Engine Mechanical: Diagnosis Infiniti Q45 III

PRECAUTIONS FOR INSPECTION, REPAIR AND REPLACEMENT

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

INSPECTION AFTER INSTALLATION

1. After installing fuel tubes, make sure there is no fuel leakage at connections in the following steps. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. Start the engine and rev it up and check for fuel leaks at connections.
2. Perform procedures for " «THROTTLE VALVE CLOSED POSITION LEARNING»(ref-151807-S22752529262003010800000) .
3. If electric throttle control actuator is replaced, perform procedures for " «IDLE AIR VOLUME LEARNING»(ref-151807-S11953106312003010800000) . .

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1. Remove heated oxygen sensors. Follow below steps to remove each heated oxygen sensor. Remove engine undercover and engine cover with power tool. Remove harness connector of each heated oxygen sensor, and harness from bracket and middle clamp. Using heated oxygen sensor wrench, remove both left and right heated oxygen sensors. 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; use a new one.
2. Remove exhaust manifold and three way catalyst (left bank) in below steps. Remove A/C compressor with power tool and put aside with piping connected. Refer to «COMPRESSOR»(ref-182027-S03631927382005080600000) . Remove exhaust front tube with power tool. Remove steering lower joint to enable steering shaft to move freely. Support and lift up bottom of engine with transmission jack. Remove left engine mount insulator along with left engine mount brackets. Remove exhaust manifold cover. Loosen nuts in reverse order of illustration to remove exhaust manifold and three way catalyst. CAUTION: Disregard the numerical order No. 9 to 12 in removal.
3. Remove exhaust manifold and three way catalyst (right bank) loosening nuts in reverse order in the figure. Remove drive belt and alternator with power tool. Refer to «GENERATOR»(ref-166387-S15258593472004091700000) . Remove exhaust front tube with power tool. Remove nuts on bottom of right engine mounting insulator, and lift up right side of engine approximately 3 cm (1.18 in) with transmission jack. Remove starter motor with power tool. Refer to «REMOVAL & INSTALLATION»(ref-167713-S37775669052004102000000) . Support and lift up bottom of engine with transmission jack. Remove right engine mount insulator along with right engine mount brackets. Remove exhaust manifold cover. Loosen nuts in reverse order of illustration to remove exhaust manifold and three way catalyst with power tool. CAUTION: Disregard the numerical order No. 9 to 12 in removal.

INSPECTION AFTER REMOVAL

Clean oil strainer if any object attached.

Scheme 44

Scheme 45

1. Install oil strainer.
2. Install oil pan in the order below. Apply liquid gasket thoroughly as in illustration. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-182064-S38599864392005080600000). Install new O-ring to oil pump and timing chain case side. Tighten bolts in numerical order as shown. No. 11 and 17 indicate double tightening of bolts 1 and 2. NOTE: Refer to the below for locating bolts. M6 x 30 mm (1.18 in): No. 18, 19 M8 x 100 mm (3.97 in): No. 5, 9 M8 x 45 mm (1.77 in): Except the above Tighten transmission joint bolts. Refer to «REMOVAL AND INSTALLATION»(ref-182060-S29594330552005080600000). Install rear plate cover.
3. Install oil pan drain plug. see scheme 35
4. Install in the reverse order of removal after this step. Pour engine oil at least 30 minutes after oil pan is installed.

1. Check engine oil level.
2. Check for leakage of engine oil when engine is warmed.

Scheme 46

1. Use standard type spark plug for normal condition.

The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as

1. Frequent engine starts
2. Low ambient temperatures

The cold type spark plug is suitable when spark knock occurs with the standard type spark plug under conditions such as

Scheme 47

1. Extended highway driving
2. Frequent high engine revolution Spark plug (Platinum-tipped type)

1. Gap (Nominal) : 1.1 mm (0.043 in)

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Check for cracks and any excessive wear at link plates. Replace chain if necessary.

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Note. The above figure shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed. Parts with an identification mark (R or L) should be installed on the corresponding bank according to the mark.

Parts with an identification mark

1. Intake camshaft sprocket
2. Dowel pin groove of exhaust camshaft sprocket (camshaft sprocket is same part both banks)
3. Chain tension guide
4. Chain slack guide
5. Because of parallel manufacture, there are two types of mark (link colors) for timing chain.
6. To install timing chain and associated parts, start with those on right bank. The procedure for installing parts on left bank is omitted because it is the same as that for installation on right bank.

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1. Check that the crankshaft key and dowel pin of each camshaft are facing in the direction indicated.
2. Install camshaft sprockets. Install onto correct side by checking with identification mark on surface Install exhaust-side camshaft sprocket by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.) Lock the hexagonal part of camshaft in the same way as for removal, and tighten fixing bolts.
3. Install crankshaft sprockets for both banks. Install each crankshaft sprocket so that its flange side (the larger diameter side without teeth) faces in the direction shown in figure. NOTE: The same parts are used but facing directions are different.
4. Install timing chains and associated parts. Align the mating mark on each sprocket and the timing chain for installation. NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment. CAUTION: For the above reason, after the mating marks are aligned, keep them aligned by holding them with a hand. Install slack guides and tension guides onto correct side by checking with identification mark on surface. Install chain tensioner with plunger fixed as described in its removal. CAUTION: Before and after the installation of chain tensioner, make sure that the mating mark on timing chain is not out of alignment. After installing chain tensioner, remove the stopper pin to release tensioner. Check that tensioner is released. To avoid chain-link skipping of timing chain, never move crankshaft or camshafts until front cover is installed.
5. In the same way as for right bank, install timing chain and associated parts on left side.
6. Install oil pump.
7. Install oil pump drive spacer as follows: Insert oil pump drive spacer according to the directions of crankshaft key and the two flat surfaces of oil pump inner rotor. If the positional relationship does not allow the insertion, rotate oil pump inner rotor with a finger to allow the spacer. After confirming that the position of each part is in correct condition to allow for the spacer, force fit the spacer by lightly tapping with a plastic hammer until it contacts and does not go further.
8. Install front oil seal onto front cover. Using oil seal drift or drift with 54 mm (2.13 in) diameter, force fit the seal until it levels with the front end surface of front cover. Install new oil seal in the direction shown in the figure. CAUTION: Be careful not to scratch or make burrs on circumference of oil seal.
9. Install chain tensioner cover onto front cover. Apply liquid gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent . Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-182064-S38599864392005080600000) .
10. Install front cover as follows: Install new O-rings onto RH and LH cylinder heads and cylinder block. Apply liquid gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent . Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-182064-S38599864392005080600000) . Check again that the timing mating mark on timing chain and that on each sprocket are aligned. Then, install front cover. CAUTION: Be careful to avoid interference with the front end of oil pump drive spacer. Such interference may damage front oil seal. Tighten fixing bolts in the order shown in figure. After tightening, re-tighten to the specified torque. CAUTION: Be sure to wipe off any excessive liquid gasket leaking onto surface mating with oil pan.
11. Install intake valve timing control cover as follows: At the back of intake valve timing control cover, install new seal rings (three for each) to the area to be inserted into intake camshaft sprocket. CAUTION: Do not spread seal ring excessively to avoid breaks and deformation. On the side of front cover, install new O-ring (one for each bank). Apply liquid gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent . Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-182064-S38599864392005080600000) . Tighten fixing bolts in the order shown in figure.
12. Install intake valve timing control position sensor, intake valve timing control solenoid valve and camshaft position sensor (PHASE) to intake valve timing control cover and front cover. Be sure to tighten bolts with flanges completely seated.
13. Install crankshaft pulley. Install according to the dowel pin of oil pump drive spacer. Lightly tapping its center with plastic hammer, insert pulley. CAUTION: Do not tap pulley on the side surface where belt is installed (outer circumference).
14. Tighten fixing bolts of crankshaft pulley. Lock crankshaft with a hammer handle or similar tool to tighten fixing bolts. Perform the following steps for angular tightening: Apply engine oil onto threaded parts of bolts and seating areas. Tighten bolt 88.2 to 98.0 N.m (9.0 to 9.9 kg-m, 65 to 72 ft-lb). Select one most visible notch of the four on bolt flange. Corresponding to the selected notch, put a mating mark (such as paint) on crankshaft pulley. Tighten further by 90° to 96° [target: 90°]. Check the tightening angle by referencing to the notches. The angle between two notches is 90°.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from FRONT) to check for interference among parts.
16. For the following operations, perform steps in the reverse order of removal.

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1. Remove timing chain. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S18612675642006050300000) .
2. With hexagonal part of camshaft locked with wrench, loosen bolts securing camshaft sprocket to remove camshaft sprocket. CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft with timing chain disconnected.
3. Loosen fixing bolts in the reverse order of that shown in figure to remove camshaft brackets. Lightly tapping with plastic hammer, remove No. 1 camshaft bracket and No. 6 camshaft bracket. NOTE: The bottom surface of each bracket will be stuck to cylinder head because of liquid gasket.
4. Remove camshaft.
5. Remove adjusting shims and valve lifters if necessary. Correctly identify location where each part is installed. Keep parts organized in a way to avoid mixing them up.

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1. Install adjusting shims and valve lifters if necessary. Install removed parts in the same locations as before.
2. Install camshafts. Refer to the table below for identification of right and left bank, and intake and exhaust. Install so that dowel pin at the front of camshaft face is in the direction shown in the figure.
3. Install camshaft brackets. Install by referring to identification mark on upper surface and front mark. Install so that identification mark can be correctly read when viewed from the side of left exhaust bank. Install No. 1 camshaft bracket as follow: Apply liquid gasket to No. 1 camshaft bracket as in illustration. Use Genuine RTV Silicone Sealant or equivalent . Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-182064-S38599864392005080600000) . CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part "A" and "B"(both on right and left sides). Remove completely any excess of liquid gasket inside bracket. Apply liquid gasket to No. 6 camshaft bracket on left bank intake as in illustration. CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part "A", and "B"(both on right and left sides). Remove completely any excess of liquid gasket inside bracket.
4. Tighten fixing bolts of camshaft brackets as follows: Tighten in the order from 9 to 12 with tightening torque 1.96 N.m (0.2 kg-m, 17 in-lb). Tighten in the order from 1 to 8 with tightening torque 1.96 N.m (0.2 kg-m, 17 in-lb). Tighten in the order from 13 to 14 with tightening torque 1.96 N.m (0.2 kg-m, 17 in-lb) (Left bank only). Tighten all bolts in the specified order with tightening torque 5.88 N.m (0.6 kg-m, 52 in-lb) Tighten in the order from 1 to 12 with tightening torque 9.02 to 11.8N.m (0.92 to 1.2 kg-m, 80 to 104 in-lb). Tighten in the order from 13 to 14 with tightening torque 29.4 to 33.3 N.m (3.0 to 3.3 kg-m, 22 to 24 ft-lb) (left bank only). CAUTION: After tightening fixing bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the parts listed below. Mating surface of rocker cover Mating surface of front cover
5. Install camshaft sprockets. Install by checking with identification mark on surface. Install exhaust-side camshaft sprocket by selectively using the groove of dowel pin according to the bank. (Common part used for both banks.) Lock the hexagonal part of camshaft in the same way as for removal, and tighten fixing bolts.
6. For the following operations, perform steps in the reverse order of removal.
7. Check and adjust valve clearances. Refer to «VALVE CLEARANCE»(ref-231095-S33143687582006050300000) .

Scheme 79

1. Put V block on precise flat bed, and support No. 2 and No. 5 journal of camshaft.
2. Set dial gauge vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure camshaft runout on dial gauge. 1/2 of runout is bend. Standard: Less than 0.02 mm (0.0008 in)
4. If it exceeds the specification, replace camshaft.

Scheme 80

1. Measure camshaft cam height. Standard cam height: Intake: 44.865 - 45.055 mm (1.7663 - 1.7738 in) Exhaust: 43.925 - 44.115 mm (1.7293 - 1.7368 in)
2. If wear is beyond the specifications, replace camshaft.

INSPECTION

Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions due to changes in valve clearance over time (starting, idling, and/or noise).

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1. Warm up engine. Then, stop it.
2. Remove engine cover and engine room covers (RH and LH) with power tool and air duct (inlet). Refer to «REMOVAL AND INSTALLATION»(ref-231095-S21134367422006050300000) .
3. Remove RH and LH rocker covers with power tool. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S35103533352006050300000) .
4. Turn crankshaft pulley in normal direction (clockwise when viewed from FRONT) to align TDC identification notch (without paint mark) with timing indicator.
5. At this time, check that the both intake and exhaust cam noses of No. 1 cylinder (top front on left bank) face outside. If they do not face outside, turn crankshaft pulley once more.
6. By referring to the figure, measure valve clearances at locations marked X as shown in the table below (locations indicated with black arrow in figure) with a thickness gauge. NOTE: Firing order 1-8-7-3-6-5-4-2 No. 1 cylinder compression TDC Use a fine thickness gauge. Valve clearance standard: CAUTION: If inspection was carried out with cold engine, check that values with fully warmed up engine are still within specifications.
7. Turn crankshaft pulley clockwise by 270° from the position of No. 1 cylinder compression TDC to obtain No. 3 cylinder compression TDC.
8. By referring to the figure, measure valve clearances at locations marked X as shown in the table below (locations indicated with white arrow in figure) No. 3 cylinder compression TDC
9. Turn crankshaft pulley clockwise by 90° from the position of No. 3 cylinder compression TDC (clockwise by 360° from the position of No. 1 cylinder compression TDC) to measure intake and exhaust valve clearances of No. 6 cylinder and exhaust valve clearance of No. 2 cylinder.
10. If out of specifications, adjust as follows

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1. Turn crankshaft, to position cam lobe on camshaft of valve that must be adjusted upward.
2. Thoroughly wipe off engine oil around adjusting shim using a rag.
3. Using a extra-fine screwdriver, turn the round hole of the adjusting shim in the direction of the arrow.
4. Place Tool (A) around camshaft as shown in figure. Before placing Tool (A), rotate cam lobe toward center of cylinder head (Scheme 91) to simplify shim removal later. CAUTION: Be careful not to damage cam surface with Tool (A).
5. Rotate Tool (A) ( (Scheme 91)) so that valve lifter is pushed down.
6. Place Tool (B) between camshaft and the edge of the valve lifter to retain valve lifter. CAUTION: Tool (B) must be placed as close to camshaft bracket as possible. Be careful not to damage cam surface with Tool (B).
7. Remove Tool (A).
8. Blow air into the hole to separate adjusting shim from valve lifter. CAUTION: When blowing, use goggles to protect your eye.
9. Remove adjusting shim using a small screwdriver and a magnetic finger.
10. Determine replacement adjusting shim size following formula. Using a micrometer determine thickness of removed shim with measured at center. Calculate thickness of new adjusting shim so valve clearance comes within specified values (Cold value). R = Thickness of removed shim N = Thickness of new shim M = Measured valve clearance Intake: N = R + [M - 0.30 mm (0.0118 in)]* Exhaust: N = R + [M - 0.33 mm (0.0130 in)]* *: Approximately 20°C (68°F) Shims are available in 64 sizes from 2.32 mm (0.0913 in) to 2.95 mm (0.1161 in) in steps of 0.01 mm (0.0004 in). Select new shim with thickness as close as possible to calculated value.
11. Install new shim using a suitable tool. Install with the surface on which the thickness is stamped facing down.
12. Place Tool (A) as mentioned in steps 4 and 5.
13. Remove Tool (B).
14. Remove Tool (A).
15. Recheck valve clearance. (Cold value)
16. Finally check valve clearance with warmed up engine. (Hot value)

Valve clearance

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Scheme 101

1. Remove camshaft relating to valve oil seal to be removed. Refer to «CAMSHAFT»(ref-231095-S35005084482006050300000) .
2. Remove adjusting shims and valve lifters. Refer to «CAMSHAFT»(ref-231095-S35005084482006050300000) . Correctly identify location where each part is installed. Keep parts organized in a way to avoid mixing them up.
3. Turn crankshaft until the cylinder requiring new oil seals is at TDC, This will prevent the valve from dropping into the cylinder.
4. Remove valve collet. Compress valve spring with valve spring compressor. Remove valve collet with magnet driver.
5. Remove valve spring retainer and valve spring. CAUTION: Do not remove valve spring seat from valve spring.
6. Remove valve oil seal using valve oil seal puller (special service tool).

Scheme 102

1. Apply engine oil on new valve oil seal joint and seal lip.
2. Install valve oil seal. Install with valve oil seal drift to match dimension in illustration.
3. Perform steps in the reverse order of removal for the following operations.

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1. Remove the following parts: Undercover Drive belt; Refer to «DRIVE BELTS»(ref-231095-S03052435852006050300000) . Cooling fan; Refer to «COOLING FAN»(ref-183866-S08949419212005081700000) .
2. Set ring gear stopper (SST).
3. Remove crankshaft pulley.
4. Remove front oil seal using a suitable tool. CAUTION: Be careful not to damage front timing chain case and crankshaft.

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1. Install front oil seal onto front cover. Apply engine oil on new front oil seal. Using oil seal drift or drift with 54 mm (2.13 in) diameter, force fit the seal until it levels with the front end surface of front cover. Install new oil seal in the direction shown in the figure. CAUTION: Be careful not to scratch or make burrs on circumference of oil seal.
2. For the following operations, perform steps in the reverse order of removal.
3. Perform steps in the reverse order of removal for the following operations.

Scheme 108

1. Remove transmission assembly. Refer to «REMOVAL AND INSTALLATION»(ref-182060-S29594330552005080600000) . Remove drive plate. Holding crankshaft pulley mounting bolts, lock crankshaft to remove bolts fixing drive plate. Loosen fixing bolts diagonally. CAUTION: Be careful not to damage drive plate. Especially, avoid deforming and damaging of signal plate teeth (circumference position). Place the drive plate with signal plate surface facing other than downward. Keep magnetic materials away from signal plate. Remove engine rear plate.
2. Remove rear oil seal using a suitable tool. CAUTION: Be careful not to damage crankshaft and oil seal retainer surface.

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1. Install rear oil seal to oil seal retainer. Tap until flattened with front edge of oil seal retainer. Do not damage or scratch outer circumference of oil seal. Install new oil seal in the direction shown in the figure. CAUTION: Be careful not to scratch or make burrs on circumference of oil seal.
2. Perform steps in the reverse order of removal for the following operations.

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1. Remove engine cover with power tool, air cleaner cover and battery cover. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S21134367422006050300000) .
2. Warm up engine thoroughly. Then, stop it.
3. Release fuel pressure. Remove fuel pump fuse, and start engine. Refer to «FUEL PRESSURE RELEASE»(ref-151802-S17369107142003010800000) for fuel pump fuse location. After engine stalls, crank it two or three times to release all fuel pressure. Let fuel pump fuse removed until the end of step 7 .
4. Remove ignition coil and spark plug from each cylinder. Refer to «IGNITION COIL REMOVAL AND INSTALLATION»(ref-231095-S26003145532006050300000) and «SPARK PLUG (PLATINUM-TIPPED TYPE) REMOVAL AND INSTALLATION»(ref-231095-S22237772942006050300000) .
5. Connect engine tachometer (not required in use of CONSULT-II).
6. Install compression gauge with adapter onto spark plug hole. Use compression gauge adapter which is required on No. 7 and No. 8 cylinders. Use compression gauge 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 CAUTION: Always use a fully charged battery to obtain 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, the 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, the valves may be malfunctioning. Check the valves for damage. Replace the 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, the gaskets are leaking. In such a case, replace the cylinder head gaskets.
8. Install removed parts in the reverse order of removal.
9. Start engine, and confirm that engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to «SELF-DIAGNOSTIC SYSTEM»(ref-151807-S29007442602003010800000) .

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1. Remove engine assembly from vehicle. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S06636579622006050300000) .
2. Remove the following components and related parts: Auto tensioner of drive belts and idler pulley. Refer to «DRIVE BELT AUTO TENSIONER AND IDLER PULLEY»(ref-231095-S05769777882006050300000) . Thermostat housing and hose. Refer to «THERMOSTAT AND WATER CONTROL VALVE»(ref-183866-S26807185872005081700000) . Oil pan and oil strainer. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S41795030392006050300000) . Intake manifold upper and intake manifold lower. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S12730739602006050300000) . Fuel tube and fuel injector assembly. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S27218587162006050300000) . Ignition coil. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S26003145532006050300000) . Rocker cover. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S35103533352006050300000) . Exhaust manifold and three way catalyst. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S11496126002006050300000) .
3. Remove crankshaft pulley, front cover, oil pump, and timing chain. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S18612675642006050300000) .
4. Remove camshaft sprockets and camshafts. Refer to «REMOVAL AND INSTALLATION»(ref-231095-S16767897562006050300000) .
5. Remove cylinder head loosening bolts in reverse order shown in the figure and using cylinder head bolt wrench (Commercial service tool).

Scheme 116

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) : More than 0.18 mm (0.0071 in)
2. If reduction of outer diameter appears in a position other than d2, use it as d2 point.

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Scheme 118

1. Install cylinder head gasket.
2. Follow the steps below to tighten fixing bolts in the order shown in figure to install cylinder head. CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. (Scheme 116) In step "c", loosen bolts in the reverse order of that indicated in figure. Apply engine oil to threads and seating surface of bolts. Tighten all bolts to 98.1 N.m (10 kg-m, 72 ft-lb). Completely loosen all bolts. Tighten all bolts to 39.2 to 49.0 N.m (4.0 to 5.0 kg-m, 29 to 36 ft-lb). Turn all bolts 60 to 65 (target: 60) degrees clockwise. Turn all bolts 60 to 65 (target: 60) degrees clockwise again. CAUTION: Check and confirm the tightening angle by using angle wrench (SST) and cylinder head bolt wrench (commercial service tool). Avoid judgment by visual inspection without the SST.
3. Install followings in reverse order of removal.

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1. Remove spark plug with spark plug wrench.
2. Remove spark plug tube, as necessary. Using a pair of pliers, pull spark plug tube out of cylinder head. CAUTION: Take care not to damage cylinder head. Once spark plug tube is removed, it will be deformed and cannot be reused. Do not remove it unless absolutely necessary.
3. Remove adjusting shim and valve lifter. Confirm installation point. Keep parts organized.
4. Remove valve collet. Compress valve spring with valve spring compressor. Remove valve collet with magnet driver.
5. Remove valve spring retainer and valve spring. CAUTION: Do not remove valve spring seat from valve spring.
6. Push valve stem to combustion chamber side, and remove valve. Inspect valve guide clearance before removal. Refer to «VALVE GUIDE CLEARANCE»(ref-231095-S10193256772006050300000) . Confirm installation point. Keep parts organized.
7. Remove valve oil seal with valve oil seal puller.
8. When valve seat must be replaced, Refer to «VALVE SEAT REPLACEMENT»(ref-231095-S22881293922006050300000) .
9. When valve guide must be replaced, Refer to «VALVE GUIDE REPLACEMENT»(ref-231095-S31182809112006050300000) .

Scheme 122

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Scheme 124

1. Install valve guide. Refer to «VALVE GUIDE REPLACEMENT»(ref-231095-S31182809112006050300000) .
2. Install valve seat. Refer to «VALVE SEAT REPLACEMENT»(ref-231095-S22881293922006050300000) .
3. Install valve oil seal. Install with valve oil seal drift to match dimension in illustration.
4. Install valve. Install larger diameter to intake side.
5. Install valve spring. Install smaller pitch (valve spring seat side) to cylinder head side.
6. Install valve spring retainer.
7. Install valve collet. Compress valve spring with valve spring compressor. Install valve collet with magnet hand. Tap stem edge lightly with plastic hammer after installation to check its installed condition.
8. Install valve lifter.
9. Install spark plug tube. Press-fit spark plug tube following procedure below. Remove old liquid gasket adhering to cylinder-head mounting hole. Apply liquid gasket to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. Use Genuine liquid gasket or equivalent. Using a drift, press-fit spark plug tube so that its height "H" in the figure is as specified. Standard press-fit height "H": 38.4-39.4 mm (1.512-1.551 in) CAUTION: When press-fitting spark plug tube, take care not to deform it. After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face.
10. Install spark plug with spark plug wrench.

Scheme 125

1. Wipe off oil and remove water scale (like deposit), gasket, sealer, carbon, etc. with scraper. CAUTION: Use utmost care not to allow liquid gasket debris to enter passages for oil or water.
2. At each of several locations on bottom surface of cylinder head, measure distortion in six directions. Limit : 0.1mm (0.004 in)

Scheme 126

1. Check dimensions of each valve. For dimensions, Refer to «VALVE DIMENSIONS»(ref-231095-S19283877682006050300000) .

1. Before starting engine, check the levels of engine coolant, lubrications, working oils.
2. Run engine to check for unusual noise and vibration.
3. Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil, fuel, and exhaust gas.
4. Bleed air from passages in pipes and tubes of applicable lines.

Scheme 127