Engine Mechanical (VK45DE): Removal & Installation Infiniti FX45 I рестайлинг

Precautions for 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. 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 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 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. Guide pins are used for several parts alignment. When replacing and reassembling parts with guide pins, make sure that guide pins are installed in the original portion.
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 engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

REMOVAL

1. Major parts and inspection points under each cover are as follows; (numbered as in the figure) Upper side of engine assembly and power steering reservoir tank Relay and battery Engine assembly front side, drive belts and cooling fan

INSTALLATION

Install in the reverse order of removal.

Scheme 39

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

Scheme 40

1. Remove air duct (inlet). Refer to " «AIR CLEANER AND AIR DUCT»(ref-282589-S15320710262008040500000) ".
2. Remove front engine undercover with power tool.
3. Remove drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-282589-S19799211382008040500000) ". Keep auto tensioner pulley arm locked after belt is removed.
4. Remove auto tensioner and idler pulley with power tool. Keep auto tensioner pulley arm locked to install or remove auto tensioner. CAUTION: Do not loosen the hexagonal part in center of drive belt auto-tensioner pulley (Do not turn it clockwise). If turned clockwise, the complete drive belt auto-tensioner must be replaced as a unit, including the pulley.

Install in the reverse order of removal.

Scheme 41

1. Refer to " «COMPONENTS»(ref-282577-S24063487152008040500000) " for symbol marks in the figure.

1. Remove engine cover with power tool. Refer to " «ENGINE ROOM COVER»(ref-282589-S28193856052008040500000) ".
2. Disconnect harness connector from mass air flow sensor.
3. Disconnect vacuum hose and PCV hose.
4. Remove air duct (inlet), power duct, air cleaner case and mass air flow sensor assembly, air duct and resonator assembly disconnecting their joints. Add marks as necessary for easier installation.
5. Remove mass air flow sensor from air cleaner case. CAUTION: Handle mass air flow sensor with following cares. Do not shock it. Do not disassemble it.

1. Do not touch its sensor.

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

1. Align marks. Attach each joint. Screw clamps firmly.

1. Remove air duct (inlet), power duct, air cleaner case and mass air flow sensor assembly.
2. Remove air cleaner filter from air cleaner case.

Install in the reverse order of removal.

Scheme 42

1. Refer to " «COMPONENTS»(ref-282577-S24063487152008040500000) " for symbol marks in the figure.

Scheme 43

Scheme 44

Scheme 45

Scheme 46

1. Remove engine cover with power tool.
2. Release fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-282582-S37014521492008040500000) ".
3. Remove air duct (inlet), power duct, air cleaner case and air duct and resonator assembly. Refer to " «AIR CLEANER AND AIR DUCT»(ref-282589-S15320710262008040500000) ".
4. Drain engine coolant from radiator. Refer to " «DRAINING ENGINE COOLANT»(ref-282602-S12763491742008040500000) ". CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belts.
5. Disconnect fuel feed hose quick connector on engine side. Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-282589-S29083167252008040500000) ".
6. Remove fuel damper and fuel hose assembly. Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-282589-S29083167252008040500000) ". CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate fuel damper and fuel hose.
7. Remove or disconnect harnesses, engine cover bracket (RH and LH), vacuum hose, EVAP tube and hose and PCV hose and tube from intake manifold (upper).
8. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (upper) with power tool. <-- : Engine front
9. Remove electric throttle control actuator as follows: Disconnect harness connector. Loosen mounting bolts diagonally. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Do not disassemble.
10. Remove fuel injector and fuel tube assembly. Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-282589-S29083167252008040500000) ".
11. Disconnect water hoses from intake manifold adaptor.
12. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (lower) with power tool. <-- : Engine front
13. Remove intake manifold adaptor from intake manifold (lower).
14. Remove intake manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 47

1. Check the surface distortion of both the intake manifold (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 manifolds (lower and/or upper).

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

Scheme 48

Scheme 49

Scheme 50

1. Remove engine cover with power tool. Refer to " «ENGINE ROOM COVER»(ref-282589-S28193856052008040500000) ".
2. Remove front and rear engine undercovers with power tool.
3. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly. Refer to " «AIR CLEANER AND AIR DUCT»(ref-282589-S15320710262008040500000) ".
4. Remove front cross bar. Refer to " «FRONT SUSPENSION ASSEMBLY»(ref-282592-S12182459512008040500000) ".
5. Drain engine coolant from radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-282602-S27107886192008040500000) ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
6. Remove radiator. Refer to " «RADIATOR»(ref-282602-S11575308512008040500000) ".
7. Remove drive belts. Refer to " «DRIVE BELTS»(ref-282589-S19760269682008040500000) ".
8. Remove air fuel ratio sensor 1 and heated oxygen sensor 2 as follows: Disconnect air fuel ratio sensor 1 and heated oxygen sensor 2 harness connectors. Remove air fuel ratio sensor 1 and heated oxygen sensor 2 on both bank with heated oxygen sensor wrench (SST). CAUTION: Be careful not to damage air fuel ratio sensor 1 and heated oxygen sensor 2. Discard any air fuel ratio sensor 1 and heated oxygen sensor 2 which have been dropped onto a hard surface such as a concrete floor: replace with a new one.
9. Remove exhaust mounting bracket between three way catalysts (right and left bank) and transmission. Refer to " «EXHAUST SYSTEM»(ref-282587-S06618524512008040500000) ".
10. Disconnect A/C piping from A/C compressor, then remove A/C compressor with power tool. Refer to " «COMPONENTS»(ref-282599-S01777336322008040500000) ".
11. Remove alternator and bracket. Refer to " «CHARGING SYSTEM»(ref-282594-S19747209432008040500000) ".
12. Remove exhaust front tube with power tool. Refer to " «EXHAUST SYSTEM»(ref-282587-S06618524512008040500000) ".
13. Remove steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «POWER STEERING GEAR AND LINKAGE»(ref-282598-S22927323182008040500000) ".
14. Remove three way catalysts (right and left bank).
15. Remove exhaust manifold covers. (right and left bank)
16. Loosen mounting nuts in reverse order as shown in the figure to remove exhaust manifold. Left bank Right bank <-- : Engine front NOTE: Disregard the numerical order No. 9 to 12 in removal.
17. Remove exhaust manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 51

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

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

Scheme 52

Scheme 53

1. Remove front road wheels and tires.
2. Remove hood assembly. Refer to " «HOOD»(ref-282591-S25367663642008040500000) ".
3. Remove engine cover with power tool. Refer to " «ENGINE ROOM COVER»(ref-282589-S28193856052008040500000) ".
4. Remove front and rear engine undercovers with power tool.
5. Drain engine oil. Refer to " «CHANGING ENGINE OIL»(ref-282603-S07652170962008040500000) ". CAUTION: Perform this step when engine is cold. Do not spill engine oil on drive belts.
6. Drain engine coolant. Refer to " «CHANGING ENGINE COOLANT»(ref-282602-S27107886192008040500000) ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
7. Remove drive belts. Refer to " «DRIVE BELTS»(ref-282589-S19760269682008040500000) ".
8. Remove auto tensioner of power steering oil pump belt. Refer to " «DRIVE BELT AUTO TENSIONER AND IDLER PULLEY»(ref-282589-S33051603782008040500000) ".
9. Remove power steering oil pump with piping connected, and temporarily secure it aside with ropes or equivalent. Refer to " «POWER STEERING OIL PUMP»(ref-282598-S16768411232008040500000) ".
10. Remove A/C compressor with piping connected, and temporarily secure it aside with ropes or equivalent. Refer to " «COMPONENTS»(ref-282599-S01777336322008040500000) ".
11. Remove A/C compressor fitting bolts, and install A/C compressor temporarily on vehicle side with ropes or equivalent.
12. Remove harness of lower side of oil pan.
13. Remove crankshaft position sensor (POS) from transmission. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble it. 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.
14. Install engine slinger and hang engine assembly to secure position. Refer to " «ENGINE ASSEMBLY»(ref-282589-S34866902322008040500000) ".
15. Remove front suspension member with power tool. Refer to " «FRONT SUSPENSION MEMBER»(ref-282592-S18073365372008040500000) ".
16. Remove front final drive assembly. Refer to " «FRONT FINAL DRIVE ASSEMBLY»(ref-282597-S25934875392008040500000) ".
17. Remove oil filter. Refer to " «OIL FILTER»(ref-282603-S24514704202008040500000) ".
18. Disconnect oil cooler water hoses, and remove oil cooler water pipe and oil cooler. Refer to " «OIL COOLER»(ref-282603-S11740715032008040500000) ".
19. Remove oil pan as the follows: Remove rear plate cover. Remove transmission joint bolts which pierce oil pan. Refer to " «REMOVAL AND INSTALLATION (AWD MODELS)»(ref-282595-S01027442092008040500000) ". Loosen mounting bolts with power tool in reverse order as shown in the figure. NOTE: Disregard the numerical order No. 11 and 17 in removal. Insert seal cutter (SST) between oil pan and cylinder block. Slide seal cutter by tapping on the side of seal cutter with hammer. Remove oil pan. CAUTION: Be careful not to damage the mating surfaces. Do not insert screwdriver, this will damage the mating surface. Remove O-rings from bottom of oil pump and front cover.
20. As necessary, pull axle pipe from oil pan. Hold pipes and pull them out to front drive shaft (left) installing side.
21. Remove oil strainer.

1. Remove engine cover with power tool. Refer to " «ENGINE ROOM COVER»(ref-282589-S28193856052008040500000) ".
2. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, air duct and resonator assembly. Refer to " «AIR CLEANER AND AIR DUCT»(ref-282589-S15320710262008040500000) ".
3. Disconnect harness connector from ignition coil.
4. Remove ignition coil. CAUTION: Do not shock it.

Install in the reverse order of removal.

Scheme 54

Scheme 55

1. Remove engine cover with power tool. Refer to " «ENGINE ROOM COVER»(ref-282589-S28193856052008040500000) ".
2. Remove ignition coil. Refer to " «IGNITION COIL»(ref-282589-S07813610022008040500000) ".
3. Remove spark plug with spark plug wrench (commercial service tool). CAUTION: Do not drop or shock it.

Install in the reverse order of removal.

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

1. Remove engine cover with power tool. Refer to " «INTAKE MANIFOLD»(ref-282589-S04505163712008040500000) ".
2. Release fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-282582-S37014521492008040500000) ".
3. Disconnect fuel feed hose on engine side as follows: (Perform same procedure for the side of centralized under-floor piping as well.) Remove quick connector cap from quick connector connection. Disconnect quick connector from fuel feed damper as follows: CAUTION: Disconnect quick connector by using quick connector release [SST: J-45488], not by picking out retainer tabs (centralized under-floor piping side). With the sleeve side of quick connector release facing to quick connector, install quick connector release onto fuel tube. ii. 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 fuel feed damper. CAUTION: Pull quick connector holding "A" position as shown in the figure. 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 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.
4. Disconnect fuel damper and fuel hose assembly from fuel tubes (RH and LH). CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate fuel damper and fuel hose.
5. Remove intake manifold (upper) with power tool. Refer to " «INTAKE MANIFOLD»(ref-282589-S04505163712008040500000) ".
6. Disconnect harness connector from fuel injector.
7. Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly. Right bank Left bank <-- : Engine front CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
8. Remove spacers on intake manifold (lower).
9. Remove fuel injector from fuel tube as follows: 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 injector. Do not disassemble fuel injector.
10. Remove fuel feed damper.

Scheme 61

Scheme 62

1. Install fuel feed damper. When handling new O-rings, be careful of the following caution. CAUTION: Handle O-ring with bare hands. Do not 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 new O-ring straight into fuel tube. Do not decenter or twist it. Insert fuel feed damper straight into fuel tube (RH). Tighten mounting bolts evenly in turn. After tightening mounting bolts, make sure that there is no gap between flange and fuel tube (RH).
2. Install new O-rings to fuel injector paying attention to the following caution. CAUTION: Upper and lower O-ring are different. Be careful not to confuse them. Fuel tube side : Black Nozzle side : Green Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. 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 injector. Do not decenter or twist it.
3. Install fuel injector to fuel tube as follows: Insert clip into clip mounting groove on fuel injector. Insert clip so that "protrusion A" of fuel injector matches "cutout 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 "protrusion B" of fuel tube matches "cutout 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. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
4. Install spacers on intake manifold (lower).
5. Install fuel tube and fuel injector assembly to intake manifold (lower). 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. Right bank Left bank <-- : Engine front 1st step : 10.1 N.m (1.0 kg-m, 7 ft-lb) 2nd step : 23.5 N.m (2.4 kg-m, 17 ft-lb)
6. Connect fuel feed hose on engine side as follows: (Unless otherwise indicated, the installation to the engine side and centralized under-floor piping side is exactly alike.) Make sure no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them. Thinly apply new engine oil around fuel tube from tip end to spool end. Align center to insert quick connector straightly into fuel tube. Engine side: Insert fuel tube into quick connector until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector. CAUTION: Hold "A" position as shown in the figure when inserting fuel tube into quick connector. 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. Centralized under-floor piping side: Visually confirm that the two retainer tabs are connected to the 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. Make sure it is completely engaged (connected) so that it does not come out from fuel tube. Install quick connector cap on quick connector connection. CAUTION: If cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again. Install fuel feed hose to hose clamps.
7. Install in the reverse order of removal after this step.

1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.
2. Install front oil seal. Install front oil seal so that each seal lip is oriented as shown in the figure. Using front oil seal drift, press fit until the height of front oil seal is level with the mounting surface. Front oil seal drift Outer diameter : 56 mm (2.20 in) Inner diameter : 49 mm (1.93 in) Make sure the garter spring is in position and seal lips not inverted. CAUTION: Be careful not to damage front cover and oil pump drive spacer. Press fit straight and avoid causing burrs or tilting oil seal.
3. Install in the reverse order of removal.

Scheme 63

1. Remove transmission (with transfer) assembly. Refer to " «TRANSMISSION ASSEMBLY»(ref-282595-S19775561112008040500000) ". Remove drive plate. Refer to " «CYLINDER BLOCK»(ref-282589-S37301627352008040500000) ". Remove engine rear plate. Refer to " «CYLINDER BLOCK»(ref-282589-S37301627352008040500000) ".
2. Remove rear oil seal using suitable tool. CAUTION: Be careful not to damage crankshaft and oil seal retainer surface.

1. Apply new engine oil to both oil seal lip and dust seal lip of new rear oil seal.
2. Install rear oil seal. Install rear oil seal so that each seal lip is oriented as shown in the figure. Using rear oil seal drift (commercial service tool), press fit until the height of front oil seal is level with the mounting surface. Rear oil seal drift Outer diameter : 102 mm (4.02 in) Inner diameter : 86 mm (3.39 in) Make sure the garter spring is in position and seal lips not inverted. CAUTION: Be careful not to damage crankshaft and rear oil seal retainer. Press fit straight and avoid causing burrs or tilting oil seal.
3. Install in the reverse order of removal.

Scheme 64

Scheme 65

Scheme 66

1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-282582-S37014521492008040500000) ". Remove fuel pump fuse to avoid fuel injection during measurement.
3. Remove engine cover with power tool. Refer to " «ENGINE ROOM COVER»(ref-282589-S28193856052008040500000) ".
4. Remove ignition coil and spark plug from each cylinder. Refer to " «IGNITION COIL»(ref-282589-S07813610022008040500000) " and " «SPARK PLUG (PLATINUM-TIPPED TYPE)»(ref-282589-S40861794772008040500000) ".
5. Connect engine tachometer (not required in use of CONSULT-II).
6. Install compression gauge with adapter (SST or commercial service tool) onto spark plug hole. Use compression gauge adapter (SST) which is required on No. 7 and 8 cylinders. Use compression gauge adapter (if no SST is used) whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.
7. With accelerator pedal fully depressed, turn ignition switch to "START" for cranking. When the gauge pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cylinder. Compression pressure: Unit: kPa (kg/cm 2 , psi) /rpm CYLINDER HEAD COMPRESSION PRESSURE Standard Minimum Deferential limit between cylinders 1,320 (13.5, 191) / 300 1,130 (11.5, 164) / 300 98 (1.0, 14) / 300 CAUTION: Always use a fully changed battery to obtain the specified engine speed. If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine speed again with normal battery gravity. If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure compression pressure again. If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. If the added engine oil improves the compression, piston rings may be worn out or damaged. Check the piston rings and replace if necessary. If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly. If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cylinder head gaskets.
8. After inspection is completed, install removed parts in the reverse order of removal.
9. Start engine, and make sure that engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to " «TROUBLE DIAGNOSIS»(ref-282582-S39830098662008040500000) ".

Scheme 67

Scheme 68

1. Remove engine assembly from vehicle. Refer to " «ENGINE ASSEMBLY»(ref-282589-S34866902322008040500000) ".
2. Remove exhaust manifold. Refer to " «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-282589-S27600616152008040500000) ".
3. Remove camshaft. Refer to " «CAMSHAFT»(ref-282589-S25024815792008040500000) ".
4. Remove cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool) to remove cylinder heads (right and left banks).
5. Remove cylinder head gaskets.

Scheme 69

1. Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between "d1" and "d2" exceeds the limit, replace them with new one. Limit ("d1" - "d2") : 0.18 mm (0.0071 in)
2. If reduction of outer diameter appears in a position other than "d2", use it as "d2" point.

VALVE GUIDE REPLACEMENT

When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide.

Scheme 70

Scheme 71

Scheme 72

Scheme 73

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 valve guide drift (commercial service tool). CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
3. Using valve guide reamer (commercial service tool), 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. Using valve guide drift (commercial service tool), press valve guide from camshaft side to the dimensions as in the figure. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
6. Using valve guide reamer (commercial service tool), apply reamer finish to valve guide. Standard: Intake and exhaust : 6.000 - 6.018 mm (0.2362 - 0.2369 in)

VALVE SEAT REPLACEMENT

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

Scheme 74

Scheme 75

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. Refer to " «VALVE SEAT»(ref-282589-S01071128572008040500000) ". CAUTION: Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)] Intake : 37.500 - 37.516 mm (1.4764 - 1.4770 in) Exhaust : 32.700 - 32.716 mm (1.2874 - 1.2880 in) Be sure to ream in circles concentric to 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. Refer to " «VALVE SEAT»(ref-282589-S01071128572008040500000) ". CAUTION: When using valve seat cutter, firmly grip cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on with cutter or cutting many different times may result in stage valve seat.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to " «VALVE SEAT CONTACT»(ref-282589-S10940321882008040500000) ".

Removal and Installation

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

Scheme 76

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 " «REMOVAL AND INSTALLATION»(ref-282589-S15623501712008040500000) ".
4. When installing engine mounting brackets (RH and LH) on cylinder block, tighten two upper bolts (shown as "A" in the figure) first. Then tighten two lower bolts (shown as "B" in the figure).