Engine Mechanical: Removal & Installation Nissan 370Z I

FOR USA AND CANADA : Removal and Disassembly

1. When instructed to use SST, use the specified tools. Always be careful to work safely, and avoid forceful or uninstructed operations.
2. Exercise maximum care to avoid damage to mating or sliding surfaces.
3. Dowel pins are used for the alignment of several parts. When replacing and reassembling parts with dowel pins, check that dowel pins are installed in the original position.
4. Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.
5. Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
6. 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.

FOR USA AND CANADA : 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 the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

FOR MEXICO : Removal and Disassembly

1. When instructed to use SST, use the specified tools. Always be careful to work safely, and avoid forceful or uninstructed operations.
2. Exercise maximum care to avoid damage to mating or sliding surfaces.
3. Dowel pins are used for the alignment of several parts. When replacing and reassembling parts with dowel pins, check that dowel pins are installed in the original position.
4. Cover openings of engine system with tape or equivalent, if necessary, to seal out foreign materials.
5. Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
6. 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.

FOR MEXICO : 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 the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

INSTALLATION

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

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 163

Refer to " COMPONENTS " for symbols in the figure.

Scheme 164

1. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-402630-S30675446912011053100000) ".
2. Remove air cleaner case and air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-402630-S30945629272011053100000) ".
3. Remove electric throttle control actuator. Refer to " «EXPLODED VIEW»(ref-402630-S33004613582011053100000) ".
4. Remove ignition coil. Refer to " «REMOVAL AND INSTALLATION»(ref-402630-S14338146372011053100000) ".
5. Remove spark plug with a spark plug wrench (commercial service tool).

Installation is the reverse order of removal.

Removal and Installation

REMOVAL

1. Loosen mounting bolts of engine cover (front) with power tool.
2. Remove engine cover (front).
3. Loosen mounting bolts and nuts of engine cover (rear) with power tool.
4. Remove engine cover (rear).

Installation is the reverse order of removal.

Scheme 165

1. Remove drive belt. Refer to " «EXPLODED VIEW»(ref-402630-S06407024782011053100000) ". Keep auto-tensioner pulley arm locked after drive belt is removed.
2. Remove auto-tensioner and idler pulley. Keep auto-tensioner pulley arm locked to install or remove auto-tensioner.

Installation is the reverse order of removal.

Scheme 166

Refer to " COMPONENTS " for symbols in the figure.

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

1. Disconnect mass air flow sensor harness connector.
2. Disconnect PCV hose.
3. Remove air cleaner case with mass air flow sensor and air duct, disconnecting each joints. Add marks if necessary for easier installation.
4. Remove mass air flow sensor from air cleaner case if necessary. CAUTION: Handle mass air flow sensor according to the following instructions. Never shock mass air flow sensor Never disassemble mass air flow sensor. Never touch mass air flow sensor.

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

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

Scheme 167

Scheme 168

1. Remove front tower bar assembly. Refer to " «EXPLODED VIEW»(ref-402643-S29880040022011053100000) ".
2. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-402630-S30675446912011053100000) ".
3. Remove air cleaner case and air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-402630-S30945629272011053100000) ".
4. Remove electric throttle control actuator as follows: Drain engine coolant. When water hoses are disconnected, attach plug to prevent engine coolant leakage. CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belt. Disconnect water hoses from electric throttle control actuator. When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant leakage. Disconnect harness connector. Loosen mounting bolts in reverse order as shown in the figure. NOTE: When removing only intake manifold collector, move electric throttle control actuator without disconnecting the water hose. The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. Viewed from the air duct side, the order of loosening mounting bolts of electric throttle control actuator (bank 2) is the same as that of the electric throttle control actuator (bank 1). CAUTION: Handle carefully to avoid any shock to electric throttle control actuator.
5. Disconnect vacuum hose, PCV hose, and EVAP hose from intake manifold collector.
6. Remove EVAP canister purge volume control solenoid valve and EVAP tube assembly from intake manifold collector.
7. Loosen mounting bolts and nuts with power tool in the reverse order as shown in the figure to remove intake manifold collector.

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

INTAKE MANIFOLD COLLECTOR

Scheme 169

1. If stud bolts were removed, install them and tighten to the torque specified below. : 10.8 N.m (1.1 kg-m, 8 ft-lb)
2. Tighten mounting bolts and nuts in numerical order as shown in the figure.

WATER HOSE

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 (BANK 1 AND BANK 2)

Scheme 170

1. Tighten in numerical order as shown in the figure. NOTE: The figure shows the electric throttle control actuator (bank 1) viewed from the air duct side. Viewed from the air duct side, the order of tightening mounting bolts of electric throttle control actuator (bank 2) is the same as that of the electric throttle control actuator (bank 1).
2. Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to " «THROTTLE VALVE CLOSED POSITION LEARNING : DESCRIPTION»(ref-402633-S11323317062011053100000) ".
3. 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 : DESCRIPTION»(ref-402633-S35699001962011053100000) " and " «THROTTLE VALVE CLOSED POSITION LEARNING : DESCRIPTION»(ref-402633-S11323317062011053100000) ".

Scheme 171

Refer to " COMPONENTS " for symbols in the figure.

Scheme 172

1. Release fuel pressure. Refer to " «INSPECTION»(ref-402633-S12269264022011053100000) ".
2. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-402630-S33004613582011053100000) ".
3. Remove fuel tube and fuel injector assembly. Refer to " «EXPLODED VIEW»(ref-402630-S19680395262011053100000) ".
4. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold with power tool. CAUTION: Cover engine openings to avoid entry of foreign materials. Put a mark on the intake manifold and the cylinder head with paint before removal because they need to be installed in the specified direction.
5. Remove gaskets.

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

INTAKE MANIFOLD

Scheme 173

1. If stud bolts were removed, install them and tighten to the torque specified below. : 10.8 N.m (1.1 kg-m, 8 ft-lb)
2. Tighten all mounting bolts to the specified torque in two or more steps in numerical order as shown in the figure. CAUTION: Install intake manifold with the marks (put on the intake manifold and the cylinder head before removal) aligned. 1st step: : 7.4 N.m (0.75 kg-m, 5 ft-lb) 2nd step and after: : 25.5 N.m (2.6 kg-m, 19 ft-lb)

Note. When removing bank 1 side parts only, steps 2 , 6 , and 8 are unnecessary.

Scheme 174

Scheme 175

1. Remove engine undercover with power tool.
2. Drain engine coolant. Refer to " «DRAINING»(ref-402632-S39255201782011053100000) ".
3. Remove front tower bar assembly. Refer to " «EXPLODED VIEW»(ref-402643-S29880040022011053100000) ".
4. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-402630-S30675446912011053100000) ".
5. Remove air cleaner case and air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-402630-S30945629272011053100000) ".
6. Remove heater pipe and water hose. Refer to " «EXPLODED VIEW»(ref-402632-S19935215662011053100000) ".
7. Remove exhaust front tube and three way catalysts (bank 1 and bank 2). Refer to " «EXPLODED VIEW»(ref-402635-S33524790992011053100000) ".
8. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-402649-S11167871112011053100000) ".
9. Disconnect air fuel ratio sensor 1 (bank 1 and bank 2) harness connectors and remove harness clip.
10. Using the heated oxygen sensor wrench [SST: KV10114400 (J-38365)] (C), remove air fuel ratio sensor 1 (bank 1 and bank 2). CAUTION: Be careful not to damage air fuel ratio sensor 1. Discard any air fuel ratio sensor 1 that has been dropped onto a hard surface such as a concrete floor. Replace with a new sensor. NOTE: Exhaust manifold is removal without removing air fuel ratio sensor 1. (The harness connector must be disconnected.)
11. Remove exhaust manifold cover (upper) (bank 1 and bank 2).
12. Loosen mounting nuts in the reverse order as shown in the figure 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

Scheme 176

1. Install exhaust manifold gasket in direction shown in the figure. (Follow the same procedure for both banks.)

EXHAUST MANIFOLD

Scheme 177

1. If stud bolts were removed, install them and tighten to the torque specified below. Tightening torque : Refer to " «EXPLODED VIEW»(ref-402630-S40598656022011053100000) ".
2. Install exhaust manifold and tighten mounting nuts in numerical order as shown in the figure. NOTE: Tighten nuts the No. 1 and 2 in two steps. The numerical order No. 7 and 8 shows the second step.

AIR FUEL RATIO SENSOR 1

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1. Release fuel pressure. Refer to " «INSPECTION»(ref-402633-S12269264022011053100000) ".
2. Disconnect battery cable from the negative terminal. Refer to " «EXPLODED VIEW»(ref-402650-S40875309862011053100000) ".
3. Remove engine cover with power tool. Refer to " «EXPLODED VIEW»(ref-402630-S30675446912011053100000) ".
4. Remove air cleaner case and air duct (RH and LH). Refer to " «EXPLODED VIEW»(ref-402630-S30945629272011053100000) ".
5. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-402630-S33004613582011053100000) ".
6. Remove fuel feed hose (with damper) (1) from fuel sub-tube (2) and remove harness bracket (3). NOTE: There is no fuel return route. CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Never separate damper and hose.
7. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows: Remove quick connector cap (2) from quick connector connection on right member side. Disconnect fuel feed hose (with damper) (1) from bracket hose clamp. Disconnect quick connector from centralized under-floor piping as follows: CAUTION: Disconnect quick connector by using quick connector release (commercial service tool: 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 (A) into quick connector (2) until sleeve (B) 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 "D" 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 because fuel will leak 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 (with damper) during installation/removal. To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or a similar item.
8. Remove fuel sub tube mounting bolt.
9. Disconnect harness connector from fuel injector.
10. Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly. CAUTION: Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.
11. Remove fuel injector (2) from fuel tube (4) as follows: Open and remove clip (1). 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.
12. Remove fuel sub-tube and fuel damper, if necessary.

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1. Install fuel damper (4) as follows: Install new O-ring (1) to fuel tube as shown in the figure. When handling new O-ring, pay attention to the following caution items: 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, do not insert it quickly into fuel tube. Insert new O-ring straight into fuel tube. Never twist it. Install spacer (3) to fuel damper. Insert fuel damper straight into fuel tube. CAUTION: Insert straight, checking that the axis is lined up. Never pressure-fit with excessive force. Reference value : 130 N (13.3 kg, 29.2 lb) Insert fuel damper until (A) is touching (B) of fuel tube. Install the cut-out (A) of the clip (2) to the projection (B), which ensures that the fuel tube does not move or rotate. Unlock the clip after checking that the rib of the cup and the brim of the fuel damper are mated each other and positioned in the holes (C) of the clip. Check that the opening (B) and the slit (C) of the clip are positioned and fixed properly so it does not rotate or pull out.
2. Install fuel sub-tube. When handling new O-rings, be careful of the following caution items: 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 sub-tube straight into fuel tube. Tighten mounting bolts evenly in turn. After tightening mounting bolts, check that there is no gap between flange and fuel tube.
3. Install new O-rings to fuel injector, paying attention to the following items: 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.
4. Install fuel injector to fuel tube as follows: Insert clip (3) into clip mounting groove (F) on fuel injector (5). 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 clip so that protrusion (E) of fuel injector matches cut-out (C) of clip. Insert fuel injector into fuel tube (1) with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip. Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. Check that protrusions of fuel injectors and fuel tube are aligned with cutouts of clips after installation.
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 as shown in the figure. 1st step: 10.1 N.m (1.0 kg-m, 7 ft-lb) 2nd step: 23.6 N.m (2.4 kg-m, 17 ft-lb)
6. Connect injector sub-harness.
7. Install fuel sub tube mounting bolt.
8. 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, check that there is no gap between flange and fuel sub-tube.
9. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping connection as follows: Check that no foreign substances are deposited in and around centralized under-floor piping and quick connector, and that there is no damage to them. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end. Align center to insert quick connector (1) straightly into centralized under-floor piping. Insert quick connector to centralized under-floor piping until top spool (2) is completely inside quick connector and 2nd level spool (3) exposes just below quick connector. CAUTION: Hold (A) position as shown in the figure 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 a "click" sound is heard and the engagement is felt. To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Pull quick connector by hand holding (A) position. Check that 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 (3) with arrow (A) on surface facing in the direction of quick connector (fuel feed hose side). CAUTION: If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check the connection again.
10. Install in the reverse order of removal after this step.

Scheme 191

Scheme 192

1. Remove engine undercover with power tool.
2. Drain engine oil. Refer to " «DRAINING»(ref-402631-S40028903152011053100000) ".
3. Remove oil pan (lower) as follows: Loosen mounting bolts in reverse order as shown in the figure, and then remove mounting bolts. Insert the seal cutter [SST: KV10111100 (J-37228)] (A) between oil pan (upper) and oil pan (lower). CAUTION: Be careful not to damage the mating surfaces. Never insert a screwdriver. This damages the mating surfaces. Slide the seal cutter by tapping on the side of tool with a hammer. Remove oil pan (lower).

Scheme 193

Scheme 194

Scheme 195

1. Install oil pan (lower) as follows: Use scraper (A) to remove old liquid gasket from mating surfaces. Remove old liquid gasket from the bolt holes and thread. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the oil pan (lower) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-402629-S16543919932011053100000) ". CAUTION: Attaching should be done within 5 minutes after coating. Install oil pan (lower). Tighten mounting bolts in numerical order as shown in the figure.
2. Install oil pan drain plug. Refer to the figure of the components of on the prior information for installation direction of drain plug washer. Refer to " «EXPLODED VIEW»(ref-402630-S35556213242011053100000) ".
3. Install in the reverse order of removal after this step. NOTE: Wait at least 30 minutes after oil pan is installed before pouring engine oil.

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

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1. Check that dowel pin (A) and crankshaft key (1) are located as shown in the figure. (No. 1 cylinder at compression TDC) NOTE: Though camshaft does not stop at the position as shown in the figure, for the placement of cam noses, it is generally accepted that camshaft is placed in the same direction as that of the figure. Camshaft dowel pin : At cylinder head upper face side in each bank. Crankshaft key : At cylinder head side of bank 1.
2. Install timing chains (secondary) and camshaft sprockets as follows: CAUTION: Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process. Push plunger of timing chain tensioner (secondary) and keep it pressed in with a stopper pin (A). Install timing chains (secondary) and camshaft sprockets. NOTE: Figure shows bank 1 (rear view). Align the matching marks on timing chain (secondary) (orange link) with the ones on intake and exhaust camshaft sprockets (punched), and install them. NOTE: Matching marks for camshaft sprockets (INT) are on the back side of camshaft sprockets (secondary). There are two types of matching marks, the circle and oval types. They should be used for the bank 1 and bank 2, respectively. Bank 1 : Use circle type Bank 2 : Use oval type Shape (orientation of signal plate) of camshaft sprocket (INT) varies depending on the bank position. See the right figure to install. Align dowel pin camshafts with the pin groove on sprockets, and install them. In case that positions of each matching mark and each dowel pin do not fit with matching parts, make fine adjustment to the position holding the hexagonal portion on camshaft (EXH) or drive shaft with wrench or equivalent tool. Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is sufficient to prevent the dislocation of dowel pins. It may be difficult to visually check the dislocation of matching marks during and after installation. To make the matching easier, make a matching mark on the top of sprocket teeth and its extended line in advance with paint. Tighten camshaft sprocket (EXH) mounting bolt. Secure camshaft (EXH) using a wrench at the hexagonal portion to tighten mounting bolt. After confirming the matching marks are aligned, tighten camshaft sprocket (INT) mounting bolt. Secure the hexagonal portion (located in between journal No. 1 and journal No. 2) of drive shaft (A) using a wrench to tighten mounting bolt. CAUTION: When holding the hexagonal part of drive shaft on the intake side with a wrench, be careful not to allow the wrench to cause interference with other parts. Pull stopper pins (C) out from timing chain tensioners (secondary) (1), (2).
3. Install timing chain (primary) as follows: Install crankshaft sprocket (1). Check that the matching marks on crankshaft sprocket face the front of the engine. Install timing chain (primary). Install timing chain (primary) so that the matching mark (punched) (B) on camshaft sprocket (INT) (1) is aligned with the yellow link (A) on timing chain, while the matching mark (notched) (C) on crankshaft sprocket (2) is aligned with the orange link (D) one on timing chain, as shown in the figure. When it is difficult to align matching marks of timing chain (primary) with each sprocket, gradually turn drive shaft using wrench on the hexagonal portion to align it with the matching marks.
4. Install internal chain guide (1), slack guide (2), and tension guide (3). CAUTION: Never overtighten slack guide mounting bolt (2). It is normal for a gap (A) to exist under the bolt seats when mounting bolt are tightened to the specification.
5. Install the timing chain tensioner (primary) with the following procedure: Pull plunger stopper tab (A) up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger (D). NOTE: Plunger stopper tab and lever (C) are synchronized. Push plunger into the inside of tensioner body. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet. To secure lever, insert stopper pin (E) through hole of lever into tensioner body hole (B). The lever parts and the plunger stopper tab are synchronized. Therefore, the plunger is secured under this condition. NOTE: Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin. Install timing chain tensioner (primary) (1). Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary). Pull out stopper pin (A) after installing, and then release plunger.
6. Check again that the matching marks on sprockets and timing chain have not slipped out of alignment.
7. Install new o-rings (1) on rear timing chain case.
8. Install new front oil seal on front timing chain case. Apply new engine oil to both oil seal lip (A) and dust seal lip (B). Install it so that each seal lip is oriented as shown in the figure. Using a suitable drift [outer diameter: 60 mm (2.36 in)] (A), press-fit oil seal until it becomes flush with front timing chain case end face. Check that the garter spring is in position and seal lip is not inverted.
9. Install front timing chain case as follows: Check that O-rings stay in place during installation to rear timing chain case. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case back side as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-402629-S16543919932011053100000) ". Apply liquid gasket to top surface of oil pan (upper) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-402629-S16543919932011053100000) ". Assemble front timing chain case. CAUTION: Be careful not to damage front oil seal by interference with front end of crankshaft. Attaching should be done within 5 minutes after liquid gasket application. Install front timing chain case fitting its dowel pin hole together with dowel pin on rear timing chain case. Tighten mounting bolts to the specified torque in numerical order as shown in the figure. There are two types of mounting bolts. Refer to the following for locating bolts. M10 bolts : 1, 2, 3, 4, 5, 6, 7 : 55.0 N.m (5.6 kg-m, 41 ft-lb) M6 bolts : Except the above : 12.7 N.m (1.3 kg-m, 9 ft-lb) After all bolts are tightened, retighten them to the specified torque in numerical order shown in the figure. CAUTION: Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper). Install two mounting bolts in front of oil pan (upper) in numerical order shown in the figure. Tightening torque : Refer to " «EXPLODED VIEW»(ref-402630-S12185434132011053100000) ".
10. Install intake valve timing control covers as follows: Install new seal rings (1) in shaft grooves. CAUTION: When replacing seal ring, replace all rings with new ones. NOTE: The figure shows an example of bank 2. Install intake valve timing control cover with new gasket to front timing chain case. CAUTION: Align the center of both shaft holes of the camshaft sprocket (INT) and the shaft, and then insert them. Be careful not to drop the seal ring from the shaft groove. Being careful not to move seal ring from the installation groove, align dowel pins on front timing chain case with dowel pin holes (C) to install intake valve timing control covers. Tighten mounting bolts in numerical order as shown in the figure. After all bolts are tightened, tighten No. 1 bolt to the specified torque again.
11. Install oil pan (lower). Refer to " «EXPLODED VIEW»(ref-402630-S35556213242011053100000) ".
12. Install rocker covers (bank 1 and bank 2). Refer to " «EXPLODED VIEW»(ref-402630-S10774314442011053100000) ".
13. Install crankshaft pulley as follows: Fix crankshaft using the ring gear stopper [SST: KV10118600 (J-48641)]. 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. : 44.1 N.m (4.5 kg-m, 33 ft-lb) Tighten the bolt 90 degrees (one mark) (b). Place a matching mark (A) on crankshaft pulley (2) aligning with the matching mark (C) of crankshaft pulley bolt (1). Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
14. For the following operations, perform steps in the reverse order of removal.

FRONT OIL SEAL : Removal and Installation

REMOVAL

Scheme 221

1. Remove the following parts: Engine undercover with power tool. Drive belt: Refer to " «EXPLODED VIEW»(ref-402630-S06407024782011053100000) ". Crankshaft pulley: Refer to " «EXPLODED VIEW»(ref-402630-S39642212362011053100000) ".
2. Remove front oil seal using a suitable tool. CAUTION: Be careful not to damage front timing chain case and crankshaft.

INSTALLATION

Scheme 222

Scheme 223

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 a 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). Check that the garter spring is in position and seal lips are not inverted. 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.

REAR OIL SEAL : Removal and Installation

REMOVAL

Scheme 224

1. Remove transmission assembly, refer to the following: M/T models " «WITHOUT S-MODE : EXPLODED VIEW»(ref-518789-S32545726492011053100000) " (WITHOUT S-MODE) " «WITH S-MODE : EXPLODED VIEW»(ref-518789-S18770263102011053100000) " (WITH S-MODE) A/T models " «EXPLODED VIEW»(ref-402639-S32434319502011053100000) "
2. Remove drive plate (A/T models) or fly wheel (M/T models). Refer to " «EXPLODED VIEW»(ref-402630-S21054746752011053100000) ".
3. Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block.

INSTALLATION

Scheme 225

Scheme 226

Scheme 227

1. Install rear oil seal. Install rear oil seal so that each seal lip is oriented as shown in the figure. Press in rear oil seal (1) to the position as shown in the figure. Using a suitable drift (A), press-fit until the height of rear oil seal is level with the mounting surface. Suitable drift: outer diameter 100 mm (3.94 in), inner diameter 85 mm (3.35 in). CAUTION: Be careful not to damage crankshaft and cylinder block. Press-fit straight and avoid causing burrs or tilting oil seal.
2. Install in the reverse order of removal after this step.

Scheme 228

Refer to " COMPONENTS " for symbols in the figure.

Outline

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

Preparation

1. Release fuel pressure. Refer to " «INSPECTION»(ref-402633-S12269264022011053100000) ".
2. Disconnect both battery cables. Refer to " «EXPLODED VIEW»(ref-402650-S40875309862011053100000) ".
3. Drain engine coolant from radiator. Refer to " «DRAINING»(ref-402632-S39255201782011053100000) ". CAUTION: Perform this step when engine is cold. Never spill engine coolant on drive belt.
4. Remove the following parts: Engine undercover (power tool) Front road wheel and tires (power tool) Front tower bar assembly: Refer to " «EXPLODED VIEW»(ref-402643-S29880040022011053100000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-402630-S30675446912011053100000) ". Radiator reservoir tank: Refer to " «EXPLODED VIEW»(ref-402632-S19383167382011053100000) ". Air duct and air cleaner case assembly (RH and LH): Refer to " «EXPLODED VIEW»(ref-402630-S30945629272011053100000) ". Cowl top cover: Refer to " «EXPLODED VIEW»(ref-402671-S03247072472011053100000) ".
5. Discharge refrigerant from A/C circuit. Refer to " «RECYCLE REFRIGERANT»(ref-402652-S11220679192011053100000) ".
6. Disconnect radiator hoses (upper and lower) at engine side. Refer to " «EXPLODED VIEW»(ref-402632-S19383167382011053100000) ".

Engine Room LH

1. Disconnect heater hose at vehicle side, and fit a plug onto hose end to prevent engine coolant leakage.
2. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to " «EXPLODED VIEW»(ref-402652-S42720246482011053100000) ".
3. Disconnect brake booster vacuum hose.
4. Disconnect ground cable.

Engine Room RH

1. Disconnect bonding wire from exhaust manifold (bank 1).
2. Disconnect heater hose at vehicle side, and fit a plug onto hose end to prevent engine coolant leakage.
3. Disconnect battery positive cable at vehicle side and temporarily fasten it on engine.
4. Disconnect all clips and connectors of the engine room harness from engine back side.
5. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to " «EXPLODED VIEW»(ref-402630-S19680395262011053100000) ". CAUTION: Fit plugs onto disconnected hoses to prevent fuel leakage.
6. Drain power steering fluid from reservoir tank of power steering oil pump. CAUTION: Be careful not to spill power steering fluid in engine room.
7. Disconnect power steering oil pump suction hose at power steering oil pump side. Refer to " «EXPLODED VIEW»(ref-402649-S29614259422011053100000) ". CAUTION: Never spill power steering fluid on drive belt.

Vehicle Inside

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

1. Remove passenger-side kicking plate and dash side finisher. Refer to " «EXPLODED VIEW»(ref-402672-S42703072432011053100000) ".
2. Disconnect engine room harness connectors at unit side and other locations.
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 adhesion of foreign materials.

Vehicle Underbody (M/T models)

1. Disconnect heated oxygen sensor 2 harness. Refer to " «EXPLODED VIEW»(ref-402630-S40598656022011053100000) ".
2. Remove exhaust front tube and center muffler. Refer to " «EXPLODED VIEW»(ref-402635-S33524790992011053100000) ".
3. Remove rear propeller shaft. Refer to " «EXPLODED VIEW»(ref-402640-S30514047112011053100000) ".
4. Separate control rod from control lever assembly, and then remove control lever assembly. Refer to " «WITHOUT S-MODE : REMOVAL AND INSTALLATION»(ref-518789-S14448459462011053100000) " (WITHOUT S-MODE) or " «WITH S-MODE : REMOVAL AND INSTALLATION»(ref-518789-S19741073022011053100000) " (WITH S-MODE).
5. Disconnect clutch hose from clutch tube. Refer to " «EXPLODED VIEW»(ref-402638-S23276665322011053100000) ".
6. Remove suspension member stay. Refer to " «EXPLODED VIEW»(ref-402643-S22777441852011053100000) ".
7. Remove rear plate cover from oil pan (upper). Refer to " «EXPLODED VIEW»(ref-402630-S12185434132011053100000) ".
8. Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW»(ref-402630-S35556213242011053100000) ".
9. Disconnect power steering oil pump oil cooler hoses. Refer to " «EXPLODED VIEW»(ref-402649-S41049624892011053100000) ". Install plug to avoid leakage of power steering fluid.
10. Remove front wheel sensor for ABS from steering knuckle. Refer to " «FRONT WHEEL SENSOR : EXPLODED VIEW»(ref-402648-S38820940952011053100000) ". (RH and LH)
11. Remove front stabilizer connecting rod from transverse link. Refer to " «EXPLODED VIEW»(ref-402643-S36291684752011053100000) ". (RH and LH)
12. Separate steering outer sockets from steering knuckle. Refer to " «EXPLODED VIEW»(ref-402649-S04471631842011053100000) ". (RH and LH)
13. Separate lower ends of steering knuckle from transverse link. Refer to " «EXPLODED VIEW»(ref-402641-S41719262952011053100000) ". (RH and LH)
14. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-402649-S11167871112011053100000) ".

Vehicle Underbody (A/T models)

1. Disconnect heated oxygen sensor 2 harness. Refer to " «EXPLODED VIEW»(ref-402630-S40598656022011053100000) ".
2. Remove exhaust front tube and center muffler. Refer to " «EXPLODED VIEW»(ref-402635-S33524790992011053100000) ".
3. Remove rear propeller shaft. Refer to " «EXPLODED VIEW»(ref-402640-S30514047112011053100000) ".
4. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Refer to " «EXPLODED VIEW»(ref-402639-S01939414952011053100000) ".
5. Remove suspension member stay. Refer to " «EXPLODED VIEW»(ref-402643-S22777441852011053100000) ".
6. Remove rear plate cover from oil pan (upper). Refer to " «EXPLODED VIEW»(ref-402630-S12185434132011053100000) ".
7. Then remove bolts fixing drive plate to torque converter. Refer to " «EXPLODED VIEW»(ref-402639-S32434319502011053100000) ".
8. Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW»(ref-402630-S35556213242011053100000) ".
9. Disconnect A/T fluid cooler hoses. Refer to " «EXPLODED VIEW»(ref-402639-S41962262122011053100000) " Install plug to avoid leakage of A/T fluid.
10. Disconnect power steering oil pump oil cooler hoses. Refer to " «EXPLODED VIEW»(ref-402649-S41049624892011053100000) ". Install plug to avoid leakage of power steering fluid.
11. Remove front wheel sensor for ABS from steering knuckle. Refer to " «FRONT WHEEL SENSOR : EXPLODED VIEW»(ref-402648-S38820940952011053100000) ". (RH and LH)
12. Remove front stabilizer connecting rod from transverse link. Refer to " «EXPLODED VIEW»(ref-402643-S36291684752011053100000) ". (RH and LH)
13. Separate steering outer sockets from steering knuckle. Refer to " «EXPLODED VIEW»(ref-402649-S04471631842011053100000) ". (RH and LH)
14. Separate lower ends of steering knuckle from transverse link. Refer to " «EXPLODED VIEW»(ref-402641-S41719262952011053100000) ". (RH and LH)
15. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-402649-S11167871112011053100000) ".

Removal Work

Scheme 229

1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support the bottom of suspension member and the transmission assembly. CAUTION: Use a piece of wood or a similar item as the supporting surface to secure a completely stable condition. Never support the three way catalyst.
2. Remove rear engine mounting member bolts.
3. Remove front suspension member mounting bolts and nuts. Refer to " «EXPLODED VIEW»(ref-402643-S22777441852011053100000) ".
4. Carefully lower jack, or raise lift, to remove the engine, the transmission assembly and front suspension member. When performing work, observe the following caution items: CAUTION: Confirm there is no interference with the vehicle. Check that all connection points have been disconnected. Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling off the lift.

Separation Work

Scheme 230

1. Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2). Slinger bolts: : 28.0 N.m (2.9 kg-m, 21 ft-lb)
2. Remove power steering oil pump from engine. Refer to " «EXPLODED VIEW»(ref-402649-S29614259422011053100000) ".
3. Remove three way catalysts (bank 1 and bank 2).
4. Remove engine mounting insulators (RH and LH) under side nuts with power tool.
5. Lift with hoist and separate the engine and the transmission assembly from front suspension member. CAUTION: Before and during this lifting, always check that any harnesses are left connected. Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine mounting insulator.
6. Remove crankshaft position sensor. Refer to " «EXPLODED VIEW»(ref-402630-S21054746752011053100000) ". CAUTION: Handle crankshaft position sensor carefully and avoid impacts. Never disassemble. Never place crankshaft position sensor in a location where it is exposed to magnetism.
7. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-402636-S28239326512011053100000) ".
8. Separate the engine from the transmission assembly, refer to the following: M/T models " «WITHOUT S-MODE : EXPLODED VIEW»(ref-518789-S32545726492011053100000) " (WITHOUT S-MODE) " «WITH S-MODE : EXPLODED VIEW»(ref-518789-S18770263102011053100000) " (WITH S-MODE) A/T models " «EXPLODED VIEW»(ref-402639-S32434319502011053100000) "
9. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.

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

Scheme 231

Scheme 232

1. Do not damage engine mounting insulator and do not spill oil 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 " «EXPLODED VIEW»(ref-402630-S37220918692011053100000) ".
4. When installing engine mounting bracket (RH and LH) on cylinder block, tighten two upper bolts [shown as (B) in the figure] first. Then tighten two lower bolts [shown as (C) in the figure].
5. Check that all engine mounting insulators are seated properly, and then tighten mounting nuts.
6. Tighten rear engine mounting member bolts in numerical order as shown in the figure.

Scheme 233

Scheme 234

1. Remove oil level gauge, oil pressure switch and oil temperature sensor.
2. Remove oil pan (lower). Refer to " «EXPLODED VIEW»(ref-402630-S35556213242011053100000) ".
3. Remove oil strainer.
4. Loosen mounting bolts in the reverse order as shown in the figure with power tool to remove. Insert the seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and lower cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper). CAUTION: Be careful not to damage the mating surfaces. Never insert a screwdriver, because this damages the mating surfaces.
5. Remove O-rings (2) from bottom of lower cylinder block (1) and oil pump (3).

Scheme 235

Scheme 236

Scheme 237

Scheme 238

1. Install oil pan (upper) as follows: Use a scraper (A) to remove old liquid gasket from mating surfaces. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Also remove old liquid gasket from mating surface of lower cylinder block. Remove old liquid gasket from the bolt holes and threads. Install new O-rings (2) on the bottom of lower cylinder block (1) and oil pump (3). Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-402629-S16543919932011053100000) ". CAUTION: For bolt holes with marks (7 locations), apply liquid gasket outside the holes. Attaching should be done within 5 minutes after coating. Install oil pan (upper). CAUTION: Never mis-align both O-rings during installation. Tighten mounting bolts in numerical order as shown in the + figure. There are two types of mounting bolts. Refer to the following for locating bolts. M8 x 90 mm (3.54 in) : 7, 10, 13 M8 x 25 mm (0.98 in) : Except the above
2. Install oil strainer to oil pump.
3. Install oil pan (lower). Refer to " «EXPLODED VIEW»(ref-402630-S35556213242011053100000) ".
4. Install oil pan drain plug. Refer to the figure of components on the prior information for installation direction of drain plug washer. Refer to " «EXPLODED VIEW»(ref-402630-S35556213242011053100000) ".
5. Install in the reverse order of removal after this step. NOTE: Wait at least 30 minutes after oil pan is installed before pouring engine oil.