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//-->ENGINE MECHANICALSECTIONMODIFICATION NOTICE:TB45S engine¼The TB42S engine has been replaced with the TB45S engine. For the TB45S engine specifications otherthan those described here, refer to TB45E engine.TD engine¼Plain washer for glow plate installation has been eliminated.¼Tightening angle of cylinder head bolts has been changed.¼Tightening torque of crank pulley nut and flywheel bolts have been changed.¼Clearances of main bearings and connecting rod bearings have been changed.ZD engine¼ZD30DDTi engine has newly been added.GIMAEMLCECFECLMTATCONTENTSTB45SOUTER COMPONENT PARTS.......................................3TDCYLINDER HEAD............................................................5Installation....................................................................6ENGINE REMOVAL.........................................................7TB45SSERVICE DATA AND SPECIFICATIONS (SDS)............8General Specifications.................................................8Inspection and Adjustment ..........................................8TDSERVICE DATA AND SPECIFICATIONS (SDS)..........12Inspection and Adjustment ........................................12ZDPRECAUTIONS.............................................................13Parts Requiring Angular Tightening...........................13Liquid Gasket Application Procedure ........................13PREPARATION..............................................................14Special Service Tools ................................................14Commercial Service Tools .........................................16NOISE, VIBRATION AND HARSHNESS (NVH)TROUBLESHOOTING...................................................18NVH Troubleshooting Chart - Engine Noise .............19MEASUREMENT OF COMPRESSION PRESSURE....20INTERCOOLER.............................................................21Removal and Installation ...........................................21INTAKE MANIFOLD......................................................22Removal and Installation ...........................................22Inspection...................................................................23CATALYST AND TURBOCHARGER............................24Removal and Installation ...........................................24Inspection...................................................................25EXHAUST MANIFOLD..................................................28Removal and Installation ...........................................28Inspection...................................................................29ROCKER COVER..........................................................30Removal and Installation ...........................................30OIL PAN & OIL STRAINER...........................................32Removal and Installation ...........................................32VACUUM PUMP............................................................35Removal and Installation ...........................................35TIMING CHAIN..............................................................37Removal and Installation ...........................................37Removal.....................................................................37Installation..................................................................39CAMSHAFT...................................................................41Removal and Installation ...........................................41Removal.....................................................................41Inspection...................................................................42Installation..................................................................44TFPDFARABRSTRSBTHAELSEIDXEM-1CONTENTSVALVE CLEARANCE INSPECTIONS ANDADJUSTMENTS.............................................................46Inspection...................................................................46Adjustments ...............................................................47TIMING GEAR...............................................................49Removal and Installation ...........................................49Removal.....................................................................50Inspection...................................................................52Installation..................................................................57OIL SEAL REPLACEMENT..........................................61CYLINDER HEAD..........................................................63Removal and Installation ...........................................63Removal.....................................................................63Inspection...................................................................64Installation..................................................................65Disassembly...............................................................68Inspection...................................................................69Assembly ...................................................................72ENGINE REMOVAL.......................................................74Precautions ................................................................74Removal.....................................................................74Installation..................................................................76(Cont’d)Inspection...................................................................76CYLINDER BLOCK.......................................................77Selection Procedure for Selective PartCombination...............................................................78Disassembly...............................................................78Inspection...................................................................82Assembly ...................................................................91SERVICE DATA AND SPECIFICATIONS (SDS)..........95General Specifications...............................................95Compression Pressure ..............................................95Cylinder Head ............................................................95Valve ..........................................................................95Valve Seat..................................................................98Camshaft and Camshaft Bearing ............................100Cylinder Block..........................................................101Piston, Piston Ring and Piston Pin .........................101Connecting Rod .......................................................102Crankshaft................................................................103Available Main Bearing............................................103Available Connecting Rod Bearing..........................104Miscellaneous Components.....................................105EM-2OUTER COMPONENT PARTSTB45SGIMALCECFECLMTATTFPDFARABRSTRSBTHAELSEIDXSEM010GEM-3OUTER COMPONENT PARTSTB45SSEM083GEM-4CYLINDER HEADTDGIMALCECFECLMTATTFPDFARABRSTRSBTHAELSEIDXDEM145EM-5
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