Engine Mechanical (VK45DE): Removal & Installation Infiniti M45 III рестайлинг

Precaution 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.

Precaution 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, check that guide pins are installed in the original position.
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. Refer to " «REMOVAL AND INSTALLATION»(ref-356271-S00500245662010021300000) " for removal and installation of engine cover.
2. Refer to «AIR CLEANER AND AIR DUCT»(ref-356271-S05926562162010021300000) for removal and installation of air duct (inlet).
3. Remove the washer tank cap before removing the engine room cover (RH).
4. Remove the engine room covers (RH and LH) by lifting the clipped point using a clip driver.
5. Major parts and inspection points under each cover are as follows: (numbered as in the figure)

1. Upper side of engine assembly
2. Battery, relay box
3. Power steering fluid reservoir tank, engine coolant reservoir tank, relay box
4. Engine assembly front side, drive belts, cooling fan
5. Mass air flow sensor, air cleaner case
6. Brake master cylinder, brake booster

INSTALLATION

Install in the reverse order of removal.

Scheme 33

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

Scheme 34

1. Remove air duct (inlet). Refer to «AIR CLEANER AND AIR DUCT»(ref-356271-S05926562162010021300000) .
2. Remove front engine undercover with power tool.
3. Remove drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-356271-S17986762942010021300000) ". 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: Never loosen the hexagonal part in center of drive belt auto tensioner pulley (Never 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 35

1. Refer to " «COMPONENT»(ref-356247-S34736249572010021300000) " for symbols in the figure.

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

1. Remove engine room cover (RH and LH). Refer to «ENGINE ROOM COVER»(ref-356271-S37574715152010021300000) .
2. Disconnect harness connector from mass air flow sensor.
3. Disconnect vacuum hose and PCV hose.
4. Remove air duct (inlet), air cleaner case and mass air flow sensor assembly, and air duct and resonator assembly disconnecting their joints. Add marks if necessary for easier installation.
5. Remove mass air flow sensor from air cleaner case if necessary. CAUTION: Handle mass air flow sensor with following cares. Never shock mass air flow sensor. Never disassemble mass air flow sensor. Never touch the sensor of the mass air flow sensor.
6. Remove resonator in fender lifting front fender protector (LH). Refer to «FENDER PROTECTOR»(ref-356266-S36452496202010021300000) .

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

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

Scheme 36

Scheme 37

1. Remove engine room cover (LH). Refer to «ENGINE ROOM COVER»(ref-356271-S37574715152010021300000) .
2. Unhook clips (1).
3. Remove holder and air cleaner filter assembly (2) from air cleaner case (1).

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

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

Scheme 38

1. Refer to " «COMPONENT»(ref-356247-S34736249572010021300000) " for symbols in the figure.

Scheme 39

Scheme 40

Scheme 41

Scheme 42

1. Remove engine room cover (RH and LH). Refer to «ENGINE ROOM COVER»(ref-356271-S37574715152010021300000) .
2. Remove engine cover with power tool.
3. Release fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-356273-S25956159722010021300000) ".
4. Remove air duct (inlet), air cleaner case, and air duct and resonator assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-356271-S05926562162010021300000) .
5. Drain engine coolant from radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-356272-S21215035982010021300000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belts.
6. Disconnect fuel feed hose quick connector (1) on engine side. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-356271-S29172768122010021300000) .
7. Remove fuel damper and fuel hose assembly. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-356271-S29172768122010021300000) . CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Never separate fuel damper and fuel hose.
8. 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).
9. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (upper) with power tool.
10. 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. Never disassemble.
11. Remove fuel injector and fuel tube assembly. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-356271-S29172768122010021300000) .
12. Disconnect water hoses from intake manifold adaptor.
13. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold (lower) with power tool.
14. Remove intake manifold adaptor from intake manifold (lower).
15. Remove vacuum tank.
16. Remove intake manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 43

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 44

Scheme 45

Scheme 46

1. Remove engine room cover (RH and LH). Refer to «ENGINE ROOM COVER»(ref-356271-S37574715152010021300000) .
2. Remove engine cover with power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-356271-S00500245662010021300000) ".
3. Remove air duct (inlet), air cleaner case and air duct and resonator assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-356271-S05926562162010021300000) .
4. Remove front and rear engine undercovers with power tool.
5. Drain engine coolant from radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-356272-S21215035982010021300000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belts.
6. Remove radiator. Refer to «RADIATOR»(ref-356272-S23734032422010021300000) .
7. Remove drive belts. Refer to «DRIVE BELTS»(ref-356271-S33634597102010021300000) .
8. Remove exhaust front tube with power tool. Refer to «EXHAUST SYSTEM»(ref-356260-S23517049252010021300000) .
9. Remove each air fuel ratio sensor 1 as follows: Disconnect harness connector of each air fuel ratio sensor 1. Remove each air fuel ratio sensor 1 on both bank with heated oxygen sensor wrench (SST). CAUTION: Be careful not to damage air fuel ratio sensor 1. Discard any air fuel ratio sensor 1 which has been dropped onto a hard surface such as a concrete floor. Replace with a new one.
10. Remove exhaust manifold and three way catalyst (left bank) as follows: Disconnect A/C piping from A/C compressor, then remove A/C compressor with power tool. Refer to «REFRIGERANT LINES»(ref-356249-S29661446752010021300000) . Remove steering lower joint to enable steering shaft to move freely. Refer to «STEERING COLUMN»(ref-356261-S21606887582010021300000) . Remove starter motor. Refer to " «REMOVAL AND INSTALLATION»(ref-356263-S40645605992010021300000) ". Remove nuts on bottom of engine mounting insulator (LH), and lift up left side of engine approximately 3 cm (1.18 in) with transmission jack. Refer to " «2WD : COMPONENT»(ref-356271-S03159714792010021300000) " (2WD models) or " «AWD : COMPONENT»(ref-356271-S35286896862010021300000) " (AWD models). Remove exhaust manifold cover (left bank). Loosen nuts in the reverse order of figure to remove exhaust manifold and three way catalyst (left bank) with power tool. NOTE: Disregard No. 9 to No. 12 when loosening.
11. Remove exhaust manifold and three way catalyst (right bank) as follows: Remove alternator and bracket. Refer to «CHARGING SYSTEM»(ref-356263-S26435645102010021300000) . Remove nuts on bottom of engine mounting insulator (RH), and lift up right side of engine approximately 3 cm (1.18 in) with transmission jack. Refer to " «2WD : COMPONENT»(ref-356271-S03159714792010021300000) " (2WD models) or " «AWD : COMPONENT»(ref-356271-S35286896862010021300000) " (AWD models). Remove exhaust manifold cover (right bank). Loosen nuts in the reverse order of figure to remove exhaust manifold and three way catalyst (right bank) with power tool. NOTE: Disregard No. 9 to No. 12 when loosening.
12. Remove exhaust manifold gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 47

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 and three way catalyst.

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

Scheme 48

Scheme 49

Scheme 50

1. Remove front and rear engine undercovers with power tool.
2. Drain engine oil. Refer to " «CHANGING ENGINE OIL»(ref-356274-S12555854222010021300000) ". CAUTION: Perform this step when engine is cold. Never spill engine oil on drive belts.
3. Remove engine assembly from vehicle. Refer to " «2WD : COMPONENT»(ref-356271-S03159714792010021300000) " (2WD models) or " «AWD : COMPONENT»(ref-356271-S35286896862010021300000) " (AWD models).
4. Install engine slingers into front of cylinder head (left bank) and front of cylinder head (right bank). Slinger bolts: 33.4 N.m (3.4 kg-m, 25 ft-lb)
5. Remove engine mounting insulators (RH and LH) under side nut with power tool.
6. Lift with hoist and separate engine and transmission assembly from front suspension member. CAUTION: Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
7. Remove harness bracket from oil pan. (2WD models)
8. Remove oil filter. Refer to «OIL FILTER»(ref-356274-S25376877152010021300000) .
9. Remove oil pan as the follows: Remove rear plate cover. Remove transmission joint bolts which pierce oil pan. Refer to " «COMPONENT»(ref-356271-S02608491062010021300000) ". 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 (SST) by tapping on the side of seal cutter (SST) with hammer. Remove oil pan. CAUTION: Be careful not to damage the mating surfaces. Never insert screwdriver, this will damage the mating surface. Remove O-rings from bottom of oil pump and front cover.
10. Remove oil pressure switch if necessary. Refer to " «INSPECTION»(ref-356274-S00153837772010021300000) ".
11. If necessary, pull axle pipe from oil pan. (AWD models) Hold pipes and pull them out to front drive shaft (left) installing side.
12. Remove oil strainer.

1. Remove engine room cover (RH and LH). Refer to «ENGINE ROOM COVER»(ref-356271-S37574715152010021300000) .
2. Remove engine cover with power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-356271-S00500245662010021300000) ".
3. Remove air duct (inlet), air cleaner case, and air duct and resonator assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-356271-S05926562162010021300000) .
4. Disconnect harness connector from ignition coil.
5. Remove ignition coil. CAUTION: Never shock ignition coil.

Install in the reverse order of removal.

Scheme 51

1. Refer to " «COMPONENT»(ref-356247-S34736249572010021300000) " for symbols in the figure.

Scheme 52

1. Remove ignition coil. Refer to «IGNITION COIL»(ref-356271-S12182243262010021300000) .
2. Remove spark plug with spark plug wrench (commercial service tool). CAUTION: Never drop or shock spark plug.

Install in the reverse order of removal.

Scheme 53

1. Refer to " «COMPONENT»(ref-356247-S34736249572010021300000) " for symbols in the figure. CAUTION: Never remove or disassemble parts unless instructed as shown in the figure.

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

1. Remove engine room cover (RH and LH). Refer to «ENGINE ROOM COVER»(ref-356271-S37574715152010021300000) .
2. Remove engine cover with power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-356271-S00500245662010021300000) ".
3. Release fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-356273-S25956159722010021300000) ".
4. Disconnect fuel feed hose (1) 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 (commercial service tool: 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. 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. Never pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leakage out. Avoid fire and sparks. Keep parts away from heat source. Especially, be careful when welding is performed around them. Never expose parts to battery electrolyte or other acids. Never bend or twist connection between quick connector and fuel feed hose 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. 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. Never separate fuel damper and fuel hose.
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. CAUTION: Never 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. Never bump or drop fuel injector. Never disassemble fuel injector.
10. Remove fuel feed damper.

Scheme 59

Scheme 60

Scheme 61

1. Install fuel feed damper. When handling new O-rings, be careful of the following caution. CAUTION: Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. Insert new O-ring straight into fuel tube. Never decenter or twist it. Insert fuel feed damper straight into fuel tube (RH). Tighten mounting bolts evenly in turn. After tightening mounting bolts, check 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. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. Insert O-ring straight into fuel injector. Never decenter or twist it.
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: Never reuse clip. Replace it with a new one. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube 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. Check that fuel tube flange is securely fixed in flange fixing groove on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. Check that protrusions of fuel injectors are aligned with cutouts of clips after installation.
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. 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.) Check 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. Check 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 suitable drift, press fit until the height of front oil seal is level with the mounting surface. Suitable drift Outer diameter : 56 mm (2.20 in) Inner diameter : 49 mm (1.93 in) Check 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 62

1. Remove transmission assembly. Refer to «TRANSMISSION ASSEMBLY»(ref-356265-S38335924592010021300000) . Remove drive plate. Refer to «CYLINDER BLOCK»(ref-356271-S11941840042010021300000) . Remove rear plate. Refer to «CYLINDER BLOCK»(ref-356271-S11941840042010021300000) .
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 suitable drift, press fit until the height of rear oil seal is level with the mounting surface. Suitable drift Outer diameter : 102 mm (4.02 in) Inner diameter : 86 mm (3.39 in) Check 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 63

Scheme 64

Scheme 65

1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-356273-S25956159722010021300000) ". Remove fuel pump fuse to avoid fuel injection during measurement.
3. Remove engine cover with power tool. Refer to «ENGINE ROOM COVER»(ref-356271-S37574715152010021300000) .
4. Remove ignition coil and spark plug from each cylinder. Refer to " «COMPONENT»(ref-356271-S03806867712010021300000) " and " «COMPONENT»(ref-356271-S31776934442010021300000) ".
5. Connect engine tachometer (not required in use of CONSULT-III).
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: STANDARD SPECIFICATION Unit: kPa (kg/cm 2 , psi)/rpm 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 charged 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 recheck 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 check that engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to «TROUBLE DIAGNOSIS»(ref-356273-S00919948062010021300000) .

Scheme 66

Note. Figure is shown as an example of washer bolt.

Scheme 67

1. Remove engine assembly from vehicle. Refer to " «2WD : COMPONENT»(ref-356271-S03159714792010021300000) " (2WD models) or " «AWD : COMPONENT»(ref-356271-S35286896862010021300000) " (AWD models).
2. Remove exhaust manifold. Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-356271-S32358556222010021300000) .
3. Remove camshaft. Refer to «CAMSHAFT»(ref-356271-S04676191362010021300000) .
4. Remove cylinder head bolts in reverse order as shown in the figure to remove cylinder heads (right bank and left bank).
5. Remove cylinder head gaskets.

Scheme 68

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. CAUTION: Never use washer bolt together with flange bolt, when replacing cylinder head bolts. NOTE: Figure is shown as an example of washer bolt. 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 SEAT REPLACEMENT

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

Scheme 69

Scheme 70

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 " «STANDARD AND LIMIT»(ref-356271-S19368264422010021300000) ". 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. WARNING: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. CAUTION: Avoid directly touching cold valve seats.
5. Using valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. Refer to " «STANDARD AND LIMIT»(ref-356271-S19368264422010021300000) ". 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-356271-S38763953292010021300000) ".

Scheme 71

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 : 2.0 mm (0.079 in)
2. If it exceeds the limit, replace valve spring.

Scheme 72

1. Check valve spring pressure at the specified spring height. Standard: Intake and exhaust Free height : 46.35 - 46.85 mm (1.8248 - 1.8445 in) Installation height : 33.8 mm (1.331 in) Installation load : 165 - 189 N (16.8 - 19.3 kg, 37 - 42 lb) Height during valve open : 24.4 mm (0.961 in) Load with valve open : 290 - 330 N (29.6 - 33.7 kg, 65 - 74 lb)
2. If the installation load or load with valve open is out of the standard, replace valve spring.

Scheme 73

1. Refer to " «COMPONENT»(ref-356247-S34736249572010021300000) " for symbols in the figure.

2WD : Removal and Installation

Outline

At first, remove the engine and the transmission assembly with front suspension member from vehicle downward. Then separate the engine from the transmission.

Preparation

1. Release fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-356273-S25956159722010021300000) ".
2. Drain engine coolant from radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-356272-S21215035982010021300000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belts.
3. Disconnect both battery cables. Refer to «BATTERY»(ref-356263-S12531028122010021300000) .
4. Remove crankshaft position sensor (POS) from transmission. Refer to " «COMPONENT»(ref-356271-S02608491062010021300000) ". CAUTION: Handle carefully to avoid dropping and shocks. Never disassemble. Never allow metal powder to adhere to magnetic part at sensor tip. Never place sensors in a location where they are exposed to magnetism.
5. Remove the following parts: Front and rear engine undercover (power tool) Air duct (inlet), air duct and air cleaner case assembly: Refer to «AIR CLEANER AND AIR DUCT»(ref-356271-S05926562162010021300000) . Front road wheels and tires (power tool)

Engine Room LH

1. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant. Refer to " «COMPONENT»(ref-356272-S30317113762010021300000) ".
2. Disconnect wire bonding from exhaust manifold cover to vehicle.
3. Disconnect vacuum hose between vehicle and engine and set it aside.
4. Discharge refrigerant from A/C circuit. Refer to «REFRIGERANT LINES»(ref-356249-S29661446752010021300000) .
5. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to «REFRIGERANT LINES»(ref-356249-S29661446752010021300000) .

Engine Room RH

1. Disconnect fuel feed hose and EVAP hose. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-356271-S29172768122010021300000) . CAUTION: Fit plugs onto disconnected hose to prevent fuel leakage.
2. Disconnect ground cable [between vehicle and cylinder head (right bank)].
3. Disconnect vacuum hose between vehicle and engine and set it aside.
4. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work. CAUTION: When temporarily securing, keep reservoir tank upright to avoid a fluid leakage.

Vehicle inside

Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.

1. Remove passenger-side kicking plate, dash side finisher, and glove box. Refer to «BODY SIDE TRIM»(ref-356266-S29033188282010021300000) and «INSTRUMENT PANEL ASSEMBLY»(ref-356275-S36125088342010021300000) .
2. Disconnect engine room harness connectors at unit sides TCM, ECM, and other.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine. CAUTION: When pulling out harnesses, take care not to damage harnesses and connectors. After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

Vehicle Underbody

1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses. Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Disconnect heated oxygen sensor 2 harness. Refer to «EXHAUST SYSTEM»(ref-356260-S23517049252010021300000) .
3. Remove exhaust front tube with power tool. Refer to «EXHAUST SYSTEM»(ref-356260-S23517049252010021300000) .
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to «STEERING COLUMN»(ref-356261-S21606887582010021300000) .
5. Separate steering outer sockets from steering knuckle. Refer to «POWER STEERING GEAR AND LINKAGE»(ref-356261-S21466868352010021300000) .
6. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so that it does not sag. Refer to «SHIFT CONTROL SYSTEM»(ref-356265-S25298966552010021300000) .
7. Remove rear plate cover from oil pan. Then remove bolts fixing drive plate to torque converter. Refer to «OIL PAN AND OIL STRAINER»(ref-356271-S15531296612010021300000) and «TRANSMISSION ASSEMBLY»(ref-356265-S38335924592010021300000) .
8. Remove transmission joint bolts which pierce at oil pan lower rear side. Refer to " «COMPONENT»(ref-356271-S02608491062010021300000) ".
9. Remove lower ends of left and right strut from transverse link. Refer to " «COMPONENT»(ref-356268-S27303804922010021300000) ".
10. Remove transverse link mounting bolts at knuckle side. Refer to " «COMPONENT»(ref-356268-S27303804922010021300000) ".
11. Remove front stabilizer at transverse link side. Refer to " «COMPONENT»(ref-356268-S27303804922010021300000) ".
12. Remove rear propeller shaft. Refer to " «COMPONENT»(ref-356267-S13192129592010021300000) ".

Removal Work

Scheme 74

1. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission assembly. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove engine rear member mounting bolts.
3. Remove front suspension member mounting nuts and bolts with power tool. Refer to " «COMPONENT»(ref-356268-S27303804922010021300000) ".
4. Carefully lower jack, or raise lift to remove engine, transmission and front suspension member assembly. When performing work, observe the following caution: CAUTION: Confirm there is no interference with vehicle. Check that all connection points have been disconnected. Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off the lift.

Separation Work

Scheme 75

1. Install engine slingers into front of cylinder head (left bank) and front of cylinder head (right bank). Slinger bolts: 33.4 N.m (3.4 kg-m, 25 ft-lb)
2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine and transmission assembly from front suspension member. CAUTION: Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator. Refer to " «REMOVAL AND INSTALLATION»(ref-356263-S15031991652010021300000) ".
5. Remove starter motor. Refer to " «REMOVAL AND INSTALLATION»(ref-356263-S40645605992010021300000) ".
6. Separate engine from transmission assembly. Refer to «TRANSMISSION ASSEMBLY»(ref-356265-S38335924592010021300000) .
7. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
8. Remove rear engine mounting member and engine mounting insulator (rear) from transmission.

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 " «2WD : COMPONENT»(ref-356271-S03159714792010021300000) ".
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). NOTE: Figure shows left bank.

AWD : Removal and Installation

Outline

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

Preparation

1. Release fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-356273-S25956159722010021300000) ".
2. Drain engine coolant from radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-356272-S21215035982010021300000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belts.
3. Disconnect both battery cables. Refer to «BATTERY»(ref-356263-S12531028122010021300000) .
4. Remove crankshaft position sensor (POS) from transmission. Refer to " «COMPONENT»(ref-356271-S02608491062010021300000) ". CAUTION: Handle carefully to avoid dropping and shocks. Never disassemble. Never allow metal powder to adhere to magnetic part at sensor tip. Never place sensors in a location where they are exposed to magnetism.
5. Remove the following parts: Front and rear engine undercover (power tool) Air duct (inlet), air duct and air cleaner case assembly: Refer to «AIR CLEANER AND AIR DUCT»(ref-356271-S05926562162010021300000) . Front road wheels and tires (power tool) Front cross bar: Refer to " «COMPONENT»(ref-356268-S08866252942010021300000) ".

Engine Room LH

1. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant. Refer to " «COMPONENT»(ref-356272-S30317113762010021300000) ".
2. Disconnect wire bonding from exhaust manifold cover to vehicle.
3. Disconnect vacuum hose between vehicle and engine and set it aside.
4. Discharge refrigerant from A/C circuit. Refer to «REFRIGERANT LINES»(ref-356249-S29661446752010021300000) .
5. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to «REFRIGERANT LINES»(ref-356249-S29661446752010021300000) .

Engine Room RH

1. Disconnect fuel feed hose and EVAP hose. Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-356271-S29172768122010021300000) . CAUTION: Fit plugs onto disconnected hose to prevent fuel leakage.
2. Disconnect ground cable (between vehicle and right bank cylinder head).
3. Disconnect vacuum hose between vehicle and engine and set it aside.
4. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work. CAUTION: When temporarily securing, keep reservoir tank upright to avoid a fluid leakage.

Vehicle inside

Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.

1. Remove passenger-side kicking plate, dash side finisher, and glove box. Refer to «BODY SIDE TRIM»(ref-356266-S29033188282010021300000) and «INSTRUMENT PANEL ASSEMBLY»(ref-356275-S36125088342010021300000) .
2. Disconnect engine room harness connectors at unit sides TCM, ECM, and other.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine. CAUTION: When pulling out harnesses, take care not to damage harnesses and connectors. After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

Vehicle Underbody

1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses. Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Disconnect heated oxygen sensor 2 harness. Refer to «EXHAUST SYSTEM»(ref-356260-S23517049252010021300000) .
3. Remove exhaust front tube with power tool. Refer to «EXHAUST SYSTEM»(ref-356260-S23517049252010021300000) .
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to «STEERING COLUMN»(ref-356261-S21606887582010021300000) .
5. Separate steering outer sockets from steering knuckle. Refer to «POWER STEERING GEAR AND LINKAGE»(ref-356261-S21466868352010021300000) .
6. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so that it does not sag. Refer to «SHIFT CONTROL SYSTEM»(ref-356265-S25298966552010021300000) .
7. Remove rear plate cover from oil pan. Then remove bolts fixing drive plate to torque converter. Refer to «OIL PAN AND OIL STRAINER»(ref-356271-S15531296612010021300000) and «TRANSMISSION ASSEMBLY»(ref-356265-S38335924592010021300000) .
8. Remove bolts fixing the transmission assembly to lower rear side of oil pan. Refer to " «COMPONENT»(ref-356271-S02608491062010021300000) ".
9. Remove lower ends of left and right strut from transverse link. Refer to " «COMPONENT»(ref-356268-S08866252942010021300000) ".
10. Remove transverse link mounting bolts at knuckle side. Refer to " «COMPONENT»(ref-356268-S08866252942010021300000) ".
11. Remove front stabilizer at transverse link side. Refer to " «COMPONENT»(ref-356268-S08866252942010021300000) ".
12. Remove rear propeller shaft. Refer to " «COMPONENT»(ref-356267-S13192129592010021300000) ".
13. Remove front drive shaft (both side). Refer to " «REMOVAL AND INSTALLATION»(ref-356269-S35339476432010021300000) ".

Removal Work

1. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission assembly. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove engine rear member mounting bolts.
3. Remove front suspension member mounting nuts and bolts with power tool. Refer to " «COMPONENT»(ref-356268-S08866252942010021300000) ".
4. Carefully lower jack, or raise lift to remove engine, transmission and front suspension member assembly. When performing work, observe the following caution: CAUTION: Confirm there is no interference with vehicle. Check that all connection points have been disconnected. Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off the lift.

Separation Work

1. Install engine slingers into front of cylinder head (left bank) and front of cylinder head (right bank). Slinger bolts: 33.4 N.m (3.4 kg-m, 25 ft-lb)
2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine, transmission assembly, the transfer assembly and the front final drive assembly from front suspension member. CAUTION: Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator. Refer to " «REMOVAL AND INSTALLATION»(ref-356263-S15031991652010021300000) ".
5. Remove starter motor. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-356263-S29828628522010021300000) ".
6. Remove front propeller shaft from the front final drive assembly. Refer to " «COMPONENT»(ref-356267-S32958894382010021300000) ".
7. Separate engine from transmission assembly. Refer to «TRANSMISSION ASSEMBLY»(ref-356265-S38335924592010021300000) .
8. Remove the front final drive assembly from oil pan. Refer to " «REMOVAL AND INSTALLATION (VK45DE)»(ref-356270-S07718585672010021300000) ".
9. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
10. Remove rear engine mounting member and engine mounting insulator (rear) from transmission.

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

Scheme 77

1. Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
2. For a location with a positioning pin, insert it securely into hole of mating part.
3. For a part with a specified installation orientation, refer to component figure in " «AWD : COMPONENT»(ref-356271-S35286896862010021300000) ".
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). NOTE: Figure shows left bank.