Engine Mechanical: Removal & Installation Infiniti EX35 I

Removal and Disassembly

1. When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
2. Exercise maximum care to avoid damage to mating or sliding surfaces.
3. 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.
4. Cover openings of engine system with a tape or equivalent, if necessary, to seal out foreign materials.
5. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
6. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

Assembly and Installation

1. Use torque wrench to tighten bolts or nuts to specification.
2. 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.
3. Replace with new gasket, packing, oil seal or O-ring.
4. 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.
5. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.
6. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
7. Release air within route when refilling after draining engine coolant.
8. After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

INSTALLATION

Note the following, and install in the reverse order of removal.

Note the following, and install in the reverse order of removal.

1. Install the air cleaner filter by aligning the seal with the notch of air cleaner case.

Scheme 142

Refer to " COMPONENTS " for symbols in the figure.

Scheme 143

1. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-368797-S08623518782010081300000) ".
2. Remove air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-368797-S19785767342010081300000) ".
3. Remove electric throttle control actuator. Refer to " «EXPLODED VIEW»(ref-368797-S15585949212010081300000) ".
4. Remove ignition coil. Refer to " «REMOVAL AND INSTALLATION»(ref-368797-S04184967342010081300000) ".
5. Remove spark plug with a spark plug wrench (commercial service tool).

Installation is the reverse order of removal.

REMOVAL

Loosen mounting bolts and nuts in the reverse order as shown in the figure, and then remove engine cover.

Scheme 144

Install engine cover, and then tighten mounting bolts and nuts in numerical order as shown in the figure.

Scheme 145

Refer to " COMPONENTS " for symbols in the figure.

1. Remove drive belt. Refer to " «EXPLODED VIEW»(ref-368797-S29203709922010081300000) ". Keep auto-tensioner pulley arm locked after drive belt is removed.
2. Remove auto-tensioner and idler pulley. Refer to " «EXPLODED VIEW»(ref-368797-S29203709922010081300000) ". Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.

Installation is the reverse order of removal.

Scheme 146

Refer to " COMPONENTS " for symbols in the figure.

Note. Mass air flow sensor is removable under the car-mounted condition.

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. Add marks if necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case if necessary. CAUTION: Handle mass air flow sensor with the following cares. Never shock mass air flow sensor. Never disassemble mass air flow sensor. Never touch mass air flow sensor.

Note the following, and install in the reverse order of removal.

Scheme 147

Scheme 148

1. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-368797-S08623518782010081300000) ".
2. Remove air cleaner case and air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-368797-S19785767342010081300000) ".
3. Remove electric throttle control actuator as follows: Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage. CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belt. 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. Disconnect harness connector. Loosen mounting bolts in reverse order as shown in the figure. NOTE: When removing only intake manifold collector, move electric throttle control actuator without disconnecting the water hose. The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. 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 control actuator.
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 manifold collector.
6. Loosen mounting bolts and nuts with power tool in the reverse order as shown in the figure to remove intake manifold collector.

Note the following, and install in the reverse order of removal.

INTAKE MANIFOLD COLLECTOR

Scheme 149

1. 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)
2. Tighten mounting bolts and nuts in numerical order as shown in the figure.

WATER HOSE

1. Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
2. 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)

1. Tighten in numerical order as shown in the figure. NOTE: The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. 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).
2. Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to " «THROTTLE VALVE CLOSED POSITION LEARNING : DESCRIPTION»(ref-368796-S15714163592010081300000) ".
3. Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to " «IDLE AIR VOLUME LEARNING : DESCRIPTION»(ref-368796-S23023232682010081300000) " and " «THROTTLE VALVE CLOSED POSITION LEARNING : DESCRIPTION»(ref-368796-S15714163592010081300000) ".

Scheme 150

Refer to " COMPONENTS " for symbols in the figure.

Scheme 151

1. Release fuel pressure. Refer to " «INSPECTION»(ref-368796-S03735697402010081300000) ".
2. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-368797-S15585949212010081300000) ".
3. Remove fuel tube and fuel injector assembly. Refer to " «EXPLODED VIEW»(ref-368797-S24186279832010081300000) ".
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. CAUTION: Cover engine openings to avoid entry of foreign materials. 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.

Note the following, and install in the reverse order of removal.

INTAKE MANIFOLD

Scheme 152

1. 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)
2. Tighten all mounting bolts and nuts to the specified torque in two or more steps in numerical order as shown in the figure. CAUTION: Install intake manifold with the marks (put on the intake manifold and the cylinder head before removal) aligned. 1st step: : 7.4 N.m (0.75 kg-m, 5 ft-lb) 2nd step and after: : 25.5 N.m (2.6 kg-m, 19 ft-lb)

Note. When removing bank 1 side parts only, step 2 , 5 , and 7 are unnecessary.

Scheme 153

Scheme 154

1. Remove engine undercover with power tool.
2. Drain engine coolant. Refer to " «DRAINING»(ref-368795-S05263292432010081300000) ".
3. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-368797-S08623518782010081300000) ".
4. Remove air cleaner case and air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-368797-S19785767342010081300000) ".
5. Remove heater pipe and water hose. Refer to " «EXPLODED VIEW»(ref-368795-S22987212112010081300000) ".
6. Remove exhaust front tube and three way catalysts (bank 1 and bank 2). Refer to " «EXPLODED VIEW»(ref-368814-S25132821502010081300000) ".
7. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-368792-S05516104802010081300000) ".
8. Disconnect air fuel ratio sensor 1 harness connectors (bank 1 and bank 2) and remove harness clip.
9. Using the heated oxygen sensor wrench [SST: KV10114400 (J-38365)] (C), remove air fuel ratio sensor 1 (bank 1 and bank 2). CAUTION: Be careful not to damage air fuel ratio sensor 1. 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 figure to remove exhaust manifold. NOTE: Disregard the numerical order No. 7 and 8 in removal.
12. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Note the following, and install in the reverse order of removal.

EXHAUST MANIFOLD GASKET

Scheme 155

1. Install exhaust manifold gasket in direction shown in the figure. Follow same procedure for both banks.

EXHAUST MANIFOLD

Scheme 156

1. If stud bolts were removed, install them and tighten to the specified torque below. Tightening torque : Refer to " «EXPLODED VIEW»(ref-368797-S19508390202010081300000) ".
2. Install exhaust manifold and tighten mounting nuts in numerical order as shown in the figure. NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 shows second step.

AIR FUEL RATIO SENSOR 1

Scheme 157

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1. Release fuel pressure. Refer to " «INSPECTION»(ref-368796-S03735697402010081300000) ".
2. Disconnect battery cable from the negative terminal. Refer to " «EXPLODED VIEW»(ref-368780-S38384601202010081300000) ".
3. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-368797-S08623518782010081300000) ".
4. Remove air cleaner case and air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-368797-S19785767342010081300000) ".
5. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-368797-S15585949212010081300000) ".
6. Remove fuel feed hose (with damper) (1) from fuel sub-tube (2) and remove harness bracket (3). NOTE: There is no fuel return route. CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Never separate damper and hose.
7. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows: Remove quick connector cap (2) from quick connector connection on right member side. Disconnect fuel feed hose (with damper) (1) from bracket hose clamp. Push in retainer tabs (2). Draw and pull out quick connector (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. 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) during installation/removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or something similar.
8. Remove fuel sub tube mounting bolt.
9. Disconnect harness connector from fuel injector.
10. Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly. CAUTION: Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.
11. Remove fuel injector (2) from fuel tube (4) as follows: Open and remove clip (1). Remove fuel injector from fuel tube by pulling straight. CAUTION: Be careful with remaining fuel that may go out from fuel tube. Be careful not to damage injector nozzles during removal. Never bump or drop fuel injector. Never disassemble fuel injector.
12. Remove fuel sub-tube and fuel damper, if necessary.

Scheme 163

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Scheme 167

1. 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: 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. 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. 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: Insert straight, checking that the axis is lined up. Never pressure-fit with excessive force. Reference value : 130 N (13.3 kg, 29.2 lb) Insert fuel damper until (B) is touching (A) of fuel tube. Tighten bolts evenly in turn. After tightening bolts, check that there is no gap between fuel damper cap (5) and fuel tube.
2. Install fuel sub-tube. When handling new O-rings, be careful of the following caution: CAUTION: 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. 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. Insert new O-ring straight into fuel tube. Never decenter or twist it. Insert fuel sub-tube straight into fuel tube. Tighten mounting bolts evenly in turn. 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: Upper and lower O-rings 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. 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. Insert O-ring straight into fuel injector. Never decenter or twist it.
4. Install fuel injector to fuel tube as follows: Insert clip (3) into clip mounting groove (D) on fuel injector (5). CAUTION: Never reuse clip. Replace it with a new one. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube (1) with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip. Check that fuel tube flange (E) is securely fixed in flange fixing groove (C) on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. Check that protrusions of fuel injectors are aligned with cutouts of clips after installation.
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. Tighten mounting bolts in two steps in numerical order as shown in the figure. 1st 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)
6. Connect injector sub-harness.
7. Install fuel sub tube mounting bolt.
8. Connect fuel feed hose (with damper). Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube. Insert fuel damper straight into fuel sub-tube. Tighten mounting bolts evenly in turn. 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 connection as follows: Check no foreign substances are deposited in and around centralized under-floor piping and quick connector, 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. Insert quick connector to centralized under-floor piping until top spool is completely inside quick connector and 2nd level spool exposes right below quick connector. CAUTION: Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step. 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). Install quick connector cap (3) to quick connector connection. Install quick connector cap with arrow (A) on surface 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.
10. Install in the reverse order of removal after this step.

Scheme 168

Scheme 169

1. Remove engine undercover with power tool.
2. Drain engine oil. Refer to " «DRAINING»(ref-368815-S00680489972010081300000) ".
3. Remove oil pan (lower) as follows: Loosen mounting bolts in reverse order as shown in the figure to remove. Insert the seal cutter [SST: KV10111100 (J-37228)] (A) between oil pan (upper) and oil pan (lower). CAUTION: Be careful not to damage the mating surfaces. Never insert a screwdriver, this will damage the mating surfaces. Slide the seal cutter [SST: KV10111100 (J-37228)] by tapping on the side of tool with a hammer. Remove oil pan (lower).

Scheme 170

Scheme 171

Scheme 172

1. Install oil pan (lower) as follows: Use scraper (A) to remove old liquid gasket from mating surfaces. Remove old liquid gasket from the bolt holes and thread. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the oil pan (lower) 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 " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-368779-S01206784092010081300000) ". CAUTION: Attaching should be done within 5 minutes after coating. Install oil pan (lower). Tighten mounting bolts in numerical order as shown in the figure.
2. Install oil pan drain plug. Refer to the figure of components for installation direction of drain plug washer. Refer to " «EXPLODED VIEW (2WD)»(ref-368797-S38575075692010081300000) " (2WD models) and " «EXPLODED VIEW (AWD)»(ref-368797-S35437469302010081300000) " (AWD models).
3. Install in the reverse order of removal after this step. NOTE: At least 30 minutes after oil pan is installed, pour engine oil.

Note. The below figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed.

Scheme 173

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Scheme 196

1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to " «EXPLODED VIEW»(ref-368797-S18777869772010081300000) ".
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.
3. Install timing chains (secondary) and camshaft sprockets as follows: CAUTION: Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process. Push plunger of timing chain tensioner (secondary) and keep it pressed in with a stopper pin (A). Install timing chains (secondary) and camshaft sprockets. Align the matching marks on timing chain (secondary) (orange link) with the ones on intake and exhaust camshaft sprockets (punched), and install them. NOTE: Figure shows bank 1 (rear view). Matching marks for camshaft sprockets are on the back side of camshaft sprockets (secondary). There are two types of matching marks, circle and oval types. They should be used for the bank 1 and bank 2, respectively. Bank 1 : Use circle type. Bank 2 : 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). NOTE: Matching mark (punched) in the figure is for checking loose at this step. After confirming the matching marks are aligned, tighten camshaft sprocket mounting bolts. Secure camshaft using a wrench at the hexagonal portion to tighten mounting bolts. Pull stopper pins (2) out from timing chain tensioners (secondary) (1).
4. Install timing chain (primary) as follows: Install crankshaft sprocket (1). Check the matching marks on crankshaft sprocket face the front of the engine. Install timing chain (primary). 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. When it is difficult to align matching marks of timing chain (primary) 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).
5. Install internal chain guide (1), slack guide (2). CAUTION: Never overtighten slack guide mounting bolts (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolts are tightened to the specification.
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. To secure lever, insert stopper pin (E) through hole of lever into tensioner body hole (B). The lever parts and the plunger stopper tab are synchronized. Therefore, the plunger will be secured under this condition. NOTE: Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin. Install timing chain tensioner (primary) (1). Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary). 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.
9. Install new front oil seal on front timing chain case. Apply new engine oil to both oil seal lip (A) and dust seal lip (B). Install it so that each seal lip is oriented as shown in the figure. 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. Check the garter spring is in position and seal lip is not inverted.
10. Install front timing chain case as follows: 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. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-368779-S01206784092010081300000) ". Apply liquid gasket to top surface of oil pan (upper) as shown in the figure. Use Genuine RTV silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-368779-S01206784092010081300000) ". Assemble front timing chain case. CAUTION: Be careful not to damage front oil seal by interference with front end of crankshaft. 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. Tighten mounting bolts to the specified torque in numerical order as shown in the figure. There are two types of mounting bolts. Refer to the following for locating bolts. M10 bolts : 1, 2, 3, 4, 5, 6, 7 : 55.0 N.m (5.6 kg-m, 41 ft-lb) M6 bolts : Except the above : 12.7 N.m (1.3 kg-m, 9 ft-lb) 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). Install two mounting bolts in front of oil pan (upper) in numerical order shown in the figure. Tightening torque : Refer to " «2WD : EXPLODED VIEW»(ref-368797-S01509801752010081300000) ".
11. Install valve timing control covers (bank 1 and bank 2) as follows: Install new seal rings (1) in shaft grooves. CAUTION: When replacing seal ring, replace all rings with new one. To check the joint between dowel pins and dowel pin holes, check the looseness in the axle direction by pushing the circumferential looseness (between dowel pins and dowel pin holes) by twisting in the circumferential direction. 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. CAUTION: Never face the magnet retarder side down to prevent magnet retarder from dropping. Check the mating surface of magnet retarder and the drum of exhaust side camshaft sprocket for foreign materials. 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 figure. Tightening torque : Refer to " «EXPLODED VIEW»(ref-368797-S18777869772010081300000) ". After all bolts are tightened, tighten No. 1 bolt to the specified torque again.
12. Install oil pan (lower). Refer to " «EXPLODED VIEW (2WD)»(ref-368797-S38575075692010081300000) " (2WD models) or " «EXPLODED VIEW (AWD)»(ref-368797-S35437469302010081300000) " (AWD models).
13. Install rocker covers (bank 1 and bank 2). Refer to " «EXPLODED VIEW»(ref-368797-S24620149682010081300000) ".
14. Install crankshaft pulley as follows: Fix crankshaft using the ring gear stopper [SST: KV10118600 (J-48641)]. Install crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). Tighten crankshaft pulley bolt. : 44.1 N.m (4.5 kg-m, 33 ft-lb) 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). Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
15. Install power steering oil pump bracket and idler pulley bracket as follows: Tighten mounting bolts in numerical order as shown in the figure. (temporarily) Tighten mounting bolts to specified torque in numerical order as shown in the figure.
16. For the following operations, perform steps in the reverse order of removal.

2WD : Removal and Installation

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 " «INSPECTION»(ref-368796-S03735697402010081300000) ".
2. Disconnect both battery cables. Refer to " «EXPLODED VIEW»(ref-368780-S38384601202010081300000) ".
3. Drain engine coolant from radiator. Refer to " «DRAINING»(ref-368795-S05263292432010081300000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belt.
4. Remove the following parts: Radiator reservoir tank: Refer to " «EXPLODED VIEW»(ref-368795-S35101085722010081300000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-368797-S08623518782010081300000) ". Front road wheel and tires (power tool) Engine undercover (power tool) Cowl top cover: Refer to " «EXPLODED VIEW»(ref-368788-S15581677152010081300000) ". Air duct and air cleaner case assembly (RH and LH): Refer to " «EXPLODED VIEW»(ref-368797-S19785767342010081300000) ". Cooling fan assembly: Refer to " «EXPLODED VIEW»(ref-368795-S34258236372010081300000) ".
5. Discharge refrigerant from A/C circuit. Refer to " «COLLECTION AND CHARGE»(ref-368782-S04152314812010081300000) ".
6. Remove radiator hoses (upper and lower). Refer to " «EXPLODED VIEW»(ref-368795-S35101085722010081300000) ".

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 " «EXPLODED VIEW»(ref-368782-S15125114082010081300000) ".
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 " «EXPLODED VIEW»(ref-368797-S24186279832010081300000) ". 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 " «2WD : EXPLODED VIEW»(ref-368792-S37250794952010081300000) ". 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 temporarily secure them on engine.

1. Remove passenger-side kicking plate and dash side finisher. Refer to " «EXPLODED VIEW»(ref-368794-S03141922532010081300000) ".
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: When pulling out harnesses, take care not to damage harnesses and connectors. After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

Vehicle Underbody

1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses. Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Disconnect heated oxygen sensor 2 harness.
3. Remove three way catalyst and exhaust front tube. Refer to " «EXPLODED VIEW»(ref-368814-S25132821502010081300000) ".
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-368792-S05516104802010081300000) ".
5. Remove rear propeller shaft. Refer to " «EXPLODED VIEW»(ref-368819-S12032684712010081300000) ".
6. Disengage A/T control rod at control device assembly side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Refer to " «2WD : EXPLODED VIEW»(ref-368808-S25936053522010081300000) ".
7. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter. Refer to " «2WD : EXPLODED VIEW»(ref-368797-S01509801752010081300000) ".
8. Remove transmission joint bolts which pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW (2WD)»(ref-368797-S38575075692010081300000) ".
9. Remove front stabilizer connecting rod from transverse link. Refer to " «EXPLODED VIEW»(ref-368817-S25011449832010081300000) ".
10. Remove lower ends of left and right steering knuckle from transverse link. Refer to " «EXPLODED VIEW»(ref-368820-S06987511602010081300000) ".
11. Separate steering outer sockets from steering knuckle. Refer to " «2WD : EXPLODED VIEW»(ref-368792-S38166055452010081300000) ".
12. Remove transverse links mounting bolts at suspension member side. Refer to " «EXPLODED VIEW»(ref-368817-S18404569592010081300000) ".

Removal Work

Scheme 197

1. Use a manual lift table caddy (commercial service tool) or equivalently 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.
2. Remove rear engine mounting member bolts.
3. Remove front suspension member mounting bolts and nuts. Refer to " «EXPLODED VIEW»(ref-368817-S33613645732010081300000) ".
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: Confirm there is no interference with the vehicle. Check that all connection points have been disconnected. Keep in mind the center of 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

Scheme 198

Scheme 199

1. Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2). Slinger bolts: : 28.0 N.m (2.9 kg-m, 21 ft-lb) 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. NOTE: Spacer (2) is a component part of engine rear upper slinger assembly.
2. Remove power steering oil pump from engine side. Refer to " «EXPLODED VIEW»(ref-368792-S27348689992010081300000) ".
3. 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: Before and during this lifting, always check that any harnesses are left connected. Never damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator. Refer to " «2WD : EXPLODED VIEW»(ref-368816-S23566666092010081300000) ".
6. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-368821-S39473784482010081300000) ".
7. Separate the engine from the transmission assembly. Refer to " «2WD : EXPLODED VIEW»(ref-368808-S29587353892010081300000) ".
8. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.

Note the following, and install in the reverse order of removal.

Scheme 200

Scheme 201

1. Do not allow engine mounting insulator to be damage and careful no oil gets on it.
2. For a location with a positioning pin, insert it securely into hole of mating part.
3. For a part with a specified installation orientation, Refer to component figure in " «2WD : EXPLODED VIEW»(ref-368797-S25216674212010081300000) ".
4. 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].
5. Check all engine mounting insulators are seated properly, and then tighten mounting nuts.
6. Tighten rear engine mounting member bolts in numerical order as shown in the figure.

AWD : Removal and Installation

Outline

At first, remove the engine, the transmission assembly, the transfer assembly and the front final drive assembly with front suspension member downward. Then separate the engine, the transmission assembly, the transfer and the front final drive assembly.

Preparation

1. Release fuel pressure. Refer to " «INSPECTION»(ref-368796-S03735697402010081300000) ".
2. Disconnect both battery terminals. Refer to " «EXPLODED VIEW»(ref-368780-S38384601202010081300000) ".
3. Drain engine coolant from radiator. Refer to " «DRAINING»(ref-368795-S05263292432010081300000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belt.
4. Remove the following parts: Radiator reservoir tank: Refer to " «EXPLODED VIEW»(ref-368795-S35101085722010081300000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-368797-S08623518782010081300000) ". Front road wheel and tires (power tool) Engine undercover (power tool) Front cross bar: Refer to " «EXPLODED VIEW»(ref-368817-S32806668972010081300000) ". Cowl top cover: Refer to " «EXPLODED VIEW»(ref-368788-S15581677152010081300000) ". Air duct and air cleaner case assembly (RH and LH): Refer to " «EXPLODED VIEW»(ref-368797-S19785767342010081300000) ". Cooling fan assembly: Refer to " «EXPLODED VIEW»(ref-368795-S34258236372010081300000) ".
5. Discharge refrigerant from A/C circuit. Refer to " «COLLECTION AND CHARGE»(ref-368782-S04152314812010081300000) ".
6. Remove radiator hoses (upper and lower). Refer to " «EXPLODED VIEW»(ref-368795-S35101085722010081300000) ".

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 " «EXPLODED VIEW»(ref-368782-S15125114082010081300000) ".
3. Disconnect brake booster vacuum hose.
4. Disconnect ground cables.

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 hose. Refer to " «EXPLODED VIEW»(ref-368797-S24186279832010081300000) ". 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 " «AWD : EXPLODED VIEW»(ref-368792-S24703786772010081300000) ". 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 temporarily secure them on engine.

1. Remove passenger-side kicking plate and dash side finisher. Refer to " «EXPLODED VIEW»(ref-368794-S03141922532010081300000) ".
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: When pulling out harnesses, take care not to damage harnesses and connectors. After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

Vehicle Underbody

1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses. Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Disconnect heated oxygen sensor 2 harness. Refer to " «REMOVAL AND INSTALLATION»(ref-368814-S28325526122010081300000) ".
3. Remove three way catalyst and exhaust front tube. Refer to " «EXPLODED VIEW»(ref-368814-S25132821502010081300000) ".
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-368792-S05516104802010081300000) ".
5. Remove rear propeller shaft. Refer to " «EXPLODED VIEW»(ref-368819-S12032684712010081300000) ".
6. Remove front drive shaft (both side). Refer to " «EXPLODED VIEW»(ref-368820-S32250294262010081300000) ".
7. Disconnect harness connector from transmission assembly and transfer assembly.
8. Disengage A/T control rod at control device assembly side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Refer to " «AWD : EXPLODED VIEW»(ref-368808-S05523532882010081300000) ".
9. Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter. Refer to " «AWD : EXPLODED VIEW»(ref-368797-S03398100652010081300000) ".
10. Remove bolts fixing the transmission assembly to lower rear side of oil pan (upper). Refer to " «AWD : EXPLODED VIEW»(ref-368797-S03398100652010081300000) ".
11. Remove front stabilizer connecting rod from transverse link. Refer to " «EXPLODED VIEW»(ref-368817-S38814700122010081300000) ".
12. Remove lower ends of left and right steering knuckle from transverse link. Refer to " «EXPLODED VIEW»(ref-368820-S04370115372010081300000) ".
13. Separate steering outer sockets from steering knuckle. Refer to " «AWD : EXPLODED VIEW»(ref-368792-S25794089272010081300000) ".
14. Remove transverse links mounting bolts at suspension member side. Refer to " «EXPLODED VIEW»(ref-368817-S40616539722010081300000) ".

Removal Work

1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and transmission. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove rear engine mounting member bolts.
3. Remove front suspension member mounting bolts and nuts. Refer to " «EXPLODED VIEW»(ref-368817-S32806668972010081300000) ".
4. 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: Confirm there is no interference with the vehicle. Check that all connection points have been disconnected. 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. Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2). Slinger bolts: :28.0 N.m (2.9 kg-m, 21 ft-lb) 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. NOTE: Spacer (2) is a component part of engine rear upper slinger assembly.
2. Remove power steering oil pump from engine side. Refer to " «EXPLODED VIEW»(ref-368792-S27348689992010081300000) ".
3. Remove engine mounting insulators (RH and LH) under side nuts with power tool.
4. Lift with hoist and separate the engine, the transmission assembly, the transfer assembly and the front final drive assembly from front suspension member. CAUTION: Before and during this lifting, always check if any harnesses are left connected. Never damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator. Refer to " «AWD : EXPLODED VIEW»(ref-368816-S42039004872010081300000) ".
6. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-368821-S39473784482010081300000) ".
7. Remove front propeller shaft from the front final drive assembly side. Refer to " «EXPLODED VIEW»(ref-368822-S05935512492010081300000) ".
8. Separate the engine from the transmission assembly. Refer to " «AWD : EXPLODED VIEW»(ref-368808-S17582747052010081300000) ".
9. Remove the front final drive assembly from oil pan (upper). Refer to " «EXPLODED VIEW»(ref-368823-S29368669382010081300000) ".
10. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.

Note the following, and install in the reverse order of removal.

Scheme 202

Scheme 203

1. Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
2. For a location with a positioning pin, insert it securely into hole of mating part.
3. For a part with a specified installation orientation, Refer to component figure in " «AWD : EXPLODED VIEW»(ref-368797-S34161627752010081300000) ".
4. 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].
5. 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.
6. Engine mounting bracket (RH) (1) to engine mounting bracket (RH) (lower) [shown as (D) and (E) in the figure].
7. Front final drive to engine mounting bracket (RH) (lower) [shown as (F) in the figure].
8. Check all engine mounting insulators are seated properly, and then tighten mounting nuts.
9. Tighten rear engine mounting member bolts in numerical order as shown in the figure.

Scheme 204

Scheme 205

1. Remove oil level gauge, oil pressure switch and oil temperature sensor.
2. Remove oil pan (lower). Refer to " «EXPLODED VIEW (2WD)»(ref-368797-S38575075692010081300000) ".
3. Remove oil strainer.
4. Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove. Insert the seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and lower cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper). CAUTION: Be careful not to damage the mating surfaces. 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).

Scheme 206

Scheme 207

1. Install oil pan (upper) as follows: Use a scraper (A) to remove old liquid gasket from mating surfaces. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Also remove old liquid gasket from mating surface of lower cylinder block. Remove old liquid gasket from the bolt holes and threads. Install new O-rings (2) on the bottom of lower cylinder block (1) and oil pump (3). 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. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-368779-S01206784092010081300000) ". CAUTION: For bolt holes with marks (7 locations), apply liquid gasket outside the holes. Attaching should be done within 5 minutes after coating. Install oil pan (upper). CAUTION: Be careful not to drop O-rings from the lower cylinder block and oil pump. Tighten mounting bolts in numerical order as shown in the figure. 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
2. Install oil strainer to oil pump.
3. Install oil pan (lower). Refer to " «EXPLODED VIEW (2WD)»(ref-368797-S38575075692010081300000) ".
4. Install oil pan drain plug. Refer to the figure of components for installation direction of drain plug washer. Refer to " «EXPLODED VIEW (2WD)»(ref-368797-S38575075692010081300000) ".
5. Install in the reverse order of removal after this step. NOTE: At least 30 minutes after oil pan is installed, pour engine oil.

Scheme 208

1. Remove oil level gauge, oil pressure switch and oil temperature sensor.
2. Remove oil filter bracket. Refer to " «EXPLODED VIEW»(ref-368815-S03940593322010081300000) ".
3. Remove oil pan (lower). Refer to " «EXPLODED VIEW (AWD)»(ref-368797-S35437469302010081300000) ".
4. Remove oil strainer.
5. Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove. Insert the seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and lower cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper). CAUTION: Be careful not to damage the mating surfaces. Never insert a screwdriver, this will damage the mating surfaces.
6. Remove O-rings (2) from bottom of lower cylinder block (1) and oil pump (3).
7. Remove axle pipe, if necessary. Remove axle pipe from oil pan (upper) using a suitable drift (A) [outer diameter: 37 mm (1.46 in)].

Scheme 209

Scheme 210

Scheme 211

1. Install axle pipe (3) to oil pan (upper), if removed. Lubricate O-ring groove of axle pipe, O-rings (1), (2), and O-ring joint of oil pan with new engine oil. ITEM SPECIFICATION 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) 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: Use a scraper (A) to remove old liquid gasket from mating surfaces. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Also remove old liquid gasket from mating surface of lower cylinder block. Remove old liquid gasket from the bolt holes and threads. Install new O-rings (2) on the bottom of lower cylinder block (1) and oil pump (3). 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. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-368779-S01206784092010081300000) ". CAUTION: For bolt holes with marks (7 locations), apply liquid gasket outside the holes. Attaching should be done within 5 minutes after coating. Install oil pan (upper). CAUTION: Be careful not to drop O-rings from the lower cylinder block and oil pump. Tighten mounting bolts in numerical order as shown in the figure. 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 (1.97 in) : 2 M8 x 90 mm (3.54 in) : 1, 4, 5, 7, 10, 13
3. Install oil strainer to oil pump.
4. Install oil pan (lower). Refer to " «EXPLODED VIEW (AWD)»(ref-368797-S35437469302010081300000) ".
5. Install oil pan drain plug. Refer to the figure of components for installation direction of drain plug washer. Refer to " «EXPLODED VIEW (AWD)»(ref-368797-S35437469302010081300000) ".
6. Install in the reverse order of removal after this step. NOTE: At least 30 minutes after oil pan is installed, pour engine oil.