Engine Mechanical: Removal & Installation Nissan 350Z I

Precautions for Removal and Disassembly

1. When instructed to use special service tools, 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 equivalent, if necessary, to seal out foreign materials.
4. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
5. When loosening bolts and nuts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

Precautions for Assembly and Installation

1. Use torque wrench to tighten bolts or nuts to specification.
2. When tightening bolts and nuts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
3. Replace with new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.
5. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
6. Release air within route when refilling after draining engine coolant.
7. After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

REMOVAL OF LIQUID GASKET SEALING

1. After removing mounting bolts and nuts, separate the mating surface using seal cutter [SST] and remove old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces.
2. Tap seal cutter to insert it, and then slide it by tapping on the side (Scheme 169)
3. In areas where seal cutter [SST] is difficult to use, use plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason tool such as screwdriver is used, be careful not to damage the mating surfaces.

Scheme 169

Scheme 170

Scheme 171

1. Using scraper, remove old liquid gasket adhering to the gasket application surface and the mating surface. Remove liquid gasket completely from the groove of the gasket application surface, mounting bolts, and bolt holes.
2. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials.
3. Attach liquid gasket tube to tube presser [SST: WS39930000 ( - )]. Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
4. Apply liquid gasket without breaks to the specified location with the specified dimensions. If there is a groove for liquid gasket application, apply liquid gasket to the groove. As for bolt holes, normally apply liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of this manual. Within five minutes of liquid gasket application, install the mating component. If liquid gasket protrudes, wipe it off immediately. Do not retighten mounting bolts or nuts after the installation. After 30 minutes or more have passed from the installation, fill engine oil and engine coolant.

Scheme 172

REMOVAL

1. Remove undercover with power tool.
2. Remove alternator and power steering oil pump belt, Refer to " «ALTERNATOR AND POWER STEERING OIL PUMP BELT»(ref-170482-S24083721482005011000000) ".
3. Remove A/C compressor belt, Refer to " «A/C COMPRESSOR BELT»(ref-170482-S29022840142005011000000) " . CAUTION: Grease is applied to idler pulley adjusting bolt. Be careful to keep grease away from belt.

INSTALLATION

1. Install belts to pulley in the reverse order of removal. CAUTION: Make sure belt is correctly engaged with the pulley groove. Check for engine oil and engine coolant are not adhered belt and each pulley groove.
2. Adjust belt tension, Refer to " «Tension Adjustment»(ref-170482-S34877404932005011000000) ".
3. Tighten each nuts and bolts and nut to the specified torque.
4. Make sure that tension of each belt is within the standard.

Scheme 173

Scheme 174

1. Remove clips, and slide air duct (inlet) frontward, disengage clips and air cleaner case. NOTE: When removing air duct (inlet), remove front bumper and bumper fascia stay radiator core support center, Refer to "FRONT BUMPER " and "RADIATOR CORE SUPPORT ".
2. Disconnect harness connector from mass air flow sensor.
3. Disconnect PCV hose.
4. Remove air cleaner case/mass air flow sensor assembly and air duct 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 care. Do not shock it. Do not disassemble it. 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. Unhook clips, and lift holder.
2. Remove air cleaner filter.

Scheme 175

Install in the reverse order of removal.

Scheme 176

Note. To remove intake manifold collector (upper) only, removing tower bar is unnecessary.

Scheme 177

Scheme 178

Scheme 179

1. Remove tower bar, Refer to "TOWER BAR ".
2. Remove engine cover with power tool. CAUTION: When removing/installing engine cover with tower bar installed, remove and install carefully in order to prevent damage to top surface.
3. Drain engine coolant, or when water hose is disconnected, attach plug to prevent engine coolant leakage, Refer to "Changing Engine Coolant ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
4. Remove air cleaner case and air duct, Refer to " «AIR CLEANER AND AIR DUCT»(ref-170482-S13775754652005011000000) ".
5. Remove electric throttle control actuator as follows: Disconnect harness connector. Loosen mounting bolts in reverse order (Scheme 178) CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Do not disassemble.
6. Remove fuel sub-tube mounting bolt to disconnect from rear of intake manifold collector (lower), Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-170482-S02503672052005011000000) ".
7. Disconnect vacuum hose and water hose from intake manifold collector (upper).
8. Remove EVAP canister purge volume control solenoid valve bracket mounting bolt from intake manifold collector (upper).
9. Loosen mounting bolts with power tool in reverse order (Scheme 179)to remove intake manifold collector (upper).
10. Remove PCV hose [between intake manifold collector (lower) and rocker cover (right bank)].
11. Loosen mounting bolts with power tool in reverse order (Scheme 180)and remove the intake manifold collector cover, gasket, intake manifold collector (lower) and gasket. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 180

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

Part Installation Direction

Referring to front marks, install parts (Scheme 181)

Scheme 181

Intake Manifold Collector (Lower)

Tighten mounting bolts in numerical order (Scheme 182)

Note. Tighten mounting bolts to secure gasket (lower), intake manifold collector (lower), gasket (upper), and intake manifold collector cover.

Scheme 182

Intake Manifold Collector (Upper)

1. If stud bolts were removed, install them and tighten to the specified torque below.: 4.9 - 6.9 N.m (0.5 - 0.7 kg-m, 44 - 61 in-lb)
2. Shank length under bolt head varies with bolt location. Install mounting bolts while referring to numbers shown below and in (Scheme 183). (Bolt length does not include pilot portion.) Bolt M6 x 25 mm (0.98 in): 7, 8, 10, 11, 13, 14, 15, 16, 18 M6 x 45 mm (1.77 in): 2, 4, 5 M6 x 60 mm (2.36 in): 1, 3, 6, 9 M6 Nut: 12, 17
3. Tighten mounting bolts in numerical order (Scheme 183)

Water Hose

Scheme 183

1. Insert hose by 27 to 32 mm (1.06 to 1.26 in) from connector end.
2. Clamp hose at location of 3 to 7 mm (0.12 to 0.28 in) from hose end.

Electric Throttle Control Actuator

1. Install gasket with positioning no-protrusion surface upward or downward.
2. Tighten mounting bolts in numerical order (Scheme 184)
3. Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected, Refer to "Throttle Valve Closed Position Learning ".
4. Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced, Refer to "Idle Air Volume Learning ".

Scheme 184

Scheme 185

Scheme 186

1. Release fuel pressure, Refer to "FUEL PRESSURE RELEASE ".
2. Remove intake manifold collectors (upper and lower), Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
3. Remove fuel tube and fuel injector assembly, Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-170482-S02503672052005011000000) ".
4. Loosen mounting nuts and bolts with power tool in reverse order (Scheme 186)to remove intake manifold.
5. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

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

Intake Manifold

1. If stud bolts were removed, install them and tighten to the specified torque below.: 9.8 - 11.8 N.m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
2. Tighten all mounting nuts and bolts to the specified torque in two or more steps in numerical order (Scheme 187) 1st step: 4.9 - 9.8 N.m (0.5 - 1.0 kg-m, 4 - 7 ft-lb) 2nd step and after: 26.5 - 31.4 N.m (2.7 - 3.2 kg-m, 20 - 23 ft-lb)

Scheme 187

Scheme 188

Scheme 189

Scheme 190

Scheme 191

1. Remove tower bar, Refer to "TOWER BAR ".
2. Remove engine cover with power tool, Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
3. Drain engine coolant, Refer to "Changing Engine Coolant ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
4. Remove air cleaner case and air duct, Refer to " «AIR CLEANER AND AIR DUCT»(ref-170482-S13775754652005011000000) ".
5. Remove undercover with power tool.
6. Disconnect harness connector and remove heated oxygen sensor 2 on both banks using heated oxygen sensor wrench [SST]. Put marks to identify installation positions of each heated oxygen sensor 2. CAUTION: Be careful not to damage heated oxygen sensor 2. Discard any heated oxygen sensor 2 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
7. Remove exhaust mounting bracket between three way catalysts (right and left bank) and transmission, Refer to "EXHAUST SYSTEM ".
8. Remove three way catalyst.
9. Disconnect harness connector and remove air fuel ratio sensor 1 on both banks using heated oxygen sensor wrench [SST]. Put marks to identify installation positions of each air fuel ratio sensor 1. CAUTION: Be careful not to damage air fuel ratio sensor 1. Discard any air fuel ratio sensor 1 which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; replace with a new sensor.
10. Remove water pipe and heater pipe on both right and left side, Refer to "WATER OUTLET AND WATER PIPING ".
11. Remove exhaust manifold cover.
12. Loosen mounting nuts with power tool in reverse order (Scheme 191)to remove exhaust manifold. NOTE: Disregard the numerical order No. 7 and 8 in removal.
13. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

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

Exhaust Manifold Gasket

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

Scheme 192

Exhaust Manifold

1. If stud bolts were removed, install them and tighten to the specified torque below.: 12.7 - 16.7 N.m (1.3 - 1.7 kg-m, 10 - 12 ft-lb)
2. Install mounting exhaust manifold in numerical order (Scheme 193) NOTE: Tighten nuts No. 1 and 2 in two steps. The numerical order No. 7 and 8 shown second step.

Scheme 193

Air Fuel Ratio Sensor 1 and Heated Oxygen Sensor 2

1. Install air fuel ratio sensor 1 and heated oxygen sensor 2 in the original position.
2. Install referring the following if the installation positions cannot be identified. Glass tube color Air fuel ratio sensor 1*: Black Heated oxygen sensor 2 (bank 1): White Heated oxygen sensor 2 (bank 2): White *: Air fuel ratio sensor 1 are same parts both bank 1 and bank 2.

Scheme 194

Scheme 195

Note. To remove oil pan (lower) only, take step 5 and step 6, then step 19. Step 1 to 4 and 7 to 18 are unnecessary.

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

1. Remove hood assembly.
2. Remove tower bar, Refer to "TOWER BAR ".
3. Remove engine cover with power tool, Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
4. Remove air duct, Refer to " «AIR CLEANER AND AIR DUCT»(ref-170482-S13775754652005011000000) ".
5. Drain engine oil. 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 ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
7. Remove undercover with power tool.
8. Install engine slinger to sling engine assembly for positioning, Refer to " «ENGINE ASSEMBLY»(ref-170482-S00105743472005011000000) ".
9. Remove front suspension member, Refer to " «FRONT SUSPENSION MEMBER»(ref-165835-S01357350592004090700000) ".
10. Remove drive belts, Refer to " «DRIVE BELTS»(ref-170482-S00068043942005011000000) ".
11. Remove alternator, Refer to " «GENERATOR»(ref-165597-S35450882872004083000000) ".
12. Remove starter motor, Refer to " «STARTERS»(ref-166478) ".
13. Remove idler pulley and bracket assembly, Refer to " «TIMING CHAIN»(ref-170482-S01794769552005011000000) ".
14. Disconnect oil cooler water hoses, and remove oil cooler water pipe mounting bolt, Refer to "OIL COOLER ".
15. Disconnect A/T fluid cooler hoses, and remove A/T fluid cooler tube (A/T models), Refer to "TRANSMISSION ASSEMBLY ".
16. Remove crankshaft position sensor (POS). CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
17. Remove oil filter, as necessary, Refer to "OIL FILTER ".
18. Remove oil cooler, as necessary, Refer to "OIL COOLER ".
19. Remove oil pan (lower) as follows: Loosen mounting bolts with power tool in reverse order (Scheme 196)to remove. Insert seal cutter [SST] between oil pan (upper) and oil pan (lower). CAUTION: Be careful not to damage the mating surfaces. Do not insert flat-blade screwdriver, this will damage the mating surface. Slide seal cutter by tapping on the side of the tool with hammer. Remove oil pan (lower).
20. Remove oil strainer.
21. Remove transmission joint bolts which pierce oil pan (upper), Refer to "TRANSMISSION ASSEMBLY " (M/T models) or "TRANSMISSION ASSEMBLY " (A/T models).
22. Remove rear cover plate.
23. Loosen mounting bolts with power tool in reverse order (Scheme 199)to remove oil pan (upper). Insert seal cutter [SST: KV10111100 (J37228)] between oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of tool with hammer. Remove oil pan (upper). CAUTION: Be careful not to damage mating surface.
24. Remove O-rings from bottom of cylinder block and oil pump.
25. Remove oil pan gaskets.

Scheme 201

1. Remove engine cover with power tool, Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
2. Remove air cleaner case and air duct. (At the left bank side, remove ignition coil) Refer to " «AIR CLEANER AND AIR DUCT»(ref-170482-S13775754652005011000000) ".
3. Move aside harness, harness bracket, and hoses located above ignition coil.
4. Disconnect harness connector from ignition coil.
5. Remove ignition coil. CAUTION: Do not shock it.

Install in the reverse order of removal.

Scheme 202

1. Remove engine cover with power tool, Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
2. Remove ignition coil, Refer to " «IGNITION COIL»(ref-170482-S08391874412005011000000) ".
3. Remove spark plug using spark plug wrench (commercial service tool). CAUTION: Do not drop or shock it.

Scheme 203

Install in the reverse order of removal.

Scheme 204

Scheme 205

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

1. Remove engine cover with power tool, Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
2. Release fuel pressure, Refer to "FUEL PRESSURE RELEASE ".
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage, Refer to "Changing Engine Coolant " and " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ". CAUTION: Perform this step when engine is cold.
4. Remove fuel feed hose (with damper) from fuel sub-tube. NOTE: There is no fuel return route. CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate fuel damper and fuel feed hose.
5. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows: Remove quick connector cap from quick connector connection on right member side. Disconnect fuel feed hose (with damper) from bracket hose clamp. Disconnect quick connector from centralized under-floor piping as follows: CAUTION: Disconnect quick connector by using quick connector release [SST: J-45488], not by picking out retainer tabs. With the sleeve side of quick connector release facing quick connector, install quick connector release onto centralized under-floor piping. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from centralized under-floor piping. CAUTION: Pull quick connector holding "A" position (Scheme 207) Do not pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leak out. Avoid fire and sparks. Keep parts away from heat source. Especially, be careful when welding is performed around them. Do not expose parts to battery electrolyte or other acids. Do not bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
6. Remove intake manifold collectors (upper and lower), Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
7. Disconnect harness connector from fuel injector.
8. Loosen mounting bolts in reverse order (Scheme 209), and remove fuel tube and fuel injector assembly. CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
9. Remove spacers on intake manifold.
10. 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.
11. Remove fuel sub-tube and fuel damper.

Scheme 211

Scheme 212

Scheme 213

Scheme 214

1. Install fuel damper and fuel sub-tube. 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 O-ring straight into fuel tube. Do not decenter or twist it. Insert fuel damper and fuel sub-tube straight into fuel tube. Tighten mounting bolts evenly in turn. After tightening mounting bolts, make sure that there is no gap between flange and fuel tube.
2. Install O-rings to fuel injector, paying attention to the following. CAUTION: Upper and lower O-ring are different. Be careful not to confuse them. Fuel tube side: Blue nozzle side: Brown Handle O-ring with bare hands. 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 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.
5. Install fuel tube and fuel injector assembly to intake manifold. CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts. Tighten mounting bolts in two steps in numerical order (Scheme 212) 1st step: 9.3 -10.8 N.m (0.95 -1.1 kg-m, 6.9 - 7.9 ft-lb) 2nd step: 20.6 - 26.5 N.m (2.1 - 2.7 kg-m, 16 - 19 ft-lb)
6. Connect fuel injector harness connector.
7. Install intake manifold collectors (upper and lower), Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
8. Install fuel sub-tube on rear end of intake manifold collector (lower).
9. Connect fuel feed hose (with damper). Handling procedure of O-ring is the same as that of fuel damper and fuel sub-tube. Insert fuel damper straight into fuel sub-tube. Tighten mounting bolts evenly in turn. After tightening mounting bolts, make sure that there is no gap between flange and fuel sub-tube.
10. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping connection as follows: Make sure no foreign substances are deposited in and around centralized under-floor piping and quick connector, and no damage on them. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end. Align center to insert quick connector straightly into centralized under-floor piping. Insert quick connector to centralized under-floor piping until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector. CAUTION: Hold "A" position (Scheme 213)when inserting centralized under-floor piping 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. Pull quick connector by hand holding "A" position. Make sure it is completely engaged (connected) so that it does not come out from centralized under-floor piping. Install quick connector cap to quick connector connection. Install quick connector cap with arrow on surface facing in direction of quick connector (fuel feed hose side). CAUTION: If cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again.
11. Install in the reverse order of removal after this step.

Removal and Installation

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

Scheme 215

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

1. Remove engine cover with power tool, Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
2. Remove undercover with power tool.
3. Release the fuel pressure, Refer to "FUEL PRESSURE RELEASE ".
4. Drain engine oil. CAUTION: Perform this step when engine is cold. Do not spill engine oil on drive belts.
5. Drain engine coolant from radiator, Refer to "Changing Engine Coolant ". CAUTION: Perform this step when engine is cold. Do not spill engine coolant on drive belts.
6. Remove radiator cooling fan assembly, Refer to "COOLING FAN ".
7. Separate engine harnesses removing their brackets from front timing chain case.
8. Remove drive belts, Refer to " «DRIVE BELTS»(ref-170482-S00068043942005011000000) ".
9. Remove power steering oil pump from bracket with piping connected, and temporarily secure it to aside, Refer to "POWER STEERING OIL PUMP ".
10. Remove power steering oil pump bracket, Refer to "POWER STEERING OIL PUMP ".
11. Remove alternator, Refer to " «GENERATOR»(ref-165597-S35450882872004083000000) ".
12. Remove water bypass hose, water hose clamp and idler pulley bracket from front timing chain case.
13. Remove right and left intake valve timing control covers. Loosen mounting bolts in reverse order (Scheme 215) Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal. CAUTION: Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
14. Remove collared O-ring from front timing chain case (left and right side).
15. Remove rocker covers (right and left banks), Refer to " «ROCKER COVER»(ref-170482-S18458530402005011000000) ". NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed.
16. Obtain No. 1 cylinder at TDC of its compression stroke as follows: NOTE: When timing chain is not removed/installed, this step is not required. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located (Scheme 218) If not, turn crankshaft one revolution (360 degrees) and align (Scheme 218) NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed. To make sure that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets, Refer to " «INSTALLATION»(ref-170482-S03743081322005011000000) ".
17. Remove crankshaft pulley as follows: Remove starter motor and set ring gear stopper [SST] (Scheme 219), Refer to " «STARTERS»(ref-166478) ". Loosen crankshaft pulley bolt and locate bolt seating surface as 10 mm (0.39 in) from its original position. CAUTION: Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through. CAUTION: Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
18. Remove oil pan (lower), Refer to " «OIL PAN AND OIL STRAINER»(ref-170482-S08611620792005011000000) ".
19. Loosen two mounting bolts in front of oil pan (upper) in reverse order (Scheme 222)
20. Remove front timing chain case as follows: Loosen mounting bolts in reverse order (Scheme 223) Insert suitable tool into the notch at the top of the front timing chain case as shown (1). Pry off case by moving tool as shown (2). Use seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal. CAUTION: Do not use flat-blade screwdriver or something similar. After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
21. Remove O-rings from rear timing chain case.
22. Remove oil pan gasket, Refer to " «OIL PAN AND OIL STRAINER»(ref-170482-S08611620792005011000000) ".
23. Remove water pump cover and chain tensioner cover from front timing chain case. Use seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.
24. Remove front oil seal from front timing chain case using suitable tool. Use screwdriver for removal. CAUTION: Be careful not to damage front timing chain case.
25. Remove timing chain and related parts, Refer to " «TIMING CHAIN»(ref-170482-S01794769552005011000000) ".
26. Use scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces. CAUTION: Be careful not to allow gasket fragments to enter oil pan.

Scheme 227

1. Remove old liquid gasket from bolt hole and thread.

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

Scheme 233

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

1. Install timing chain and related parts, Refer to " «TIMING CHAIN»(ref-170482-S01794769552005011000000) ".
2. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
3. Install new front oil seal on the front timing chain case. Apply new engine oil to both oil seal lip and dust seal lip. Install it so that each seal lip is oriented (Scheme 230) Using suitable drift [outer diameter: 60 mm (2.36 in)], press-fit oil seal until it becomes flush with front timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.
4. Install water pump cover and chain tensioner cover to front timing chain case. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front timing chain case (Scheme 232) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
5. Install front timing chain case as follows: Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front timing chain case back side (Scheme 233) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". Install new oil pan gasket. Apply liquid gasket to oil pan gasket (Scheme 234) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". Align notch of front timing chain case with protrusion of oil pan gasket. Apply liquid gasket with tube presser [SST: WS39930000 ( - )] to top surface of oil pan (upper) (Scheme 236) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". Install new O-rings on rear timing chain case. Assemble front timing chain case as follows: Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely. CAUTION: Be careful that oil pan gasket is in place. Since front timing chain case is offset for difference of bolt holes, tight bolts temporarily with holding front timing chain case from front and top (Scheme 239) Same as the step ii, insert dowel pin with holding front timing chain case from front and top completely. Tighten mounting bolts to the specified torque in numerical order (Scheme 240) There are two type of mounting bolts. Refer to the following for locating bolts. M8 bolts: 1, 2: 25.5 - 31.3 N.m (2.6 - 3.2 kg-m, 19 - 23 ft-lb) M6 bolts: Except the above: 11.7 - 13.7 N.m (1.2 - 1.4 kg-m, 9 - 10 ft-lb) After all bolts tightened, retighten them to the specified torque in numerical order (Scheme 240)
6. Install two mounting bolts in front of oil pan (upper) in numerical order (Scheme 241): 15.7 - 18.6 N.m (1.6 - 1.9 kg-m, 12 - 13 ft-lb)
7. Install oil pan (lower), Refer to " «OIL PAN AND OIL STRAINER»(ref-170482-S08611620792005011000000) ".
8. Install right and left intake valve timing control covers as follows: Install new seal rings in shaft grooves. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to intake valve timing control covers (Scheme 242) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". Install new collared O-rings in front timing chain case oil hole (left and right sides). Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with the holes to install intake valve timing control covers. Tighten mounting bolts in numerical order (Scheme 244)
9. Install crankshaft pulley as follows: Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)]. Install crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). Tighten crankshaft pulley bolt.: 39.2 - 49.0 N.m (4.0 - 5.0 kg-m, 29 - 36 ft-lb) Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by 60 to 65 degrees [Target: 60 degrees (equivalent to one graduation)].
10. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
11. Install in the reverse order of removal after this step.

Note. If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

Note. (Scheme 246) shows the relationship between the mating mark on each timing chain and that on the corresponding sprocket, with the components installed.

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

Scheme 251

Scheme 252

Scheme 253

Scheme 254

Scheme 255

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

Scheme 266

Scheme 267

Scheme 268

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

1. Install timing chain tensioners (secondary) to cylinder head as follows if removed, Refer to " «INSTALLATION»(ref-170482-S30713980612005011000000) ". Install timing chain tensioners (secondary) with stopper pin attached and new O-ring. Install camshaft brackets (No. 1), Refer to " «INSTALLATION»(ref-170482-S30713980612005011000000) ".
2. Install rear timing chain case as follows: Install new O-rings onto cylinder block. Install new O-rings to cylinder head. Apply liquid gasket with tube presser [SST: WS39930000 ( - )] to rear timing chain case back side (Scheme 249) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". CAUTION: For "A" in (Scheme 249), completely wipe out liquid gasket extended on a portion touching at engine coolant. Apply liquid gasket on installation position of water pump and cylinder head very completely. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block and install rear timing chain case. Make sure O-rings stay in place during installation to cylinder block and cylinder head. Tighten mounting bolts in numerical order (Scheme 250) There are two type mounting bolts. Refer to the following for locating bolts. Bolt length: Bolt position 20 mm (0.79 in): 1, 2, 3, 6, 7, 8, 9, 10 16 mm (0.63 in): Except the above: 11.7 - 13.7 N.m (1.2 - 1.4 kg-m, 9 - 10 ft-lb) After all bolts are tightened, retighten them to the specified in numerical order (Scheme 250) If liquid gasket protrudes, wipe it off immediately. After installing rear timing chain case, check the surface height difference between following parts on oil pan (upper) mounting surface. Standard Rear timing chain case to cylinder block: -0.24 to 0.14 mm (-0.0094 to 0.0055 in) If not within standard, repeat the installation procedure.
3. Install water pump with new O-rings, Refer to "WATER PUMP ".
4. Make sure that dowel pin hole, dowel pin and crankshaft key are located (Scheme 252) (No. 1 cylinder at compression TDC) NOTE: Though camshaft does not stop at the position (Scheme 252), for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of (Scheme 252). Camshaft dowel pin hole (intake side): At cylinder head upper face side in each bank. Camshaft dowel pin (exhaust side): At cylinder head upper face side in each bank. Crankshaft key: At cylinder head side of right bank. CAUTION: Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big dia. side).
5. Install timing chains (secondary) and camshaft sprockets as follows: CAUTION: Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process. Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin. Install timing chains (secondary) and camshaft sprockets. Align the mating marks on timing chain (secondary) (gold link) with the ones on intake and exhaust camshaft sprockets (punched), and install them. NOTE: Mating marks for intake camshaft sprocket are on the back side of camshaft sprocket (secondary). There are two types of mating marks, circle and oval types. They should be used for the right and left banks, respectively. Right bank: Use circle type. Left bank: Use oval type. Align dowel pin and pin hole on camshafts with the groove and dowel pin on sprockets, and install them. On the intake side, align pin hole on the small diameter side of the camshaft front end with dowel pin on the back side of camshaft sprocket, and install them. On the exhaust side, align dowel pin on camshaft front end with pin groove on camshaft sprocket, and install them. In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent. Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins. It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint. After confirming the mating marks are aligned, tighten camshaft sprocket mounting bolts. Secure camshaft using wrench at the hexagonal portion to tighten mounting bolts. Pull stopper pins out from timing chain tensioners (secondary).
6. Install tension guide.
7. Install timing chain (primary) as follows: Install crankshaft sprocket. Make sure the mating marks on crankshaft sprocket face the front of engine. Install timing chain (primary). Install timing chain (primary) so the mating mark (punched) on camshaft sprocket is aligned with the yellow link on timing chain, while the mating mark (notched) on crankshaft sprocket is aligned with the orange one on timing chain (Scheme 259) When it is difficult to align mating marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the mating marks. During alignment, be careful to prevent dislocation of mating mark alignments of timing chains (secondary).
8. Install internal chain guide, slack guide and timing chain tensioner (primary). CAUTION: Do not overtighten slack guide mounting bolts. It is normal for a gap to exist under the bolt seats when mounting bolts are tightened to specification. When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper pin. Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary). After installation, pull out stopper pin by pressing slack guide.
9. Make sure again that the mating marks on sprockets and timing chain have not slipped out of alignment.
10. Install new O-rings on rear timing chain case.
11. Install new front oil seal on front timing chain case. Apply new engine oil to both oil seal lip and dust seal lip. Install it so that each seal lip is oriented (Scheme 264) Using suitable drift, press-fit oil seal until it becomes flush with front timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.
12. Install water pump cover and chain tensioner cover to front timing chain case. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front timing chain case (Scheme 266) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ".
13. Install front timing chain case as follows: Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to front timing chain case back side (Scheme 267) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case. Tighten mounting bolts to the specified torque in numerical order (Scheme 268) There are two type of mounting bolts. Refer to the following for locating bolts. M8 bolts: 1, 2: 25.5 - 31.3 N.m (2.6 - 3.2 kg-m, 19 - 23 ft-lb) M6 bolts: Except the above: 11.7 - 13.7 N.m (1.2 - 1.4 kg-m, 9 - 10 ft-lb) After all bolts are tightened, retighten them to the specified torque in numerical order (Scheme 268) CAUTION: Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper). After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface. Standard Front timing chain case to rear timing chain case: -0.14 to 0.14 mm (-0.0055 to 0.0055 in) If not within standard, repeat the installation procedure.
14. Install right and left intake valve timing control covers as follows: Install new seal rings in shaft grooves. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to intake valve timing control covers (Scheme 270) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS ". Install new collared O-rings in front timing chain case oil hole (left and right sides). Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with holes to install intake valve timing control covers. Tighten mounting bolts in numerical order (Scheme 272)
15. Install oil pans (upper and lower), Refer to " «OIL PAN AND OIL STRAINER»(ref-170482-S08611620792005011000000) ".
16. Install rocker covers (right and left banks), Refer to " «ROCKER COVER»(ref-170482-S18458530402005011000000) ".
17. Install crankshaft pulley as follows: Fix crankshaft using ring gear stopper [SST: KV10117700 (J44716)]. Install crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). Tighten crankshaft pulley bolt.: 39.2 - 49.0 N.m (4.0 - 5.0 kg-m, 29 - 36 ft-lb) Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by 60 to 65 degrees [Target: 60 degrees (equivalent to one graduation)].
18. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
19. Install in the reverse order of removal after this step. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.

1. Remove the following parts: Undercover Drive belts; Refer to " «DRIVE BELTS»(ref-170482-S00068043942005011000000) ". Radiator cooling fan assembly; Refer to "COOLING FAN ". Starter motor; Refer to " «STARTERS»(ref-166478) ". Crankshaft pulley; Refer to " «TIMING CHAIN»(ref-170482-S01794769552005011000000) ".
2. Remove front oil seal using suitable tool. CAUTION: Be careful not to damage front timing chain case and crankshaft.

Scheme 274

Scheme 275

Scheme 276

1. Apply 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 (Scheme 275) Using suitable drift, press-fit until the height of front oil seal is level with the mounting surface. Suitable drift: outer diameter 60 mm (2.36 in), inner diameter 50 mm (1.97 in). CAUTION: Be careful not to damage front timing chain case and crankshaft. Press-fit straight and avoid causing burrs or tilting oil seal.
3. Install in the reverse order of removal after this step.

1. Remove oil pan (upper), Refer to " «OIL PAN AND OIL STRAINER»(ref-170482-S08611620792005011000000) ".
2. Remove transmission assembly, Refer to "TRANSMISSION ASSEMBLY " (M/T models) or "TRANSMISSION ASSEMBLY " (A/T models).
3. Remove clutch cover and clutch disk (M/T models), Refer to "CLUTCH DISC. CLUTCH COVER ".
4. Remove flywheel (M/T models) or drive plate (A/T models), Refer to " «CYLINDER BLOCK»(ref-170482-S23497032092005011000000) ".
5. Use seal cutter [SST] to cut away liquid gasket and remove rear oil seal retainer.

Note. Regard both rear oil seal and retainer as an assembly.

Scheme 277

Scheme 278

1. Remove old liquid gasket on mating surface of cylinder block and oil pan using scraper.
2. Apply new engine oil to both oil seal lip and dust seal lip of new rear oil seal retainer.
3. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( - )] to rear oil seal retainer (Scheme 278) Use Genuine RTV Silicone Sealant or equivalent. Refer to "RECOMMENDED FLUIDS AND LUBRICANTS ". Assembly should be done within 5 minutes after coating.
4. Install rear oil seal retainer to cylinder block, Refer to " «CYLINDER BLOCK»(ref-170482-S23497032092005011000000) ".
5. Install in the reverse order of removal after this step.

Scheme 279

Scheme 280

Scheme 281

Scheme 282

1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure, Refer to "FUEL PRESSURE RELEASE ".
3. Disconnect fuel pump fuse to avoid fuel injection during measurement.
4. Remove engine cover, Refer to " «INTAKE MANIFOLD COLLECTOR»(ref-170482-S00157874672005011000000) ".
5. Remove ignition coil and spark plug from each cylinder, Refer to " «IGNITION COIL»(ref-170482-S08391874412005011000000) " and " «SPARK PLUG (PLATINUM-TIPPED TYPE)»(ref-170482-S03414972152005011000000) ".
6. Connect engine tachometer (not required in use of CONSULT-II).
7. Install compression tester with adapter onto spark plug hole. 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.
8. 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 changed 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, 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.
9. After inspection is completed, install removed parts.
10. Start engine, and make sure that engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it, Refer to "TROUBLE DIAGNOSIS ".

Scheme 283

Scheme 284

1. Remove camshaft, Refer to " «CAMSHAFT»(ref-170482-S08610255202005011000000) ". NOTE: It is also possible to perform the following steps 2 and 3 just before removing the camshaft.
2. Temporarily fit front suspension member to support engine, Refer to " «FRONT SUSPENSION MEMBER»(ref-165835-S01357350592004090700000) ". CAUTION: Temporary fitting means the status that engine is adequately stable though the hoist is released from hanging. NOTE: At the time of the start of this procedure front suspension member is removed, and cylinder head is hanged by the hoist with engine slinger installed.
3. Release the hoist from hanging, then remove the engine slinger.
4. Remove the following parts: Fuel tube and fuel injector assembly; Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-170482-S02503672052005011000000) ". Intake manifold; Refer to " «INTAKE MANIFOLD»(ref-170482-S05108884102005011000000) ". Exhaust manifold; Refer to " «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-170482-S22859839332005011000000) ". Water inlet and thermostat assembly; Refer to "WATER INLET AND THERMOSTAT ASSEMBLY ". Water outlet and water pipe; Refer to "WATER OUTLET AND WATER PIPING ".
5. Remove cylinder head bolts in reverse order (Scheme 284)with cylinder head bold wrench (commercial service tool).
6. Remove cylinder head gaskets.

Scheme 285

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"): 0.11 mm (0.0043 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 286

Scheme 287

Scheme 288

Scheme 289

Scheme 290

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 Imp ton) pressure] or hammer and suitable tool. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
3. Using valve guide reamer (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 (Scheme 290). Projection "L". Intake and exhaust: 12.6 - 12.8 mm (0.496 - 0.504 in) CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
6. Using valve guide reamer (commercial service tool), apply reamer finish to valve guide. Standard: Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Scheme 291

Scheme 292

1. After confirming that the dimensions of valve guides and valves are within the specifications, perform this procedure.
2. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has "NG" conditions even after the re-check, replace valve seat, Refer to " «VALVE SEAT REPLACEMENT»(ref-170482-S20129329662005011000000) ".

VALVE SEAT REPLACEMENT

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

Scheme 293

Scheme 294

Scheme 295

1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. CAUTION: Prevent 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: 38.500 - 38.516 mm (1.5157 - 1.5164 in) Exhaust: 32.700 - 32.716 mm (1.2874 - 1.2880 in) Be sure to ream in circles concentric to 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-170482-S27884380012005011000000) ". 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-170482-S19200293452005011000000) ".

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

Scheme 296

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 see scheme 251.
4. When installing engine mounting brackets (RH and LH) on cylinder block, tighten two upper bolts (shown as "A" in (Scheme 296) ) first. Then tighten two lower bolts (shown as "B" in (Scheme 296) ).
5. Make sure all engine mounting insulators are seated properly, then tighten mounting nuts.
6. Tighten rear engine mounting member bolts in numerical order (Scheme 297)or (Scheme 298).

Scheme 297

Scheme 298