPINTA ENA N C 53 972 53 971 2 1249 2 1248 ANNERES E 53 970 53 969 2 1248 2 1248 ANNER F 53 969 53 968 2 1248 2 1247 ANNER G 53 968 53 967 2 1247 2 1247 1 J 53 966 53 965 2 1246 2 1246 1 2 2 2 2 2 2 3 3 3 K 53 965 53 964 2 1246 2 1246 2 2 2 2 2 2 3 3 3 3 L 53 964 53 963 2 1246 2 1245 1 1 2 2 2 2 2 2 3 3 3 3 3 M 53 963 53 962 2 1245 2 1245 1 2 2 2 2 2 2 3 3 3 3 3 3 N 53 962 53 961 2 1245 2 1244 EREECHEN ERENNERT R__ 53 960 53 959 2 1244 2 1244 S 53 959 53 958 2 1244 2 1243 HR 53 958 53 957 2 1243 2 1243 2 2 3 3 3 3 3 3 4 4 4 4 4 U 53 957 53 956 2 1243 2 1242 2 3 3 3 3 3 3 4 4 4 4 4 4 PBIC5435E CONNECTING ROD BEARING GRADE TABLE Connecting rod bearing grade table Refer to EM 149 Connecting Rod Bearing UNDERSIZE BEARING USAGE GUIDE Revision 2007 November EM 135 2008 EX35 HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt e When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings use undersize US bearings e When using undersize US bearing measure the connecting rod bearing inner diameter with bearing installed and grind cranks
115. l and rocker cover Refer to EM 47 Exploded View Remove exhaust manifold Refer to EM 34 Exploded View Other removable brackets NOTE Revision 2007 November EM 89 2008 EX35 ENGINE STAND SETTING lt DISASSEMBLY AND ASSEMBLY gt The figure shows an example of widely use engine stand A that can hold mating surface of transmission with drive plate removed CAUTION Before removing the hanging chains check the engine stand is stable and there is no risk of overturning JPBIAO190ZZ 5 Drain engine oil Refer to LU 8 Draining 6 Drain engine coolant by removing water drain plugs 1 and 4 from cylinder block both sides as shown in the figure 2 Washer 3 Plug lt Engine front JPBIA0191ZZ Revision 2007 November EM 90 2008 EX35 ENGINE UNIT lt DISASSEMBLY AND ASSEMBLY gt ENGINE UNIT D i sasse m bly INFOID 0000000003139132 Poy ONO 9 Remove intake manifold collector Refer to EM 29 Exploded View Remove intake manifold Refer to EM 32 Exploded View Remove exhaust manifold Refer to EM 34 Exploded View Remove oil pan lower Refer to EM 43 Exploded View 2WD 2WD models or EM 44 Exploded View AWD AWD models Remove ignition coil spark plug and rocker cover Refer to EM 47 Exploded View Remove fuel injector and fuel tube Refer to EM 37 Exploded View Remove timing chain Refer to EM 50 Exploded View Remove rear timing chain case Refer to EM 9
116. le puller tab on crankshaft pulley periphery as this will damage internal damper 27 Remove oil pan lower Refer to EM 43 Exploded View 2WD 2WD models or EM 44 Exploded View AWD AWD models 28 Loosen two mounting bolts in front of oil pan upper with power tool in reverse order as shown in the figure lt Engine front JPBIA0047ZZ 29 Remove front timing chain case as follows Revision 2007 November EM 53 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt a Loosen mounting bolts in reverse order as shown in the figure b Insert a suitable tool A into the notch at the top of front timing chain case as shown c Pry off case by moving the suitable tool as shown e Use the seal cutter SST KV10111100 J37228 to cut liquid gasket for removal CAUTION e Never use a screwdriver or something similar e After removal handle front timing chain case carefully so it does not tilt cant or warp under a load 30 Remove front oil seal from front timing chain case using a suit able tool e Use a screwdriver for removal CAUTION Be careful not to damage front timing chain case 31 Remove O rings 1 from rear timing chain case A Bank 1 B Bank2 32 Remove timing chain tensioner primary as follows Revision 2007 November EM 54 JPBIAO046ZZ 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt a Remove lower mounting bolt A ah b Loosen upper mounting bolt B slowly and th
117. lected row and column meet in MAIN BEARING SELEC TION TABLE Revision 2007 November EM 136 2008 EX35 HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt 4 Apply sign at crossing in above step 3 to MAIN BEARING GRADE TABLE NOTE e MAIN BEARING GRADE TABLE applies to all journals e Service parts is available as a set of both upper and lower WHEN CYLINDER BLOCK AND CRANKSHAFT ARE REUSED EM 1 Measure cylinder block main bearing housing inner diameter and crankshaft main journal diameter Refer to EM 136 Main Bearing and EM 144 Cylinder Block 2 Correspond the measured dimension in Cylinder block main bearing housing inner diameter row of MAIN BEARING SELECTION TABLE 3 Correspond the measured dimension in Crankshaft main journal diameter column of MAIN BEARING SELECTION TABLE 4 Follow step 3 and later in When New Cylinder Block and Crankshaft are Used MAIN BEARING SELECTION TABLE D E F L M N X Y 7 Cylinder block main bearing housing inner diameter Unit mm in a o ive He N N Crankshaft main journal diameter Unit mm in O ive WwW P QUAL fo E CH N Hole diameter 69 993 69 994 2 7556 2 7557 70 013 2 7564 2 7564 W 70 014 2 7564 2 7565 70 014 70 015 2 7565 2 7565 O 1O lo N O ito ito N Q oO CH CH N 69 996
118. lip is oriented as shown in the figure A Oil seal lip B Dust seal lip lt Engine inside 4a Engine outside JPBIA0054ZZ e Using a suitable drift press fit until the height of front oil seal is level with the mounting surface Suitable drift outer diameter 60 mm 2 36 in inner diameter 50 mm 1 97 in e Check the garter spring is in position and seal lips not inverted CAUTION e Be careful not to damage front timing chain case and crankshaft e Press fit straight and avoid causing burrs or tilting oil seal 3 Install in the reverse order of removal after this step REAR OIL SEAL REAR OIL SEAL Removal and Installation INFOID 0000000003139124 PBIC2931E REMOVAL 1 Remove transmission assembly Refer to TM 192 2WD Exploded View 2WD models or TM 195 AWD Exploded View AWD models 2 Remove drive plate Refer to EM 114 Exploded View 3 Remove rear oil seal with a suitable tool CAUTION Revision 2007 November EM 77 2008 EX35 OIL SEAL lt ON VEHICLE REPAIR gt Be careful not to damage crankshaft and cylinder block INSTALLATION 1 Install rear oil seal e Install rear oil seal so that each seal lip is oriented as shown in the figure A Oil seal lip B Dust seal lip Cl Engine inside 4 Engine outside JPBIA0054ZZ e Press in rear oil seal 1 to the position as shown in the figure B Cylinder block rear end face a 0 0 5 mm 0 0 020 in JPBIA0152ZZ
119. lows if necessary Remove camshaft brackets No 1 Refer to EM 67 Exploded View b Remove timing chain tensioners secondary with a stopper pin A attached D JPBIA0095ZZ Asse m bly INFOID 0000000003139136 1 Install timing chain tensioners secondary to cylinder head as follows if removed Refer to EM 67 Exploded View a Install timing chain tensioners secondary with a stopper pin attached and new O rings Install camshaft brackets No 1 Refer to EM 67 Exploded View c Measure difference in levels between front end faces of cam shaft bracket No 1 and cylinder head Standard 0 14 to 0 14 mm 0 0055 to 0 0055 in e Measure two positions both intake and exhaust side for a single bank e If the measured value is out of the standard re install cam shaft bracket No 1 EMQ0044D 2 Install rear timing chain case as follows a Install new O rings 1 onto cylinder block lt Engine front Q C Ki A Wis lt A K OC JPBIAOO90ZZ Revision 2007 November EM 94 2008 EX35 REAR TIMING CHAIN CASE lt DISASSEMBLY AND ASSEMBLY gt b Apply liquid gasket with the tube presser commercial service tool to rear timing chain case back side as shown in the figure Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Prod ucts and Sealants CAUTION EM e For A in the figure completely wipe out liquid gasket extended on a
120. lts 2 It is nor mal for a gap A to exist under the bolt seats when mount ing bolts are tightened to the specification 1 Slack guide 2 Cylinder block JPBIAO117ZZ 6 Install the timing chain tensioner primary with the following procedure Pull plunger stopper tab A up or turn lever downward so as to remove plunger stopper tab from the ratchet of plunger D NOTE Plunger stopper tab and lever C are synchronized Push plunger into the inside of tensioner body Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet d To secure lever insert stopper pin E through hole of lever into tensioner body hole B e The lever parts and the plunger stopper tab are synchronized Therefore the plunger will be secured under this condition ZER NOTE Figure shows the example of 1 2 mm 0 047 in diameter thin screwdriver being used as the stopper pin e Install timing chain tensioner primary 1 e Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner pri mary f Pull out stopper pin A after installing and then release plunger 7 Check again that the matching marks on sprockets and timing chain have not slipped out of alignment 8 Install new O rings 1 on rear timing chain case A Bank B Bank2 9 Install new front oil seal on front timing chain case Revision 2007 November EM
121. moothly by hand e Check the crankshaft end play Refer to EM 144 Cylinder Block 9 Install piston to connecting rod as follows a Using a snap ring pliers install new snap ring to the groove of piston rear side Revision 2007 November EM 119 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt e Insert it fully into groove to install b Install piston to connecting rod e Using an industrial use drier or similar tool heat piston until piston pin can be pushed in by hand without excess force approximately 60 to 70 C 140 to 158 F From the front to the rear insert piston pin into piston and connecting rod e Assemble so that the front mark on the piston head and the cylinder number on connecting rod are positioned as shown in the figure A Piston grade number B Front mark CG Pin grade number D Cylinder number E Front mark lt Engine front S JPBIAO203ZZ c Install new snap ring to the groove of the piston front side e Insert it fully into groove to install e After installing check that connecting rod moves smoothly 10 Using a piston ring expander commercial service tool A install piston rings CAUTION e When installing piston rings be careful not to damage piston e Be careful not to damage piston rings by expending them excessively JPBIAO194ZZ e If there is stamped mark on ring mount it with marked side up Stamped mark Top ring A 1N Second ring B 2N e Position
122. moved after being tightened to the specified torque with main bearings 1 installed the tip end of bearing must protrude Refer to EM 115 Disassembly and Assembly for the tightening procedure A Crush height Standard There must be crush height e If the standard is not met replace main bearings JPBIA0233ZZ CONNECTING ROD BEARING CRUSH HEIGHT e When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings 1 installed the tip end of bearing must protrude Refer to EM 115 Disassem bly and Assembly for the tightening procedure A Crush height Standard There must be crush height e If the standard is not met replace connecting rod bearings LOWER CYLINDER BLOCK BOLT OUTER DIAMETER e Measure the outer diameters c d at two positions as shown in the figure a 20 mm 0 79 in b 30 mm 1 18 in e 10mm 0 39 in e If reduction appears in a range regard it c Limit d c 0 11 mm 0 0043 in e If it exceeds the limit large difference in dimensions replace lower cylinder block bolt with new one CONNECTING ROD BOLT OUTER DIAMETER JPBIA0234ZZ Revision 2007 November EM 131 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt 1 Measure the outer diameters a b and c at the position shown in the figure a Value at the end of the smaller diameter of the bolt b Value at the end of the smalle
123. mum 981 10 0 142 kPa kg cm psi 300 rpm Differential limit between cylinders 98 1 0 14 Cylinder number VRE ce FRONT SEM713A Valve timing Valve timing control OFF PBICO187E Unit degree a b c d e f 248 248 2 66 0 68 Drive Belt INFOID 0000000003139155 DRIVE BELT Tension of drive belt Belt tension is not necessary as it is automatically adjusted by drive belt auto tensioner Revision 2007 November EM 139 2008 EX35 SERVICE DATA AND SPECIFICATIONS SDS lt SERVICE DATA AND SPECIFICATIONS SDS Spark Plug INFOID 0000000003139156 SPARK PLUG Unit mm in Make DENSO Standard type FXE22HR11 Gap Nominal 1 1 0 043 n ta ke M an ifold INFOID 0000000003139157 INTAKE MANIFOLD Unit mm in Items Limit Surface distortion Intake manifold 0 1 0 004 Exhaust Man ifold INFOID 0000000003139158 EXHAUST MANIFOLD Unit mm in Items Limit Surface distortion Exhaust manifold 0 7 0 028 Ca m S h aft INFOID 0000000003139159 CAMSHAFT Unit mm in Items Standard Limit l No 1 0 045 0 086 0 0018 0 0034 Camshaft journal oil 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 Camshaft bracket inner diameter No 2 3 4 23 500 23 521 0 9252 0 9260 f No 1 25 935 25 955 1 0211 1 0218 Camshaft journal diameter No 2 3
124. n KBIA4379J e Never disassemble Never loosen bolts A and B as shown in the figure JPBIAO096ZZ 36 Remove timing chain tensioners secondary from cylinder head as follows if necessary a Remove camshaft brackets No 1 Refer to EM 67 Exploded View b Remove timing chain tensioners secondary with a stopper pin attached 37 Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan upper and liquid gas ket mating surfaces CAUTION Be careful not to allow gasket fragments to enter oil pan JPBIA0050ZZ 38 Remove old liquid gasket from bolt hole and thread A Remove sticking old liquid gasket B Bolt hole JPBIA0051ZZ INSTALLATION NOTE The below figure shows the relationship between the matching mark on each timing chain and that on the cor responding sprocket with the components installed Revision 2007 November EM 56 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt JPBIA0066ZZ 1 Internal chain guide 2 Camshaft sprocket INT 3 Timing chain secondary 4 Camshaft sprocket EXH 5 Timing chain tensioner primary 6 Slack guide 7 Timing chain primary 8 Crankshaft sprocket 9 Water pump 10 Timing chain tensioner secondary A Matching mark punched back side B Matching mark yellow link C Matching mark punched D Matching mark orange link E Matching mark notched F Crankshaft key 1 Install timi
125. n case 2 Lower cylinder block Standard Rear timing chain case to lower cylinder block 0 24 to 0 14 mm 0 0094 to 0 0055 in e If not within the standard repeat the installation procedure Install water pump with new O rings Refer to CO 18 Exploded View Check that dowel pin A and crankshaft key 1 are located as shown in the figure No 1 cylinder at compression TDC NOTE Though camshaft does not stop at the position as shown in the figure for the placement of cam nose it is generally accepted camshaft is placed for the same direction of the figure Camshaft dowel pin At cylinder head upper face side in each bank Crankshaft key At cylinder head side of bank 1 JPBIA0094ZZ Install timing chains secondary and camshaft sprockets as follows CAUTION Matching marks between timing chain and sprockets slip easily Confirm all matching mark posi tions repeatedly during the installation process Push plunger of timing chain tensioner secondary and keep it pressed in with a stopper pin A JPBIAO095ZZ For the following operations perform steps in the reverse order of removal Revision 2007 November EM 96 2008 EX35 OIL PAN UPPER AND OIL STRAINER lt DISASSEMBLY AND ASSEMBLY gt OIL PAN UPPER AND OIL STRAINER 2WD 2WD Exploded View SEC 110 150 213 253 Wlo 6 0 98 85 0 34 0 3 5 25 DI 21 6 2 2 16 1 Oil level gauge 2 Oil level gauge guide 4 O r
126. n har ness connector of electric throttle control actuator is disconnected Refer to EC 17 THROTTLE VALVE CLOSED POSITION LEARNING Description Perform the Idle Air Volume Learning and Throttle Valve Closed Position Learning when electric throttle control actuator is replaced Refer to EC 17 IDLE AIR VOLUME LEARNING Description and EC 17 THROTTLE VALVE CLOSED POSITION LEARNING Description JPBIA0011ZZ Revision 2007 November EM 31 2008 EX35 INTAKE MANIFOLD lt ON VEHICLE REPAIR gt INTAKE MANIFOLD Exp loded View INFOID 0000000003139101 SEC 140 fw 7 3 0 74 65 H PBIC5453E Harness bracket 2 Intake manifold 3 Gasket A Refer to EM 32 Refer to GI 4 Components for symbols in the figure Removal and Installation INFOID 0000000003139102 REMOVAL 1 Release fuel pressure Refer to EC 538 Inspection 2 Remove intake manifold collector Refer to EM 29 Exploded View 3 Remove fuel tube and fuel injector assembly Refer to EM 37 Exploded View 4 Remove harness bracket 5 Loosen mounting bolts and nuts in reverse order as shown in the figure to remove intake manifold with power tool lt Engine front CAUTION e Cover engine openings to avoid entry of foreign materi als e Put a mark on the intake manifold and the cylinder head with paint before removal because they need installed in the specified direction 6 Remove gaskets ar INSTALLATION Note th
127. ng Ke Valve guide drift JPBIA0400ZZ Removing and installing valve guide Intake and Exhaust a 9 5 mm 0 374 in dia b 5 5 mm 0 217 in dia Valve guide reamer Revision 2007 November JPBIA0401ZZ EM 11 A Reaming valve guide inner hole B Reaming hole for oversize valve guide Intake and Exhaust c 6 0 mm 0 236 in dia d 10 2 mm 0 402 in dia 2008 EX35 lt PREPARATION gt Kent Moore No Tool name PREPARATION Description J 43897 18 J 43897 12 Oxygen sensor thread cleaner JPBIA0238ZZ Reconditioning the exhaust system threads before installing a new air fuel ratio sensor and heated oxygen sensor Use with anti seize lu bricant shown below A J 43897 18 18 mm 0 71 in dia for zir conia heated oxygen sensor and air fuel ratio sensor B J 43897 12 12 mm 0 47 in dia for tita nia heated oxygen sensor C Mating surface shave cylinder D Flutes EC Anti seize lubricant Permatex 133AR or equivalent meeting MIL specifica tion MIL A 907 Revision 2007 November AEM489 EM 12 Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads 2008 EX35 DRIVE BELT lt ON VEHICLE MAINTENANCE gt ON VEHICLE MAINTENANCE DRIVE BELT Exp loded View INFOID 0000000003 139083 JPBIA0002ZZ 1 Power steering oil pump 2 Alternator 3 Drive belt auto tensioner 4 Crankshaft pulley
128. ng chain tensioners secondary to cylinder head as follows if removed Refer to EM 50 Exploded View 2 Check that dowel pin A and crankshaft key 1 are located as shown in the figure No 1 cylinder at compression TDC NOTE Though camshaft does not stop at the position as shown in the figure for the placement of cam noses it is generally accepted camshaft is placed for the same direction of the figure Camshaft dowel pin At cylinder head upper face side in each bank Crankshaft key At cylinder head side of bank 1 JPBIA0094ZZ 3 Install timing chains secondary and camshaft sprockets as follows CAUTION Matching marks between timing chain and sprockets slip easily Confirm all matching mark posi tions repeatedly during the installation process Revision 2007 November EM 57 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt a Push plunger of timing chain tensioner secondary and keep it pressed in with a stopper pin A JPBIA0095ZZ b Install timing chains secondary and camshaft sprockets e Align the matching marks on timing chain secondary orange link with the ones on intake and exhaust camshaft sprockets punched and install them Camshaft sprocket INT back face Orange link Matching mark Circle Matching mark Oval Dowel groove Matching mark 2 oval Camshaft sprocket EXH back face Matching mark 2 circle Com mm DO D ZS Dowel hole Tim
129. ng cylinder head measure distance between front end faces of cylinder block and cylinder head bank 1 and bank 2 Standard 14 1 14 9 mm 0 555 0 587 in e If measured value is out of the standard reinstall cylinder head EMQ0662D 13 Install valve lifter e Install it in the original position 14 Install spark plug tube e Press fit spark plug tube as follows Revision 2007 November EM 110 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt a Remove old locking sealant adhering to cylinder head mounting hole b Apply sealant to area within approximately 12 mm 0 47 in from edge of spark plug tube press fit side Use Genuine high strength thread locking sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants c Using drift press fit spark plug tube so that its height A is as specified in the figure High strength thread locking sealant application area B Standard press fit height 37 7 38 7 mm 1 484 1 524 in CAUTION e When press fitting take care not to deform spark plug tube e After press fitting wipe off liquid gasket protruding onto cylinder head upper face 15 Install spark plug with spark plug wrench commercial service tool 16 Install in the reverse order of removal after this step n S pect i O n INFOID 0000000003139146 JPBIA0181ZZ INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter e Cylinder head bolts are tight
130. njector to fuel tube as follows a Insert clip 3 into clip mounting groove D on fuel injector 5 2 O ring Black 4 O ring Green CAUTION e Never reuse clip Replace it with a new one e Be careful to keep clip from interfering with O ring If interference occurs replace O ring b Insert fuel injector into fuel tube 1 with clip attached e Insert it while matching it to the axial center e Insert fuel injector so that protrusion A of fuel tube matches cutout B of clip e Check that fuel tube flange E is securely fixed in flange fixing groove C on clip c Check that installation is complete by checking that fuel injector does not rotate or come off e Check that protrusions of fuel injectors are aligned with cut outs of clips after installation JPBIA0037ZZ 5 Install fuel tube and fuel injector assembly to intake manifold CAUTION Be careful not to let tip of injector nozzle come in contact with other parts Revision 2007 November EM 40 2008 EX35 FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt e Tighten mounting bolts in two steps in numerical order as shown in the figure lt Engine front Diet step 10 1 N m 1 0 kg m 7 ft lb 2nd step 23 6 N m 2 4 kg m 17 ft lb JPBIA0034ZZ 6 Connect injector sub harness Install fuel sub tube mounting bolt 8 Connect fuel feed hose with damper e Handling procedure of O ring is the same as that of fuel damper and fuel s
131. normal condition Spark plug Standard type Refer to EM 140 Spark Plug CAUTION e Never drop or shock spark plug e Never use a wire brush for cleaning e If plug tip is covered with carbon spark plug cleaner may be used Cleaner air pressure Less than 588 kPa 6 kg cm 85 psi Cleaning time Less than 20 seconds SMA773C e Checking and adjusting plug gap is not required between change intervals JPBIA0031ZZ Revision 2007 November EM 17 2008 EX35 CAMSHAFT VALVE CLEARANCE lt ON VEHICLE MAINTENANCE gt CAMSHAFT VALVE CLEARANCE Inspection and Adjustment InFo10 0000000008139092 INSPECTION Perform inspection as follows after removal installation or replacement of camshaft or valve related parts or if there is unusual engine conditions regarding valve clearance In cases of removing installing or replacing camshaft and valve related parts or of unusual engine conditions due to changes in valve clearance found malfunctions during stating idling or causing noise perform inspection as follows RS lt Engine front JPBIA0164ZZ 1 Remove rocker covers bank 1 and bank 2 Refer to EM 47 Removal and Installation 2 Measure the valve clearance as follows Set No 1 cylinder at TDC of its compression stroke e Rotate crankshaft pulley clockwise to align timing mark grooved line without color with timing indicator den Timing mark grooved line without color e Check that
132. om valve timing control cover Disassembly prohibited parts 24 Remove rocker covers bank 1 and bank 2 Refer to EM 47 Exploded View 25 Obtain No 1 cylinder at TDC of its compression stroke as follows a Rotate crankshaft pulley clockwise to align timing mark grooved line without color with timing indicator dem Timing mark grooved line without color b Check that intake and exhaust cam noses on No 1 cylinder engine front side of bank 1 are located as shown in the figure lt Engine front e If not turn crankshaft one revolution 360 degrees and align as shown in the figure 26 Remove crankshaft pulley as follows a Remove front cross bar Refer to FSU 37 Exploded View AWD models b Remove power steering pipe mounting bolt Refer to ST 51 2WD Exploded View Revision 2007 November EM 52 2008 EX35 TIMING CHAIN lt ON VEHICLE REPAIR gt c Remove rear cover plate and set the ring gear stopper SST KV10118600 J 48641 A as shown in the figure 1 Oil pan upper 2 Drive plate lt 2 Vehicle front JPBIA0408ZZ d Loosen crankshaft pulley bolt and rotate bolt seating surface at 10 mm 0 39 in from its original position 1 Crankshaft pulley CAUTION Never remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller e Place suitable puller tab on holes of crankshaft pulley and pull crankshaft pulley through CAUTION Never put suitab
133. on both bank 1 and bank 2 8 5 mm 0 335 in 2 mm 0 08 in Clearance 5 mm 0 20 in 62 5 mm 0 098 in Apply liquid gasket to rear timing chain side xo 0 OD D Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants JPBIA0255ZZ Revision 2007 November EM 70 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt e Apply liquid gasket to camshaft bracket No 1 contact surface on the rear timing chain case backside as shown on both bank 1 and bank 2 1 Rear timing chain case a 63 9 mm 0 154 in Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants CAUTION For camshaft bracket No 1 near installation position and install it without disturbing the liquid gasket applied JPBIAOBB1ZZ to the surfaces 5 Tighten camshaft bracket bolts in the following steps in numeri cal order as shown in the figure lt Engine front a Tighten No 7 to 10 in numerical order as shown OJ 1 96 N m 0 20 kg m 1 ft lb b Tighten No 1 to 6 in numerical order as shown DI 1 96 N m 0 20 kg m 1 ft lb c Tighten No 1 to 10 in numerical order as shown O 5 88 N m 0 60 kg m 4 Ip d Tighten No 1 to 10 in numerical order as shown DI 10 4 N m 1 1 kg m 8 ft lb 6 Tighten camshaft sensor bracket bolts in numerical order as shown in the figure lt Engine front NOTE The order of
134. osite and so on If the order of loosening is specified do exactly as specified Power tools may be used in the step Inspection Repair and Replacement INFOID 0000000003139076 Before repairing or replacing thoroughly inspect parts Inspect new replacement parts in the same way and replace if necessary Asse m bly and n sta latio n INFOID 0000000003139077 Use torque wrench to tighten bolts or nuts to specification When tightening bolts and nuts 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 specified 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 parts with dowel pins check that dowel pins are installed in the original position Thoroughly wash clean and air blow each part Carefully check engine oil or engine 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 engine coolant After repairing start the engine and increase engine speed to check engine coolant fuel engine oil and exhaust gases for leakage Parts Requiring Angle Tightening INFOID 0000000003139078 e Use the angl
135. portion touching at engine coolant e Apply liquid gasket on installation position of water pump and cylinder head very completely JPBIA0092ZZ C Protrusion D Clearance 1 mm 0 04 in E Do not protrude in this area F Run along bolt hole inner side G Protrusions at beginning and end f gasket h 3 9 mm 0 154 in i 2 7 mm 0 106 in Refer to Gl 4 Components for symbols in the figure c Align rear timing chain case with dowel pins bank 1 and bank 2 on cylinder block and install rear timing chain case e Check O rings stay in place during installation to cylinder block and cylinder head d Tighten mounting bolts in numerical order as shown in the fig ure e There are two types of mounting bolts Refer to the following for locating bolts Bolt length Bolt position 20 mm 0 79 in 1 2 3 6 7 8 9 10 16 mm 0 63 in 4 5 11 12 13 12 7 N m 1 3 kg m 9 ft lb JPBIAO089ZZ Revision 2007 November EM 95 2008 EX35 REAR TIMING CHAIN CASE lt DISASSEMBLY AND ASSEMBLY gt Bolt length Bolt position 16 mm 0 63 in Except the above 15 0 N m 1 5 kg m 11 ft lb After all bolts are tightened retighten them to the specified torque in numerical order shown in the figure e If liquid gasket protrudes wipe it off immediately After installing rear timing chain case check the surface height difference between the following parts on the oil pan upper mounting surface 1 Rear timing chai
136. pring Dimensions and Valve Spring Pressure Load Revision 2007 November EM 112 2008 EX35 CYLINDER HEAD lt DISASSEMBLY AND ASSEMBLY gt e Check the valve spring pressure at specified spring height Standard Intake and exhaust Free height Installation height Refer to EM 142 Installation load Cylinder Head Height during valve open Load with valve open e If the installation load or load with valve open is out of the stan SEMI13 dard replace valve spring INSPECTION AFTER INSTALLATION Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage and exhaust gases leakage Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage at connection points Run engine to check for unusual noise and vibration Warm up engine thoroughly to check there is no leakage of fuel exhaust gases or any oil fluids including engine oil and engine coolant Bleed air from lines and hoses of applicable lines such as in cooling system After cooling down engine again check oil fluid levels including engine o
137. ps The numerical order No 7 and 8 shows second step JPBIA0017ZZ AIR FUEL RATIO SENSOR 1 CAUTION e Before installing a new air fuel ratio sensor 1 clean exhaust system threads using heated oxygen sensor thread cleaner tool commercial service tool J 43897 18 or J 43897 12 and apply anti seize lubricant e Never over torque air fuel ratio sensor 1 Doing so may cause damage to air fuel ratio sensor 1 resulting in the MIL coming on n S p e ct i O n INFOID 0000000003139106 INSPECTION AFTER REMOVAL Surface Distortion e Check the surface distortion of the exhaust manifold mating sur face with a straightedge A and a feeler gauge B Limit Refer to EM 140 Exhaust Manifold e If it exceeds the limit replace exhaust manifold JPBIA0018ZZ Revision 2007 November EM 36 2008 EX35 FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt FUEL INJECTOR AND FUEL TUBE Exp loded View INFOID 0000000003139107 SEC 164 o 8 4 0 86 74 1 Quick connector cap 2 Fuel feed hose with damper 3 O ring 4 Fuel sub tube 5 O ring 6 Fuel damper cap 7 Fuel damper 8 O ring 9 Fuel tube 10 Clip 11 O ring black 12 Fuel injector 13 O ring green A Refer to EM 37 Refer to Gl 4 Components for symbols in the figure CAUTION Never remove or disassemble parts unless instructed as shown in the figure Removal and Installation INFOID 0000000003139108 REMOVAL WARNING e Put a C
138. r diameter of the bolt opposite side of a c Value of the smallest diameter of the smaller of the bolt 2 Obtain a mean value d of a and b 3 Subtract c from d Limit d c 0 09 mm 0 0035 in JPBIA0262ZZ 4 If it exceeds the limit large difference in dimensions replace the bolt with new one DRIVE PLATE e Check drive plate and signal plate for deformation or damage CAUTION e Never disassemble drive plate e Never place drive plate with signal plate facing down e When handling signal plate take care not to damage or scratch it e Handle signal plate in a manner that prevents it from becom ing magnetized e If anything is found replace drive plate JPBIA0192ZZ OIL JET e Check nozzle for deformation and damage e Blow compressed air from nozzle and check for clogs e If itis not satisfied clean or replace oil jet OIL JET RELIEF VALVE e Using a clean plastic stick press check valve in oil jet relief valve Check that valve moves smoothly with proper reaction force e If itis not satisfied replace oil jet relief valve EMU0468D Revision 2007 November EM 132 2008 EX35 HOW TO SELECT PISTON AND BEARING lt DISASSEMBLY AND ASSEMBLY gt HOW TO SELECT PISTON AND BEARING Description Selection points Selection parts Selection items INFOID 0000000003 139150 Selection methods Between cylinder block and crankshaft Main bearing Main bearing grade bearing t
139. r to be damage and careful no oil gets on it e For a location with a positioning pin insert it securely into hole of mating part e For a part with a specified installation orientation refer to component figure in EM 79 2WD Exploded View e When installing engine mounting bracket RH and LH on cylinder block tighten two upper bolts shown as B in the figure first Then tighten two lower bolts shown as C in the figure Gei D Jo gi A Example left JPBIAO159ZZ e Check all engine mounting insulators are seated properly then tighten mounting nuts e Tighten rear engine mounting member bolts in numerical order as shown in the figure lt Vehicle front JPBIAO160ZZ 2WD g nspection INFOID 0000000003139127 INSPECTION AFTER INSTALLATION Revision 2007 November EM 82 2008 EX35 ENGINE ASSEMBLY lt REMOVAL AND INSTALLATION gt Inspection for Leakage The following are procedures for checking fluids leakage lubricates leakage and exhaust gases leakage Before starting engine check oil fluid levels including engine coolant and engine oil If less than required quantity fill to the specified level Refer to MA 10 Fluids and Lubricants Use procedure below to check for fuel leakage Turn ignition switch ON with engine stopped With fuel pressure applied to fuel piping check for fuel leak age at connection points Start engine With engine speed increased check again for fuel leakage
140. rive plate to crankshaft be sure to correctly align crankshaft side dowel pin and drive plate side dowel pin hole CAUTION If these are not aligned correctly engine runs roughly and MIL turns on e Install drive plate 2 and reinforcement plate 3 as shown in the figure 1 Ring gear 4 Pilot converter 5 Crankshaft A Rounded lt Engine front e Holding ring gear with the ring gear stopper SST KV10118600 J 48641 JPBIA021222 e Tighten the mounting bolts crosswise over several times n S pect i O n INFOID 0000000003139149 CRANKSHAFT END PLAY e Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator Standard and limit Refer to EM 144 Cylinder Block e If the measured value exceeds the limit replace thrust bearings and measure again If it still exceeds the limit replace crankshaft also PBIC2953E CONNECTING ROD SIDE CLEARANCE Revision 2007 November EM 123 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt e Measure the side clearance between connecting rod and crank shaft arm with a feeler gauge Standard and limit Refer to EM 144 Cylinder Block e If the measured value exceeds the limit replace connecting rod and measure again If it still exceeds the limit replace crankshaft also PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter Measure the inner diameter
141. s or har ness connectors Precaution Necessary for Steering Wheel Rotation after Battery Disconnect INFOID 0000000003657647 NOTE e Before removing and installing any control units first turn the push button ignition switch to the LOCK posi tion then disconnect both battery cables e After finishing work confirm that all control unit connectors are connected properly then re connect both battery cables e Always use CONSULT III to perform self diagnosis as a part of each function inspection after finishing work If a DTC is detected perform trouble diagnosis according to self diagnosis results This vehicle is equipped with a push button ignition switch and a steering lock unit If the battery is disconnected or discharged the steering wheel will lock and cannot be turned If turning the steering wheel is required with the battery disconnected or discharged follow the procedure below before starting the repair operation OPERATION PROCEDURE 1 Connect both battery cables NOTE Supply power using jumper cables if battery is discharged 2 Turn the push button ignition switch to ACC position At this time the steering lock will be released Revision 2007 November EM 5 2008 EX35 PRECAUTIONS lt PRECAUTION gt 3 Disconnect both battery cables The steering lock will remain released with both battery cables discon nected and the steering wheel can be turned 4 Perform the necessary repair operation 5 When t
142. shing with an inside micrometer A Standard Refer to EM 144 Cylinder Block JPBIA0223ZZ Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer A Standard Refer to EM 144 Cylinder Block JPBIA0218ZZ Connecting Rod Bushing Oil Clearance Connecting rod bushing oil clearance Connecting rod bushing inner diameter Piston pin outer diame ter Standard and limit Refer to EM 144 Cylinder Block e If the calculated value exceeds the limit replace connecting rod assembly and or piston and piston pin assembly e If replacing piston and piston pin assembly refer to EM 133 Description e If replacing connecting rod assembly refer to EM 134 Connecting Rod Bearing to select the connecting rod bearing A Sample codes B Bearing stopper groove C Small end diameter grade D Big end diameter grade E Weight grade F Cylinder No G Management code JPBIA0208ZZ Revision 2007 November EM 126 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt H Front mark l Management code Factory installed parts grading e Service parts apply only to grade 0 A Piston grade number B Front mark C Piston pin grade number Unit mm in Grade 0 1 Connecting rod bushing 22 000 22 006 22 006 22 012 inner diameter 0 8661 0 8664 0 8664 0 8666 Piston pin hole diameter 21 993 21 999 21 999 22 005
143. sket from mating sur faces CAUTION Never scratch or damage the mating surfaces when clean ing off old liquid gasket e Also remove old liquid gasket from mating surface of lower cyl inder block e Remove old liquid gasket from the bolt holes and threads b Install new O rings 2 on the bottom of lower cylinder block 1 Revision 2007 November and oil pump 3 lt Engine front EM 98 JPBIA0022ZZ 2008 EX35 OIL PAN UPPER AND OIL STRAINER lt DISASSEMBLY AND ASSEMBLY gt c Apply a continuous bead of liquid gasket with the tube presser commercial service tool to the cylinder block mating surface of oil pan upper to a limited portion as shown in the figure a 64 0 5 0 mm 0 157 0 197 in lt Engine front Use Genuine RTV Silicone Sealant or equivalent Refer to GIS Recommended Chemical Products and Sealants CAUTION e For bolt holes with A marks 7 locations apply liquid gasket outside the holes e Attaching should be done within 5 minutes after coating d Install oil pan upper CAUTION Install avoiding misalignment of both O rings e Tighten mounting bolts in numerical order as shown in the fig ure JPBIA0388ZZ lt Engine front e There are two types of mounting bolts Refer to the following for locating bolts M8 x 90 mm 3 54 in 7 10 13 M8 x 25 mm 0 98 in Except the above JPBIA0022ZZ 2 Install oil strainer to oil pump Install oil pan low
144. sor SST EM03470000 J8037 A or suitable tool install piston with the front mark on the pis ton crown facing the front of the engine CAUTION Be careful not to damage the cylinder wall and crankshaft pin resulting from an interference of the connecting rod big end JPBIA0207ZZ 13 Install connecting rod bearing cap e Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install Management code JPBIA0208ZZ A Sample codes B Bearing stopper groove CG Small end diameter grade D Big end diameter grade E Weight grade FE Cylinder No G l Management code e Be sure that front mark H on connecting rod bearing cap is facing front of the engine 14 Tighten connecting rod bolt as follows a Inspect the outer diameter of connecting rod bolt Refer to EM 123 Inspection Apply engine oil to the threads and seats of connecting rod bolts Tighten connecting rod bolts 28 4 N m 2 9 kg m 21 ft lb d Completely loosen connecting rod bolts DI 0 N m 0 kom 0 ft lb e Tighten connecting rod bolts Revision 2007 November EM 121 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt DI 24 5 N m 2 5 kg m 18 ft Ib f Then turn connecting rod bolts 90 degrees clockwise angle tightening CAUTION Always use the angle wrench SST KV10112100 BT8653 A A Never tightening based on visual check alone e After ti
145. srsssceeesansesnsnseeseees 76 Disassembly and Assembly cee 115 VALVE OIL SEAL Removal and Installation 76 leede 123 FRONT OIL SEAL jessie incendie ees 76 HOWTO SELECT PISTON AND BEARING 133 FRONT OIL SEAL Removal and Installation 76 DOSCrIPUON ET 133 PISTON eeneg gier A teed chee HE eee a ey 133 REAR OIL SEAL EEN 77 Connecting Rod Bearing cscscsecscessessesseseeeeees 134 REAR OIL SEAL Removal and Installation 77 Main Bearing EE 136 REMOVAL AND INSTALLATION 79 SERVICE DATA AND SPECIFICATIONS ENGINE ASSEMBLY ccccccccccccccccccceccccccccceccceceeeee 79 SDS idee dee ege ee 139 QW D EE 79 SERVICE DATA AND SPECIFICATIONS 2WD Exploded VieW ccscsccssessesseeseessesseeseseeseseees 79 SDS aan GENEE 139 OWD Removal and Installation 79 General Specification rcst 139 GE eeneg A 82 Drive Belt ici pe teccicerettest avid ereteectes en 139 Spark Rettel lakeside 140 AWD eessen GENEE 83 Intake MANifOld cccccccccccccccccccecececceccecccccececeeeeceeces 140 AWD Exploded View ou cccssstteieesesanensees 83 Exhaust ET EE 140 AWD Removal and Installation cccceesseseee B Camshaft a 140 AWD INSpection sn snssansesnnssnsnsrrennernnnsnrensennnentenes 87 Cylinder Head E 142 Cylinder Block c ccccceeeeeseeeeeeeeeeeeeeeeeeaeeeeeeeeees 144 DISASSEMBLY AND ASSEMBLY 89 Main Bearing saesson oia anid 148 ENGINE STAND SETTING cccccccccccccccccccccece
146. stall removed parts 10 Start the engine and check that the engine runs smoothly 11 Perform trouble diagnosis If DTC appears erase it Refer to EC 125 Description Revision 2007 November EM 24 2008 EX35 ENGINE COVER lt ON VEHICLE REPAIR gt ON VEHICLE REPAIR ENGINE COVER Exploded View INFOID 00000000034 70631 ei 0 56 49 ei 0 56 49 1 Engine cover JPBIA0256GB Re m oval a n d n stal ati O n INFOID 0000000003470632 REMOVAL Loosen mounting bolts and nuts in the reverse order as shown in the figure and then remove engine cover CAUTION Never damage or scratch engine cover when installing or removing JPBIA1823ZZ INSTALLATION Install engine cover and then tighten mounting bolts and nuts in numerical order as shown in the figure CAUTION Never damage or scratch engine cover when installing or removing JPBIA1823ZZ Revision 2007 November EM 25 2008 EX35 DRIVE BELT AUTO TENSIONER AND IDLER PULLEY lt ON VEHICLE REPAIR gt DRIVE BELT AUTO TENSIONER AND IDLER PULLEY Exp loded View INFOID 0000000003 139094 SEC 117 0 56 0 5 7 41 Si 2 0 28 0 Ly S 2 9 21 D 28 0 2 9 21 JPBIA0004ZZ 1 Front timing chain case 2 Drive belt auto tensioner 3 Idler pulley 4 Idler pulley Refer to Gl 4 Components for symbols in the figure Removal and Installation INFOID 0000000003139095 Removal 1 Remove drive belt Refer to EM 13 Exploded View e Ke
147. t because it has a different diameter from the other three locations 2 Measure the camshaft sprocket runout with a dial indicator Total indicator reading Limit Refer to EM 140 Camshaft e If it exceeds the limit replace camshaft sprocket PBICO930E Valve Lifter Revision 2007 November EM 73 2008 EX35 CAMSHAFT lt ON VEHICLE REPAIR gt Check if surface of valve lifter has any wear or cracks e If anything above is found replace valve lifter Refer to EM 140 Camshaft A KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER e Measure the outer diameter at 1 2 height of valve lifter with a micrometer A since valve lifter is in barrel shape Standard Refer to EM 140 Camshaft Intake and exhaust JPBIAO1252ZZ VALVE LIFTER HOLE DIAMETER e Measure the inner diameter of valve lifter hole of cylinder head with an inside micrometer Standard Refer to EM 140 Camshaft Intake and exhaust SEM867E VALVE LIFTER CLEARANCE e Valve lifter clearance Valve lifter hole diameter Valve lifter outer diameter Standard Refer to EM 140 Camshaft Intake and exhaust e If the calculated value is out of the standard referring to each standard of valve lifter outer diameter and valve lifter hole diameter replace either or both valve lifter and cylinder head INSPECTION AFTER INSTALLATION Inspection of Camshaft Sprocket INT Oil Groove CAUTION
148. t sprocket EXH 6 Internal chain guide 7 Timing chain primary 8 Camshaft sprocket INT 9 Timing chain tensioner primary Revision 2007 November EM 50 2008 EX35 lt ON VEHICLE REPAIR gt TIMING CHAIN Removal and Installation 10 Slack guide 11 Crankshaft sprocket 12 Camshaft sprocket INT 13 Valve aiming control Cover Gasket 14 Seal ring 15 Valve timing control cover bank 1 bank 1 F Exhaust valve timing control sole 16 O ring 17 noid valve bank 1 18 Oil level gauge e Intake valve timing control solenoid 19 Oil level gauge guide 20 O ring 21 valve bank 2 22 Valve timing control cover bank 2 23 Exhaust valve timing control sole 24 Valve timing control cover gasket bank noid valve bank 2 2 25 Front oil seal 26 Crankshaft pulley 27 Crankshaft pulley bolt Intake valve timing control solenoid 28 valve bank 1 29 Power steering oil pump bracket 30 Idler pulley bracket 31 Alternator bracket 32 Water outlet front 33 Front timing chain case 34 Rear timing chain case 35 O ring 36 O ring 37 O ring A Refer to EM 94 B Refer to EM 51 C Oil filter Refer to Gl 4 Components for symbols in the figure INFOID 0000000003 139117 REMOVAL 1 Release the fuel pressure Refer to EC 538 Inspection 2 Disconnect the battery cable from the negative terminal 3 Remove engine cover with power tool Refer to EM 25 Exploded View 4 Remove radiator reservoir tank Refer
149. to avoid the danger of being scalded 1 Remove oil level gauge oil pressure switch and oil temperature sensor 2 Remove oil filter bracket Refer to LU 11 Exploded View 3 Remove oil pan lower Refer to EM 44 Exploded View AWD 4 Remove oil strainer Revision 2007 November EM 100 2008 EX35 OIL PAN UPPER AND OIL STRAINER lt DISASSEMBLY AND ASSEMBLY gt 5 Loosen mounting bolts in the reverse order as shown in the fig ure with power tool to remove lt Engine front e Insert the seal cutter SST KV10111100 J37228 between oil pan upper and lower cylinder block Slide seal cutter by tap ping on the side of tool with a hammer Remove oil pan upper CAUTION e Be careful not to damage the mating surfaces e Never insert a screwdriver this will damage the mating EE surfaces 6 Remove O rings 2 from bottom of lower cylinder block 1 and oil pump 3 lt 2 Engine front 7 Remove axle pipe as necessary e Remove axle pipe from oil pan upper using a suitable drift A outer diameter 37 mm 1 46 in JPBIA0028ZZ INSTALLATION 1 Install axle pipe 3 to oil pan upper if removed e Lubricate O ring groove of axle pipe O rings 1 2 and O ring joint of oil pan with new engine oil Unit mm in Items O ring inner diameter Final drive side right side 31 4 1 236 Axle pipe flange side left side 33 6 1 323 JPBIA0452ZZ Revision 2007 November EM 101 2008 EX35
150. to damage the mounting surfaces e Never tighten bolts too much e Never insert screw driver this will damage the mating sur face 10 Remove crankshaft 11 Pull rear oil seal out from rear end of crankshaft 12 Remove main bearings and thrust bearings from cylinder block and lower cylinder block CAUTION e Be careful not to drop main bearing and to scratch the surface e Identify installation positions and store them without mixing them up 13 Remove oil jet ASSEMBLY 1 Fully air blow engine coolant and engine oil passages in cylinder block cylinder bore and crankcase to remove any foreign material CAUTION Use a goggles to protect your eye 2 Install each plug to cylinder block as shown in the figure 3 Plug lt Engine front e Apply sealant to the thread of water drain plugs 1 4 Use Genuine RTV Silicone Sealant or equivalent Refer to GI 15 Recommended Chemical Products and Sealants e Apply sealant to the thread of plugs Use Genuine high strength thread locking sealant or equivalent Refer to Gl 15 Recommended Chemical Products and Sealants e Replace washers 2 with new one JPBIAO191ZZ e Tighten each plug as specified below Part Washer Tightening torque 1 No 19 6 N m 2 0 kg m 14 ft lb 3 Yes 78 0 N m 8 0 kg m 58 ft lb 4 Yes 12 3 N m 1 3 kg m 9 ft lb 3 Install oil jet Revision 2007 November EM 117 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND AS
151. ton rings from piston e Before removing piston rings check the piston ring side clearance Refer to EM 144 Cylinder Block e Use a piston ring expander commercial service tool A CAUTION e When removing piston rings be careful not to damage piston e Be careful not to damage piston rings by expanding them excessively JPBIA0194ZZ 7 Remove piston from connecting rod as follows Revision 2007 November EM 115 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt a Using a snap ring pliers A remove snap rings JPBIAO195ZZ b Heat piston to 60 to 70 C 140 to 158 F with an industrial use drier A or equivalent JPBIAO196ZZ c Push out piston pin with stick of outer diameter approximately 20 mm 0 79 in PBICO262E 8 Remove lower cylinder block bolts e Before loosening lower cylinder block bolts measure the crankshaft end play Refer to EM 144 Cylinder Block e Loosen lower cylinder block bolts in the reverse order shown in the figure in several different steps lt Engine front JPBIAO197ZZ 9 Remove lower cylinder block as follows Revision 2007 November EM 116 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt Screw M8 bolt pitch 1 25 mm 0 0492 in length approximately 50 mm 1 97 in into bolt holes A Then equally tighten each bolt and remove lower cylinder block Bor Be GO CNC oe ug lt Engine front CAUTION e Be careful not
152. tor 1 straight from centralized under floor piping 3 CAUTION Pull quick connector holding position A as shown in the figure Never pull with lateral force applied O ring inside quick connector may be damaged Prepare container and cloth beforehand as fuel will leak out Avoid fire and sparks re Keep parts away from heat source Especially be careful when welding is performed around them Never expose parts to battery electrolyte or other acids Never bend or twist connection between quick connector and fuel feed hose with damper dur ing installation removal To keep clean the connecting portion and to avoid dam age and foreign materials cover them completely with plastic bags etc A or something similar JPBIAO135ZZ 8 Remove fuel sub tube mounting bolt 9 Disconnect harness connector from fuel injector Revision 2007 November EM 38 2008 EX35 FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt 10 Loosen mounting bolts in reverse order as shown in the figure 11 12 Remove fuel sub tube and fuel damper if necessary INSTALLATION 1 a and remove fuel tube and fuel injector assembly lt Engine front CAUTION Never tilt fuel tube or remaining fuel in pipes may flow out from pipes JPBIA0034ZZ Remove fuel injector 2 from fuel tube 4 as follows 2 O ring A Installed condition B Clip mounting groove Open and remove clip 1 Remove fuel injector from fuel tub
153. trainer if any object attached INSPECTION AFTER INSTALLATION 1 2 3 4 Check the engine oil level and adjust engine oil Refer to LU 6 Inspection Start engine and check there is no leakage of engine oil Stop engine and wait for 10 minutes Check the engine oil level again Refer to LU 6 Inspection Revision 2007 November EM 46 2008 EX35 IGNITION COIL SPARK PLUG AND ROCKER COVER lt ON VEHICLE REPAIR gt IGNITION COIL SPARK PLUG AND ROCKER COVER Exploded View SEC 1119118 wa ei eu GO 19 6 2 0 14 Gel 2 5 0 26 A OR 1 PCV hose 2 4 Spark plug 5 7 Rocker cover gasket bank 1 8 Camshaft position sensor PHASE 10 bank 1 11 Exhaust valve timing control position 13 14 sensor bank 2 16 PCV hose 17 A To intake manifold collector B D To air duct PEO f 9 7 0 0 71 62 Clamp PCV valve Rocker cover bank 1 Exhaust valve timing control position sensor bank 1 Rocker cover gasket bank 2 Oil filler cap Refer to EM 47 Refer to Gl 4 Components for symbols in the figure Removal and Installation REMOVAL 1 Remove the following parts e Engine cover Refer to EM 25 Exploded View e Air cleaner case and air duct RH and LH Refer to EM 27 Exploded View e Intake manifold collector Refer to EM 29 Exploded View 2 Disconnect PCV hose from rocker cover Revision 2007 November EM 47 12 15 INFOID 00000
154. ub tube e Insert fuel damper straight into fuel sub tube e Tighten mounting bolts evenly in turn e After tightening mounting bolts check that there is no gap between flange and fuel sub tube 9 Connect quick connector between fuel feed hose with damper and centralized under floor piping con nection as follows a Check no foreign substances are deposited in and around centralized under floor piping and quick con nector and no damage on them Thinly apply new engine oil around centralized under floor piping from tip end to spool end Align center to insert quick connector straightly into centralized under floor piping e Insert quick connector to centralized under floor piping until top spool is completely inside quick connec tor and 2nd level spool exposes right below quick connector CAUTION e Carefully align center to avoid inclined insertion to prevent damage to O ring inside quick con nector e Insert until you hear a click sound and actually feel the engagement e To avoid misidentification of engagement with a similar sound be sure to perform the next step d Pull quick connector by hand holding position A Check it is completely engaged connected so that it does not come out from centralized under floor piping 1 N PBIC3795E e Install quick connector cap 3 to quick connector connection 1 Centralized under floor piping 2 Fuel feed hose B Under view e Install quick connector cap with arrow A on s
155. ue Refer to EM 115 Disassembly and Assembly for the tightening procedure e Measure the inner diameter of main bearing with a bore gauge Oil clearance Main bearing inner diameter Crankshaft main journal diameter Standard and limit Refer to EM 148 Main Bearing e If the calculated value exceeds the limit select proper main bear ing according to main bearing inner diameter and crankshaft main JPBIA0232ZZ journal diameter to obtain the specified bearing oil clearance Refer to EM 133 Description Method of Using Plastigage e Remove engine oil and dust on crankshaft journal and the surfaces of each bearing completely e Cut a plastigage slightly shorter than the bearing width and place it in crankshaft axial direction avoiding oil holes e Install main bearing to cylinder block and lower cylinder block and tighten lower cylinder block bolts with lower cylinder block to the specified torque Refer to EM 115 Disassembly and Assembly for the tightening procedure CAUTION Revision 2007 November EM 130 2008 EX35 CYLINDER BLOCK lt DISASSEMBLY AND ASSEMBLY gt Never rotate crankshaft e Remove lower cylinder block and bearings and using the scale on the plastigage bag measure the plastigage width NOTE The procedure when the measured value exceeds the limit is same as that described in the Method by Calculation JPBIA0231ZZ MAIN BEARING CRUSH HEIGHT e When lower cylinder block is re
156. urface facing in direction of quick connector fuel feed hose side CAUTION If quick connector cap cannot be installed smoothly quick connector may have not been installed correctly Check the connection again ee 10 Install in the reverse order of removal after this step Revision 2007 November EM 41 2008 EX35 FUEL INJECTOR AND FUEL TUBE lt ON VEHICLE REPAIR gt n spect i O n INFOID 0000000003139109 INSPECTION AFTER INSTALLATION Check on Fuel Leakage 1 Turn ignition switch ON with the engine stopped With fuel pressure applied to fuel piping check there are no fuel leakage at connection points NOTE Use mirrors for checking at points out of clear sight 2 Start the engine With engine speed increased check again that there are no fuel leakage at connection points CAUTION Never touch the engine immediately after stopped as the engine becomes extremely hot Revision 2007 November EM 42 2008 EX35 OIL PAN LOWER lt ON VEHICLE REPAIR gt OIL PAN LOWER Exploded View 2WD SEC 110 150 213 253 9 6 0 98 85 0 34 0 3 5 25 DI 21 6 2 2 16 1 Oil level gauge 2 Oil level gauge guide 4 O ring 5 Connector bolt 7 Plug 8 Oil pressure switch 10 Oil temperature sensor 4 1 Washer 13 Drain plu 4 Drain plug washer plug 16 Rear plate cover A Refer to LU 9 B To oil pump Refer to Gl 4 Components for symbols in the figure EM 43 Revision 2007 No
157. vember INFOID 0000000003139110 DI 46 6 4 8 34 0 17 2 1 8 13 O ring Oil filter Oil strainer Oil pan upper Oil pan lower Oil pan side 2008 EX35 OIL PAN LOWER lt ON VEHICLE REPAIR gt Exploded View AWD SEC 110 150 2139253 1 Oil level gauge 2 Oil level gauge guide 4 O ring 5 Gasket Drain plug 8 Drain plug washer 10 O ring small 11 Axle pipe 13 Rear plate cover 14 Oil pan upper A Refer to LU 11 B To oil pump Refer to Gl 4 Components for symbols in the figure Removal and Installation REMOVAL CAUTION ran Sos 61 Or Com en Op JPBIA1825GB INFOID 0000000003139111 A 9 17 2 1 8 13 O ring Oil strainer Oil pan lower O ring large Oil pan side INFOID 0000000003139112 Never drain engine oil when the engine is hot to avoid the danger of being scalded 1 Remove engine undercover with power tool 2 Drain engine oil Refer to LU 8 Draining 3 Remove oil pan lower as follows EM 44 Revision 2007 November 2008 EX35 OIL PAN LOWER lt ON VEHICLE REPAIR gt a Loosen mounting bolts in reverse order as shown in the figure to remove lt Engine front b Insert the seal cutter SST KV10111100 J37228 A between oil pan upper and oil pan lower CAUTION e Be careful not to damage the mating surfaces e Never insert a screwdriver this will damage the mating surfaces c Slide the seal cutter SST KV1

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