Engine Mechanical: Removal & Installation Infiniti FX35 I

PRECAUTIONS FOR REMOVAL AND DISASSEMBLY

1. When instructed to use special service tools, use the 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. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
4. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
5. 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 where noted in the step.

PRECAUTIONS FOR ASSEMBLY AND INSTALLATION

1. Use torque wrench to tighten bolts or nuts to specification.
2. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
3. Replace with new liquid gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.
5. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
6. Release air within route when refilling after draining engine coolant.
7. Before starting engine, apply fuel pressure to fuel lines with turning ignition switch "ON" (with engine stopped). Then make sure that there are no leaks at fuel line connections.
8. After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil and exhaust systems for leakage.

Removal

1. Remove front engine undercover with power tool.
2. Remove alternator and power steering oil pump belt. Refer to «ALTERNATOR AND POWER STEERING OIL PUMP BELT»(ref-158850-S13162506332005020300000) .
3. Remove air conditioner compressor belt. Refer to «AIR CONDITIONER COMPRESSOR BELT»(ref-158850-S15346488692005020300000) . CAUTION: Grease is applied to idler pulley adjusting bolt. Be careful to keep grease away from belt.

Installation

1. Install belts to pulley in reverse order of removal. CAUTION: Make sure belt is correctly engaged with pulley groove. Check for engine oil and engine coolant are not adhered to belt and each pulley grooves.
2. Adjust belt tension. Refer to «TENSION ADJUSTMENT»(ref-158850-S31588901312005020300000) .
3. Tighten each adjusting bolt and nut to the specified torque.
4. Make sure that tension of each belt is within the standard. Refer to «CHECKING DRIVE BELTS»(ref-158850-S16142496872005020300000) .

Scheme 111

1. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) . This work is unnecessary when parts located forward of mass air flow sensor are removed/installed.
2. Remove air duct (inlet) and power duct.
3. Disconnect mass air flow sensor harness connector.
4. Disconnect PCV hose.
5. Remove air cleaner case/mass air flow sensor and air duct disconnecting their joints. Add marks as necessary for easier installation.
6. Remove mass air flow sensor from air cleaner case. CAUTION: Handle mass air flow sensor with care. Do not shock it. Do not disassemble it. Do not touch its sensor.
7. Remove resonator in fender, lifting left fender protector.

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

1. Align marks. Attach each joint. Screw clamps firmly.
2. To position air cleaner case, refer to «CHANGING AIR CLEANER FILTER»(ref-158850-S32014389142005020300000) .

Removal is in the order below.

Scheme 112

1. Remove air duct (inlet) from air cleaner case.
2. Disconnect harness connector from mass air flow sensor.
3. Loosen clamp bolts of air hose.
4. Remove mounting bolts for air cleaner case. Remove air cleaner case/mass air flow sensor/air hose assembly.
5. Unclip and open air cleaner case, and remove air cleaner filter.

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

Scheme 113

1. If grommet at bottom of air cleaner case comes off together with air cleaner case, fix it to vehicle before installation.
2. Look at internal bottom face through power duct hole, and position air cleaner case with resonator upper end circle and air cleaner case round hole aligned. Then push air cleaner case straight down.
3. At this time, check by hand if protrusion at bottom of air cleaner case has been inserted into grommet on vehicle side.
4. Clip power duct with bulge on reverse side of lower end engaged with air cleaner case.

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1. Remove engine cover with power tool.
2. Disconnect water hoses from intake manifold collector (upper), attach blind plug to prevent engine coolant leakage. CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
3. Remove air cleaner case and air duct. Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
4. Remove electric throttle control actuator as the following: Disconnect harness connector. Loosen bolts in reverse order as shown in the figure. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Do not disassemble.
5. Remove fuel sub-tube mounting bolt to disconnect from rear of intake manifold collector (lower). Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-158850-S33821907532005020300000) .
6. Disconnect vacuum hose and water hose from intake manifold collector (upper).
7. Disconnect EVAP canister purge volume control solenoid valve bracket mounting bolt from intake manifold collector (upper).
8. Loosen bolts in reverse order of illustration to remove intake manifold collector (upper) with power tool.
9. Remove PCV hose [between intake manifold collector and rocker cover (right bank)].
10. Loosen bolts in reverse order of illustration, and remove intake manifold collector cover, gasket, intake manifold collector (lower) and gasket with power tool. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 119

1. Check the surface distortion of both the intake manifold collector (upper and lower) mating surfaces with straightedge and feeler gauge. Limit : 0.1 mm (0.004 in)
2. If it exceeds the limit, replace intake manifold collector (upper and/or lower).

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

Part Installation Direction

Referring to front marks, install parts shown in figure.

Scheme 120

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

Scheme 121

1. If stud bolts were removed, install them and tighten to the specified torque. 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 shown in the figure. 1st step: 7.4 N.m (0.75 kg-m, 5 ft-lb) 2nd step and after: 29.0 N.m (3.0 kg-m, 21 ft-lb)

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1. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
2. Remove air cleaner case and air duct. Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
3. Remove front and rear engine undercover and front cross bar with power tool.
4. Disconnect heated oxygen sensors 2 (bank 1 and bank 2) harness connectors.
5. Using heated oxygen sensor wrench (SST), remove heated oxygen sensors 2 (bank 1 and bank 2). CAUTION: Be careful not to damage heated oxygen sensor. Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
6. Remove exhaust mounting bracket between right/left catalytic converter and transmission. Refer to EXHAUST SYSTEM .
7. Remove three way catalyst (right and left bank).
8. Disconnect air fuel ratio sensor 1 (bank 1 and bank 2) harness connectors and remove harness clip.
9. Using heated oxygen sensor wrench (SST), remove air fuel ratio sensor 1 (bank 1 and bank 2). CAUTION: Be careful not to damage air fuel ratio sensor. Discard any air fuel ratio sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
10. Remove water pipes on both right and left side. Refer to WATER OUTLET AND WATER PIPING .
11. Remove exhaust manifold cover (right and left bank).
12. Loosen nuts in the reverse order of illustration to remove exhaust manifold with power tool. NOTE: Disregard the numerical order No. 7 and No. 8 in removal.
13. Remove exhaust manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 126

1. Check the surface distortion of the exhaust manifold mating surface with straightedge and feeler gauge. Limit : 0.3 mm (0.012 in)
2. If it exceeds the limit, replace exhaust manifold.

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

Scheme 127

1. Install in direction shown. (Follow same procedure for both banks.)
2. Locate thick side of port connecting part on right side from technician's view.
3. Locate round press in thick side of port connecting part above center level line of port.

Scheme 128

1. If stud bolts were removed, install them and tighten to the specified torque below. 14.7 N.m (1.5 kg-m, 11 ft-lb)
2. Install exhaust manifold in the numerical order as shown in the figure. NOTE: Tighten nuts No. 1 and No. 2 in two steps. The numerical order No. 7 and No. 8 shows second step.

Note. To remove oil pan (lower) only, take step 5 , then step 20 . Removal of step 1 , hood assembly (step 2 ) and step 4 are unnecessary.

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1. Remove front tire.
2. Remove hood assembly. Refer to HOOD .
3. Remove front and rear engine undercover with power tool.
4. Remove front cross bar with power tool. FRONT SUSPENSION ASSEMBLY .
5. Drain engine oil. Refer to CHANGING ENGINE OIL .
6. Drain engine coolant. Refer to CHANGING ENGINE COOLANT . CAUTION: Perform when engine is cold.
7. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
8. Remove air hose from air duct to mass air flow sensor side and electric throttle control actuator side. Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
9. Removal engine rear lower slinger, and install engine rear slinger to sling engine assembly for positioning. Refer to «SPECIAL SERVICE TOOLS»(ref-158850-S13570512012005020300000) . Slinger bolts: 28.0 N.m (2.9 kg-m, 21 ft-lb)
10. Remove front suspension member. Refer to FRONT SUSPENSION MEMBER .
11. Remove belt for alternator and power steering pump and A/C compressor. Refer to «DRIVE BELTS»(ref-158850-S01616040242005020300000) .
12. Remove alternator stay. Refer to «GENERATOR»(ref-166067-S04166173422004091000000) .
13. Remove starter motor. Refer to «REMOVAL & INSTALLATION»(ref-167750-S19717379932004102000000) .
14. Remove alternator and power steering pump and A/C compressor idler pulley and bracket assembly. Refer to «DRIVE BELTS»(ref-158850-S01616040242005020300000) .
15. Disconnect A/T fluid cooler hoses, and remove oil cooler water pipe mounting bolt. Refer to OIL COOLER .
16. Disconnect A/T fluid cooler tube.
17. Remove crankshaft position sensor (POS). CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
18. Remove oil filter, as necessary. Refer to OIL FILTER .
19. Remove oil cooler, as necessary. Refer to OIL COOLER .
20. Remove oil pan (lower) as the following: Loosen bolts in reverse order as shown in the figure to remove. Insert seal cutter (SST) between oil pan (upper) and oil pan (lower). Slide seal cutter (SST) by tapping on the side of tool with hammer. Remove oil pan (lower). CAUTION: Be careful not to damage the mating surface. Do not insert flat-bladed screwdriver, this will damage the mating surface.
21. Remove oil strainer.
22. Remove transmission joint bolts which pierce oil pan (upper). Refer to «REMOVAL AND INSTALLATION (2WD MODELS)»(ref-171001-S13768524782005012500000) .
23. Remove rear cover plate.
24. Loosen oil pan (upper) bolts with power tool in the reverse order of illustration to remove. Insert seal cutter [SST: KV10111100 (J37228)] between oil pan (upper) and 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 surface. Do not insert a screwdriver, this will damage the mating surfaces.
25. Remove O-rings from bottom of cylinder block and oil pump.
26. Remove oil pan gaskets.

Note. To remove oil pan (lower) only, take step 5, then step 24. Removal of step 1, hood assembly (step 2) and step 4 are unnecessary.

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1. Remove front tire.
2. Remove hood assembly. Refer to HOOD .
3. Remove front and rear engine undercover with power tool.
4. Remove front cross bar with power tool. Refer to «REMOVAL & INSTALLATION»(ref-166182-S14780889182004091500000) .
5. Drain engine oil. Refer to CHANGING ENGINE OIL .
6. Drain engine coolant. Refer to CHANGING ENGINE COOLANT . CAUTION: Perform when engine is cold.
7. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
8. Remove air hose from air duct to mass air flow sensor side and electric throttle control actuator side. Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
9. Remove belt for alternator and power steering pump and A/C compressor. Refer to «DRIVE BELTS»(ref-158850-S01616040242005020300000) .
10. Remove front drive shaft (LH and RH) and side shaft. Refer to FRONT DRIVE SHAFT .
11. Remove side shaft. Refer to FRONT FINAL DRIVE ASSEMBLY .
12. Removal engine rear lower slinger, and install engine rear slinger to sling engine assembly for positioning. Refer to «SPECIAL SERVICE TOOLS»(ref-158850-S13570512012005020300000) . Slinger bolts: 28.0 N.m (2.9 kg-m, 21 ft-lb)
13. Remove front suspension member. Refer to «FRONT SUSPENSION MEMBER»(ref-166182-S01650036442004091500000) .
14. Remove engine mounting bracket, engine mounting bracket (lower) and insulator. Refer to «ENGINE ASSEMBLY»(ref-158850-S37374893042005020300000) .
15. Remove front propeller shaft. Refer to FRONT PROPELLER SHAFT .
16. Remove oil filter and oil filter bracket. Refer to OIL FILTER BRACKET (AWD) .
17. Remove alternator stay. Refer to «GENERATORS & REGULATORS»(ref-166067) .
18. Remove alternator and power steering pump and A/C compressor idler pulley and bracket. Refer to «DRIVE BELTS»(ref-158850-S01616040242005020300000) .
19. Disconnect A/T fluid cooler hoses, and remove oil cooler water pipe mounting bolt. Refer to OIL COOLER .
20. Disconnect A/T fluid cooler tube.
21. Remove front final drive assembly. Refer to FRONT FINAL DRIVE ASSEMBLY .
22. Remove starter motor. Refer to «REMOVAL & INSTALLATION»(ref-167750-S19717379932004102000000) .
23. Remove crankshaft position sensor (POS). CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
24. Remove oil pan (lower) as the following: Loosen bolts in reverse order as shown in the figure to remove. Insert seal cutter (SST) between oil pan (upper) and oil pan (lower). Slide seal cutter (SST) by tapping on the side of tool with hammer. Remove oil pan (lower). CAUTION: Be careful not to damage the mating surface. Do not insert flat-bladed screwdriver, this will damage the mating surface.
25. Remove oil strainer.
26. Remove transmission joint bolts which pierce oil pan (upper). Refer to «REMOVAL AND INSTALLATION (AWD MODELS)»(ref-171001-S14766714062005012500000) .
27. Loosen oil pan (upper) bolts with power tool in the reverse order of illustration to remove. Insert seal cutter [SST: KV10111100 (J37228)] between oil pan (upper) and 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 surface. Do not insert a screwdriver, this will damage the mating surfaces.
28. Remove O-rings from bottom of cylinder block and oil pump.
29. Remove oil pan gaskets.
30. Remove axle pipe, as necessary. Remove axle pipe from oil pan (upper) using a suitable drift [37 mm (1.46 in)].

1. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
2. Remove air duct (for ignition coil of left bank side). Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
3. Move aside harness, harness bracket, and hoses located above ignition coil.
4. Disconnect harness connector from ignition coil.
5. Remove ignition coil. CAUTION: Do not shock it.

Install in the reverse order of removal.

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1. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
2. Remove ignition coil. Refer to «IGNITION COIL»(ref-158850-S36818243042005020300000) .
3. Remove spark plug with spark plug wrench (commercial service tool).

Install in the reverse order of removal.

REMOVAL AND INSTALLATION

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1. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000).
2. Release fuel pressure. Refer to FUEL PRESSURE RELEASE.
3. Remove fuel feed hose (with damper) from fuel sub-tube. NOTE: There is no fuel return route. CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate damper and hose.
4. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as the following: Remove quick connector cap from quick connector connection on right member side. Disconnect fuel feed hose (with damper) from bracket hose clamp. CAUTION: Disconnect quick connector by using quick connector release [SST:-(J-45488)], not by picking out retainer tabs. Disconnect quick connector from centralized under-floor piping as the following: With the sleeve side of quick connector release facing quick connector, install quick connector release onto centralized under-floor piping. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from centralized under-floor piping. CAUTION: Pull quick connector holding "A" position (Scheme 145) Do not 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. Do not expose parts to battery electrolyte or other acids. Do not 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 or something similar.
5. Remove intake manifold collector (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000).
6. Disconnect harness connector from fuel injector.
7. Loosen mounting bolts in the reverse order in the figure, and remove fuel tube and fuel injector assembly. CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
8. Remove spacers on intake manifold.
9. Remove fuel injector from fuel tube with following procedure. Open and remove clip. 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. Do not bump or drop fuel injectors. Do not disassemble fuel injectors.
10. Remove fuel sub-tube and fuel damper.

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1. Install fuel damper and fuel sub-tube. When handling O-rings, be careful of the following: CAUTION: Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure 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, do not insert it quickly into fuel tube. Insert O-ring straight into fuel tube. Do not decenter or twist it. Insert fuel damper and fuel sub-tube straight into fuel tube. Tighten mounting bolts evenly in turn. After tightening mounting bolts, make sure that there is no gap between flange and fuel tube.
2. Install O-rings to fuel injector paying attention to the items below. CAUTION: Upper and lower O-ring are different. Be careful not to confuse them. Fuel tube side : Blue Nozzle side : Brown Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure 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, do not insert it quickly into fuel tube. Insert O-ring straight into fuel tube. Do not decenter or twist it.
3. Install fuel injector to fuel tube with the following procedure. Insert clip into clip mounting groove on fuel injector. Insert clip so that lug "A" of fuel injector matches notch "A" of clip. CAUTION: Do not 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 with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that lug "B" of fuel tube matches notch "B" of clip. Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by checking that fuel injector does not rotate or come off.
4. Install spacers on intake manifold.
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 shown in 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 intake manifold collector (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
8. Install fuel sub-tube on rear end of intake manifold collector (lower).
9. 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, make sure that there is no gap between flange and fuel sub-tube.
10. Connect quick connector between fuel feed hose and centralized under-floor piping connection with the following procedure: Check the connection for damage and foreign materials. Align connector with tube, then insert connector straight into tube until a click is heard. After connecting quick connector, use the following method to make sure it is full connected. Visually confirm that the two retainer tabs are connected to connector. Pull tube and connector to make sure they are securely connected. Install quick connector cap to quick connector connection. Install quick connector cap with arrow on surface facing in direction of quick connector (fuel feed hose side). CAUTION: If cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again. Secure fuel feed hose to clamp.
11. Install in the reverse order of removal after this step.

Note. This section describes removal/installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on vehicle. When oil pan (upper) needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (upper and lower) first. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and install in reverse order of removal. Refer to TIMING CHAIN . Refer to TIMING CHAIN for component parts location.

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1. Place vehicle onto lift.
2. Disconnect negative battery terminal.
3. Remove engine cover with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
4. Remove air cleaner case assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-158850-S12244247462005020300000) .
5. Remove front and rear engine undercover with power tool.
6. Drain engine coolant from radiator. Refer to CHANGING ENGINE COOLANT .
7. Drain engine oil from oil pan. Refer to CHANGING ENGINE OIL .
8. Remove engine harnesses.
9. Remove intake manifold collector (upper and lower) with power tool. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-158850-S25261397642005020300000) .
10. Remove power steering oil pump from bracket with piping connected, and temporarily secure it aside. Refer to POWER STEERING OIL PUMP .
11. Remove power steering oil pump bracket. Refer to POWER STEERING OIL PUMP .
12. Remove alternator. Refer to «GENERATOR»(ref-166067-S04166173422004091000000) .
13. Remove water bypass hose, water hose clamp and idler pulley bracket and alternator and power steering oil pump and A/C compressor belt tensioner from front timing chain case.
14. Remove right and left intake valve timing control covers with power tool. Loosen bolts in reverse order as shown. Use seal cutter [SST: KV10111100 (J37228)] or an equivalent tool to cut liquid gasket for removal. CAUTION: Shaft is internally jointed with intake camshaft sprocket center hole. When removing, keep it horizontal until it is completely disconnected.
15. Remove collared O-ring from front timing chain case (left and right side).
16. Remove right and left rocker covers. Refer to «ROCKER COVER»(ref-158850-S25733701052005020300000) . NOTE: When secondary timing chain is not removed/installed, this step is not required.
17. Obtain compression TDC of No. 1 cylinder as follows: NOTE: When timing chain is not removed/installed, this step is not required. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator. Make sure intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown. If not, turn crankshaft one revolution (360°) and align as shown. NOTE: When only primary timing chain is removed, rocker cover does not need to be removed. To confirm that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets. Refer to «TIMING CHAIN»(ref-158850-S12050631142005020300000) .
18. Remove crankshaft pulley with the following procedure: Remove rear cover plate (2WD) or starter motor (AWD) and set ring gear stopper (SST) as shown in the figure. Refer to «REMOVAL & INSTALLATION»(ref-167750-S19717379932004102000000) . Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 in) from its original position. CAUTION: Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through. CAUTION: Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
19. Remove oil pan (lower). Refer to «OIL PAN AND OIL STRAINER»(ref-158850-S11058956642005020300000) .
20. Loosen two mounting bolts in front of oil pan (upper) with power tool in reverse order shown in figure.
21. Remove front timing chain case. Loosen mounting bolts with power tool in reverse order as shown. Insert suitable tool into the notch at the top of front timing chain case as shown (1). Pry off case by moving tool as shown (2). Use seal cutter [SST: KV10111100 (J37228)] or an equivalent tool to cut liquid gasket for removal. CAUTION: Do not use screwdrivers or something similar. After removal, handle it carefully so it does not tilt, cant, or warp under a load.
22. Remove O-rings from rear timing chain case.
23. Remove oil pan gasket front side.
24. Remove water pump cover and chain tensioner cover from front timing chain case. Use seal cutter [SST: KV10111100 (J37228)] or an equivalent tool to cut liquid gasket for removal.
25. Remove front oil seal from front timing chain case using a suitable tool. Use flat-bladed screwdriver for removal. CAUTION: Exercise care not to damage front timing chain case.
26. Remove timing chain and related parts. Refer to «TIMING CHAIN»(ref-158850-S12050631142005020300000) .
27. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces. CAUTION: Be careful not to allow gasket fragments to enter oil pan. Remove old liquid gasket from bolt hole and thread.
28. Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.

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Scheme 181

Scheme 182

Scheme 183

Scheme 184

1. Install timing chain and related parts. Refer to «TIMING CHAIN»(ref-158850-S12050631142005020300000).
2. Hammer dowel pins (left and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
3. Install front oil seal on front timing chain case. Apply new engine oil to the oil seal edges. Install it so that each seal lip is oriented as shown in the figure. Using suitable drift, press-fit oil seal until it becomes flush with front timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.
4. Install water pump cover and chain tensioner cover to front timing chain case. Apply liquid gasket to front timing chain case front side as shown with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
5. Install front timing chain case as follows: Apply liquid gasket to front timing chain case back side as shown with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Install oil pan gasket front side. Apply liquid gasket to oil pan gasket as shown with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Align notch of front timing chain case with protrusion of oil pan gasket. Apply liquid gasket to top surface of oil pan (upper) as shown in figure with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Install new O-rings on rear timing chain case. Assemble front timing chain case as follows. Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely. CAUTION: Be careful that oil pan gasket is in place. While pressing front timing chain case from its front and top as shown in figure, install bolts and temporarily tighten them. For bolt length and positions, refer to the step 6. Hammer dowel pin until the outer end becomes flush with surface.
6. Tighten bolts to the specified torque in order shown in the see scheme 8 mm (0.31 in) dia. bolts: 1, 2 28.4 N.m (2.9 kg-m, 21 ft-lb) 6 mm (0.24 in) dia. bolts: Except the above 12.7 N.m (1.3 kg-m, 9 ft-lb) After tightening, retighten them to specified torque in numerical order (Scheme 179)
7. Install two mounting bolts in front of oil pan (upper) in numerical order see scheme 172 N.m (1.8 kg-m, 13 ft-lb)
8. Install oil pan (lower). Refer to «OIL PAN AND OIL STRAINER»(ref-158850-S11058956642005020300000).
9. Install right and left intake valve timing control covers as follows: Install seal rings in shaft grooves. Apply liquid gasket to intake valve timing control covers with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Install collared O-ring in front timing chain case oil hole (left and right sides). Being careful not to move seal ring from the installation groove, align dowel pins on chain case with the holes to install intake valve timing control covers. Tighten bolts in the numerical order as shown. 11.3 N.m (1.2 kg-m, 8 ft-lb)
10. Install crankshaft pulley as follows: Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)]. Install crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). Tighten bolt. 44.1 N.m (4.5 kg-m, 33 ft-lb) Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by "60" degrees (equivalent to one graduation)].
11. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
12. For the following operations, perform steps in the reverse order of removal. NOTE: If hydraulic pressure inside chain tensioner drops after removal/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.

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

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

1. Install timing chain tensioners (secondary) to cylinder head as the following if removed. Refer to «INSTALLATION»(ref-158850-S41067908182005020300000). Install chain tensioners with stopper pin attached and new O-rings. Install No. 1 camshaft brackets. Refer to «INSTALLATION»(ref-158850-S41067908182005020300000).
2. Install new O-rings onto cylinder block.
3. Install new O-rings to cylinder head.
4. Apply liquid gasket to rear timing chain case back side as shown with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. CAUTION: For "A" in the figure, completely wipe out liquid gasket extended on a portion touching at engine coolant. Apply liquid gasket on installation position of water pump and cylinder head very completely.
5. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block and install case. Make sure O-rings stay in place during installation to cylinder block and cylinder head. Tighten mounting bolts in the numerical order as shown. There are two bolt lengths used. Follow the below for proper bolt length specifications. Bolt length/Bolt position: 20 mm (0.79 in): 1, 2, 3, 6, 7, 8, 9, 10 16 mm (0.63 in): Except the above: 12.7 N.m (1.3 kg-m, 9 ft-lb) After all bolts are temporarily tightened, retighten them to the specification in the numerical order as shown. If RTV Silicone Sealant protrudes, wipe it off immediately.
6. After installing rear timing chain case, check surface height difference between following parts on oil pan mounting surface. Standard (Rear timing chain case to cylinder block): - 0.24 to 0.14 mm (-0.0094 to 0.0055 in) If not within standard, repeat above installation procedure.
7. Position crankshaft so No. 1 piston is set at TDC on the compression stroke. Make sure that dowel pin hole, dowel pin and crankshaft key are located as shown. NOTE: Though camshaft does not stop at 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 hole (intake side): At cylinder head upper face side in each bank. Camshaft dowel pin (exhaust side): At cylinder head upper face side in each bank. Crankshaft key: At cylinder head side of right bank. CAUTION: Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big dia. side).
8. Install timing chains (secondary) and camshaft sprockets. CAUTION: Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process. Push plunger of secondary chain tensioner and keep it pressed in with a stopper pin. Install secondary timing chains and camshaft sprockets. Align the mating marks on secondary timing chain (gold link) with the ones on intake and exhaust camshaft sprockets (stamped), and install them. NOTE: Mating marks for intake camshaft sprocket are on the back side of secondary camshaft sprocket. There are two types of mating marks, circle and oval types. They should be used for the right and left banks, respectively. Right bank: use circle type. Left bank: use oval type. Align dowel pin and pin hole on camshaft with the groove and dowel pin on sprocket, and install them. On the intake side, align the pin hole on the small diameter side of camshaft front end with dowel pin on the back side of camshaft sprocket, and install them. On the exhaust side, align dowel pin on camshaft front end with the pin groove on camshaft sprocket, and install them. In case that positions of each mating mark and each dowel pin are not fit on mating 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. It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint.
9. After confirming the mating marks are aligned, tighten camshaft sprocket mounting bolts. Secure camshaft using a wrench at the hexagonal portion to tighten mounting bolts.
10. Pull stopper pins out from timing chain tensioners (secondary).
11. Install primary timing chain as follows: Install crankshaft sprocket. Make sure the mating marks on crankshaft sprocket face the front of engine. Install primary timing chain. Install primary timing chain so the mating mark (punched) on camshaft sprocket is aligned with the yellow link on timing chain, while the mating mark (notched) on crankshaft sprocket is aligned with the orange one on timing chain, as shown. When it is difficult to align mating marks of primary timing chain with each sprocket, gradually turn camshaft using a wrench on the hexagonal portion to align it with the mating marks. During alignment, be careful to prevent dislocation of mating mark alignments of secondary timing chains.
12. Install internal chain guide and timing chain tensioner (primary).
13. Install slack guide. CAUTION: Do not overtighten slack guide mounting bolts. It is normal for a gap to exist under the bolt seats when mounting bolts are tightened to specification.
14. Install chain tensioner for slack guide. When installing chain tensioner, push in sleeve and keep it pressed in with stopper pin. Remove any dirt and foreign materials completely from the back and the mounting surfaces of chain tensioner. After installation, pull out stopper pin by pressing slack guide.
15. Reconfirm that the mating marks on sprockets and timing chain have not slipped out of alignment.
16. Install new O-rings on rear timing chain case.
17. Install front oil seal on front timing chain case. Apply new engine oil to the oil seal edges. Install it so that each seal lip is oriented as shown in the figure. Using suitable drift, press-fit oil seal until it becomes flush with front timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.
18. Install water pump cover and chain tensioner cover to front timing chain case. Apply liquid gasket to front timing chain case front side as shown with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS.
19. Install front timing chain case as follows: Apply liquid gasket to front timing chain case back side as shown with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Install dowel pin on rear timing chain case into dowel pin hole on front timing chain case. Tighten bolts to the specified torque in order shown in the see scheme 8 mm (0.31 in) dia. bolts: 1, 2: 28.4 N.m (2.9 kg-m, 21 ft-lb) 6 mm (0.24 in) dia. bolts: Except the above: 12.7 N.m (1.3 kg-m, 9 ft-lb) After tightening, retighten them to specified torque in numerical order (Scheme 207)
20. After installing front timing chain case, check the surface height difference between the following parts on the oil pan mounting surface. Standard Front timing chain case to rear timing chain case: -0.14 to 0.14 mm (-0.005 to 0.0055 in) If not within specification, repeat the installation procedure.
21. Install right and left intake valve timing control covers as follows: Install seal rings in shaft grooves. Apply liquid gasket to intake valve timing control covers with tube presser [SST: WS39930000 (-)]. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Install collared O-ring in front cover engine oil hole (left and right sides). Being careful not to move seal ring from the installation groove, align dowel pins on chain case with the holes to install intake valve timing control covers. Tighten bolts in the numerical order as shown.
22. Install crankshaft pulley as follows: Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)]. Install crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). Tighten bolt. 44.1 N.m (4.5 kg-m, 33 ft-lb) Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by "60" degrees (equivalent to one graduation).
23. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
24. For the following operations, perform steps in the reverse order of removal. NOTE: If hydraulic pressure inside chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after engine start. However, this does not indicate an unusualness. Noise will stop after hydraulic pressure rises.

Valve Guide Replacement

When valve guide is removed, replaced with oversized (0.2 mm, 0.008 in) valve guide.

Scheme 213

Scheme 214

Scheme 215

Scheme 216

Scheme 217

Scheme 218

1. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or hammer and suitable tool. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
3. Using valve guide reamer, ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake and exhaust: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
5. Press valve guide from camshaft side to dimensions as in illustration. Projection "L" Intake and exhaust: 12.6 - 12.8 mm (0.496 - 0.504 in) CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
6. Using valve guide reamer, apply reamer finish to valve guide. Standard: Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Scheme 219

1. After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure.
2. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace valve seat.

Valve Seat Replacement

When valve seat is removed, replace with oversized (0.5 mm, 0.020 in) valve seat.

Scheme 220

Scheme 221

Scheme 222

Scheme 223

1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. CAUTION: Prevent scratching cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)] Intake: 38.500 - 38.516 mm (1.5157 - 1.5164 in) Exhaust: 32.700 - 32.716 mm (1.2874 - 1.2880 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head. CAUTION: Avoid directly touching cold valve seats. Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. CAUTION: When using valve seat cutter, firmly grip the 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. Grind to obtain the dimensions indicated. Standard: D1 dia.: 35 mm (1.38 in) *1 D2 dia.: 36.6 - 36.8 mm (1.441 - 1.449 in) *2 D3 dia.: 28.7 mm (1.130 in) *1 D4 dia.: 30.6 - 30.8 mm (1.205 - 1.213 in) *2 *1 : Diameter made by intersection point of conic angles 60° and 90° *2 : Diameter made by intersection point of conic angles 89.5° and 120°
6. Using compound, grind to adjust valve fitting.
7. Check for normal contact again.

Scheme 224

1. Set try square along the side of valve spring and rotate spring. Measure the maximum clearance between the top face of spring and try square. Limit: Less than 2.1 mm (0.083 in)
2. If it exceeds the limit, replace valve spring.

Scheme 225

1. Check the valve spring pressure at specified spring height. Standard: Intake and exhaust Free height: 47.07 mm (1.8531 in) Installation height: 37.0 mm (1.457 in) Installation load: 166 - 188 N (16.9 - 19.2 kg, 37.3 - 42.3 lb) Height during valve open: 27.2 mm (1.0709 in) Load with valve open: 373 - 421 N (38.0 - 42.9 kg, 83.9 - 94.6 lb)
2. If the installation load or load with valve open is out of the standard, replace valve spring.

Scheme 226

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 member mounting bolt.
3. Remove suspension member mounting bolt and nut. Refer to «FRONT»(ref-166182) .
4. Carefully lower jack to remove engine, transmission, and suspension member assembly. When performing work, observe the following: CAUTION: Confirm there is no interference with vehicle. Make sure all connection points have been disconnected. Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off lift.

Scheme 227

1. Install engine slingers into front of right bank cylinder head and rear ofleft bank cylinder head. Slinger bolts: 28.0 N.m (2.9 kg-m, 21 ft-lb)
2. Remove power steering oil pump from engine side. Refer to POWER STEERING OIL PUMP .
3. Remove engine mounting insulator under side nut with power tool.
4. Lift with hoist and separate engine and transmission assembly from suspension member. CAUTION: Before and during this lifting, always check if any harnesses are left connected. Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator. Refer to «GENERATOR»(ref-166067-S04166173422004091000000) .
6. Remove starter motor. Refer to «REMOVAL & INSTALLATION»(ref-167750-S19717379932004102000000) .
7. Separate engine from transmission assembly. Refer to «REMOVAL & INSTALLATION»(ref-171001) .
8. Remove engine mounting insulator and bracket with power tool.

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

Scheme 228

Scheme 229

1. For a location with a positioning pin, insert it securely into hole of mating part.
2. For a part with a specified installation orientation (Scheme 226)
3. When installing engine mounting bracket on cylinder block, tighten two upper bolts (shown as A in figure) first. Then tighten two lower bolts (shown as B in figure). (LH and RH sides)
4. Tighten rear member mounting bolts in numerical order shown in figure.

Scheme 230

1. Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than required quantity, fill to the specified level.
2. 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 leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid, fuel and exhaust gas.
5. Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
6. After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to specified level, if necessary.
7. Summary of the inspection items

Scheme 231

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

Scheme 232

Scheme 233

1. For a location with a positioning pin, insert it securely into hole of mating part.
2. For a part with a specified installation orientation see scheme 276
3. When installing engine mounting bracket on cylinder block, tighten two upper bolts (shown as A in figure) first Then tighten two lower bolts (shown as B in (Scheme 233) and (Scheme 234) ). (LH and RH sides)
4. Install engine mounting bracket (lower) paying attention to the following. a. Temporarily tighten mounting bolts (shown as C, D and E in (Scheme 234) ). b. Tighten mounting bolts to the specified torque with following mounting surfaces touched.
5. Engine mounting bracket to engine mounting bracket (lower) (shown as C and D in figure).
6. Front final drive to engine mounting bracket (lower) (shown as E in figure).

Scheme 234

1. Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than required quantity, fill to the specified level.
2. 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 leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid, fuel and exhaust gas.
5. Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
6. After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to specified level, if necessary.
7. Summary of the inspection items

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

1. Remove engine assembly from vehicle, and separate transmission from engine. Refer to «ENGINE ASSEMBLY»(ref-158850-S37374893042005020300000) .
2. Remove engine mounting bracket. Refer to «ENGINE ASSEMBLY»(ref-158850-S37374893042005020300000) .
3. Remove RH side exhaust manifold. Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-158850-S21791013992005020300000) .
4. Install engine sub-attachment with engine stand shaft (SST) to right side of cylinder block. Use spacer to engine rear side.
5. Lift engine, and mount it onto engine stand (SST). A commercial engine stand can be used. CAUTION: Use an engine stand that has a load capacity [approximately 220 kg (441 1b) or more] large enough for supporting the engine weight.
6. Drain engine oil. Refer to CHANGING ENGINE OIL .
7. Drain engine coolant by removing water drain plugs from cylinder block both sides at "B" and "C" and cylinder block front side at "A" as shown in the figure.
8. Remove cylinder head. Refer to «CYLINDER HEAD»(ref-158850-S04725185252005020300000) .
9. Remove knock sensor. CAUTION: Carefully handle sensor avoiding shocks.
10. Remove drive plate with power tool. Fix crankshaft with a ring gear stopper [SST: KV1011770 (J44716)], and remove mounting bolts. Loosen mounting bolts in diagonal order. CAUTION: Do not disassemble drive plate. Never place drive plate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized.
11. Remove pilot converter using pilot bushing puller (SST) or suitable tool as necessary.
12. Use a seal cutter (SST) to cut away liquid gasket and remove rear oil seal retainer. CAUTION: Be careful not to damage mounting surface. If rear oil seal retainer is removed, replace it with a new one. NOTE: Rear oil seal and retainer make up a single part and are removed as an assembly.
13. Remove baffle plate from main bearing beam (2WD model).
14. Remove piston and connecting rod assembly. Before removing piston and connecting rod assembly, check connecting rod side clearance. Refer to «CONNECTING ROD SIDE CLEARANCE»(ref-158850-S22913513872005020300000) . Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to cylinder head side.
15. Remove connecting rod bearings from connecting rod and connecting rod cap. CAUTION: When removing them, note the installation position. Keep them in the correct order.
16. Remove piston rings from piston. Use a piston ring expander (commercial service tool). CAUTION: When removing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expanding them excessively.
17. Remove piston from connecting rod as follows. Using a snap ring pliers, remove snap ring. Heat piston to 60 to 70°C (140 to 158°F) with industrial use drier or equivalent. Push out piston pin with stick of outer diameter approximately 20 mm (0.79 in).
18. Remove main bearing cap bolt. NOTE: Use TORX socket (size E14). Before loosening main bearing cap bolts, measure crankshaft end play. Refer to «CRANKSHAFT END PLAY»(ref-158850-S25349835442005020300000) . Loosen them in the numerical order shown in the figure in several different steps.
19. Remove main bearing beam.
20. Remove main bearing cap. Using main bearing cap bolts, remove main bearing cap while shaking it back-and-forth.
21. Remove crankshaft.
22. Remove main bearings and thrust bearings from cylinder block and main bearing cap. CAUTION: Identify installation positions, and store them without mixing them up.
23. Remove oil jet.

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

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 water drain plug to cylinder block as shown in the figure. Apply liquid gasket to the thread of water drain plugs. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Water drain plug (front) "A": 9.8 N.m (1.0 kg-m, 87 in-lb) Water drain plug (RH) "B": 19.6 N.m (2.0 kg-m, 14 ft-lb) Water drain plug (LH) "C": 19.6 N.m (2.0 kg-m, 14 ft-lb)
3. Install each plug to cylinder block (Scheme 252)if removed. Apply liquid gasket to the thread of plugs and install plugs with new gaskets. Use Genuine High Strength Thread Locking Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Plug (RH) "D": 12.3 N.m (1.3 kg-m, 9 ft-lb) Plug (rear) "E": 62 N.m (6.3 kg-m, 46 ft-lb) Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. Plug (LH) "F": 62 N.m (6.3 kg-m, 46 ft-lb)
4. Install oil jet. Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten mounting bolts.
5. Install main bearings and thrust bearings. Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block and main bearing cap. Install thrust bearings to the both sides of No. 3. journal housing on cylinder block and main bearing cap. Install thrust bearings with the oil groove facing to the crankshaft arm (outside). Install bearing with a projection on one end on cylinder block, and bearing with a projection at center on cap. Align each projection with mating notch. Install main bearings paying attention to the direction. Main bearing with an oil hole and groove goes on cylinder block. The one without them goes on main bearing cap. Before installing bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align the bearing stopper to the notch. Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
6. Install crankshaft to cylinder block. While turning crankshaft by hand, make sure it turns smoothly.
7. Install main bearing cap. Main bearing caps are identified by identification mark cast on them. For installation, face front mark to front side. NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
8. Install main bearing beam. Install main bearing beam with front mark facing downward (oil pan side). Install main bearing beam with front mark facing front of engine.
9. Inspect outer diameter of main bearing cap bolt. Refer to «MAIN BEARING CAP BOLT OUTER DIAMETER»(ref-158850-S06166146432005020300000).
10. Install main bearing cap bolt. Apply new engine oil to threads and seat surfaces of mounting bolts. Tighten bolts in numerical order with tightening torque in several different steps. 35.3 N.m (3.6 kg-m, 26 ft-lb) Turn all bolts another "90" degrees clockwise (Angle tightening). CAUTION: Use an angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection. After installing mounting bolts, make sure that crankshaft can be rotated smoothly by hand. Check crankshaft end play. Refer to «CRANKSHAFT END PLAY»(ref-158850-S25349835442005020300000).
11. Inspect outer diameter of connecting rod bolt. Refer to «CONNECTING ROD BOLT OUTER DIAMETER»(ref-158850-S00146933942005020300000).
12. Install piston to connecting rod. Using a snap ring pliers (commercial service tool), install a new snap ring to the groove of the piston rear side. Insert it fully into groove to install. Install piston to connecting rod. Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approx. 60 to 70 °C (140 to 158 °F)]. From the front to the rear, insert piston pin into piston and connecting rod. Assemble so that the front mark on the piston crown and the cylinder number on connecting rod are positioned as shown in the figure. Install a new snap ring to the groove of the piston front side. Insert it fully into groove to install. After installing, make sure connecting rod moves smoothly.
13. Using a piston ring expander (commercial service tool), install piston rings. CAUTION: Be careful not to damage piston. If there is stamped mark on ring, mount it with marked side up. NOTE: If there is no stamp on ring, no specific orientation is required for installation. Stamped mark: Top ring: - Second ring: "R" Position each ring with the gap as shown in the figure refering to the piston front mark.
14. Install connecting rod bearings to connecting rod and connecting rod cap. When 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. When installing, align connecting rod bearing stopper protrusion with the cutout of connecting rod to install. Check the oil hole on connecting rod and that on the corresponding bearing are aligned.
15. Install piston and connecting rod assembly to crankshaft. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. Apply engine oil sufficiently to cylinder bore, piston and crankshaft pin. Match cylinder position with the cylinder number on connecting rod to install. Using a piston ring compressor (SST) or suitable tool, install piston with the front mark on the piston crown facing the front of engine. CAUTION: Be careful not to damage cylinder wall and crankshaft pin, resulting from an interference of connecting rod big end.
16. Install connecting rod cap. Match the stamped cylinder number marks on connecting rod with those on cap to install. Be sure that front mark on connecting rod cap is facing front of engine.
17. Tighten connecting rod bolt as follows. Apply engine oil to the threads and seats of connecting rod bolts. Tighten bolts. 19.6 N.m (2.0 kg-m,14 ft-lb) Then tighten all bolts "90" degrees clockwise (Angle tightening). CAUTION: Always use an angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone. After tightening bolt, make sure that the crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to «CONNECTING ROD SIDE CLEARANCE»(ref-158850-S22913513872005020300000).
18. Install baffle plate to main bearing beam.
19. Install rear oil seal retainer to cylinder block. Apply new engine oil to the oil and dust seal lips. Apply liquid gasket to rear oil seal retainer using tube presser [SST: WS39930000 (-)] as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS. CAUTION: Replace with the new parts. NOTE: Rear oil seal with rear oil seal retainer.
20. Install pilot converter using suitable tool. Outer diameter of drift. Pilot converter: Approx. 33 mm (1.30 in) Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure.
21. Install drive plate. Install drive plate and reinforcement plate as shown in figure. Secure crankshaft using a ring gear stopper [SST: KV1011770 (J44716)]. Tighten the installation bolts crosswise over several times.
22. Install knock sensor. Install knock sensor so that connector faces front of engine. After installing knock sensor, connect harness connector, and lay it out to rear of engine. CAUTION: Do not tighten mounting bolts while holding connector. If any impact by dropping is applied to knock sensor, replace it with new one. NOTE: Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Make sure that knock sensor does not interfere with other parts.
23. Install following in reverse order of removal.

Scheme 271

1. The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts.
2. For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the measurement with the values of each selection table.
3. 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.