Engine Mechanical (Coupe): Removal & Installation Nissan Altima L33

Precaution for Removal and Disassembly

1. When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful operations.
2. Use 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 assembly.
5. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, follow the specifications.

Precaution for Assembly and Installation

1. Use torque wrench to tighten bolts or nuts.
2. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, follow the specifications.
3. Always replace the old with a new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check oil or 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. Bleed the air trapped within the system after draining the coolant.
7. Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections.
8. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage or rattles.

REMOVAL OF LIQUID GASKET SEALANT

1. After removing the bolts and nuts, separate the mating surface and remove the sealant using Tool. Tool number: KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surfaces.
2. In areas where the cutter is difficult to use, use a plastic hammer to lightly tap (1) the cutter where the RTV Silicone Sealant is applied. Use a plastic hammer to slide the cutter (2) by tapping on the side.

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Scheme 595

1. Using a scraper, remove the old Silicone RTV Sealant of the gasket application surface and the mating surface. Remove the sealant completely from the groove of the gasket application surface, mounting bolts, and bolt holes.
2. Thoroughly clean the gasket application surface and the mating surface and remove moisture, grease and foreign materials.
3. Attach the sealant tube to the tube presser. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ".
4. Apply the sealant using Tool without breaks to the specified location. Tube presser WS39930000 (-) If there is a groove for the sealant application, apply the sealant to the groove. As for the bolt holes, normally apply the sealant inside the holes. If specified, it should be applied outside the holes. Make sure to read the text of this information. Within five minutes of the sealant application, install the mating component. If the sealant protrudes, wipe it off immediately. Do not retighten after the installation. After 30 minutes or more have passed from the installation, fill the engine with the specified oil and coolant. Refer to " «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-592017-S29316942162014010800000) ".

INSTALLATION

Installation is in the reverse order of removal.

Scheme 596

1. Make sure that the stamp mark of drive belt auto-tensioner is within the usable range.

Note. Check the drive belt auto-tensioner indicator (notch) when the engine is cold. When the new drive belt is installed, the range should be (A) as shown above. Visually check entire belt for wear, damage or cracks. If the indicator is out of allowable use range or belt is damaged, replace the belt.

1. Install the drive belt onto all of the pulleys except for the water pump pulley. Then install the drive belt onto water pump pulley last. CAUTION: Confirm belts are completely set on the pulleys.
2. Release tensioner, and apply tension to drive belt. WARNING: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. CAUTION: Do not loosen the auto-tensioner pulley bolt. Don't turn it counterclockwise. If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator is within the allowable use range. Refer to " «CHECKING DRIVE BELTS»(ref-592016-S23413086692014010800000) ".
5. Install the fender protector side cover RH. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S24442268552014010800000) ".

Scheme 597

REMOVAL

1. Disconnect the battery negative terminal. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-592011-S06046231102014010800000) ".
2. Remove the front RH wheel and tire assembly. Refer to " «ADJUSTMENT»(ref-592020-S33110986762014010800000) ".
3. Remove the fender protector side cover RH. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S24442268552014010800000) ".
4. Remove the engine room cover.
5. Remove the drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S23796880142014010800000) ". Insert a rod approximately 6 mm (0.24 in) in diameter through the rear of tensioner into the retaining boss to lock tensioner pulley.
6. Remove power steering reservoir and position aside. Refer to " «EXPLODED VIEW»(ref-592021-S40268001982014010800000) ".
7. Support the engine with a suitable tool.
8. Remove RH engine mounting bracket, mounting insulator and support bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S00521159162014010800000) ".
9. Remove the drive belt auto-tensioner, with power tool. CAUTION: Do not loosen the auto-tensioner pulley bolt. (Don't turn it counterclockwise.) If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley.

Installation is in the reverse order of removal.

Scheme 598

1. Remove the engine room cover.
2. Remove front air duct.
3. Disconnect the air duct hose clamps at the electric throttle control actuator and the air cleaner assembly.
4. Disconnect the blow-by hose.
5. Remove air duct hose.
6. Disconnect the transaxle breather hose.
7. Disconnect the mass air flow sensor.
8. Remove mass air flow sensor from air cleaner assembly, as necessary. CAUTION: Handle the mass air flow sensor with care: Do not shock it. Do not disassemble it. Do not touch the internal sensor.
9. Remove the air cleaner assembly, as necessary.

Installation is in the reverse order of removal.

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1. Remove engine room cover.
2. Release the fuel pressure. Refer to " «INSPECTION»(ref-592022-S08111032412014010800000) " (California), " «INSPECTION»(ref-592023-S21357902862014010800000) " (Except California).
3. Disconnect battery negative terminal. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-592011-S06046231102014010800000) ".
4. Remove blow-by hose, air duct hose and front air duct. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S14803150462014010800000) ".
5. Remove cowl top finisher. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S27643968262014010800000) ".
6. Remove strut tower bar. Refer to " «EXPLODED VIEW»(ref-592024-S13535819192014010800000) ".
7. Disconnect the following components at the intake side: PCV hose EVAP hose and EVAP canister purge volume control solenoid Electric throttle control actuator Brake booster vacuum hose
8. Disconnect the fuel quick connector on the engine side. Using Tool perform the following steps to disconnect the quick connector. Tool number: 16441 6N210 (J-45488) Remove quick connector cap. With the sleeve side of Tool facing quick connector, install Tool onto fuel tube. Insert Tool into quick connector until sleeve contacts and goes no further. Hold the Tool on that position. CAUTION: Inserting the Tool hard will not disconnect quick connector. Hold Tool where it contacts and goes no further. Pull the quick connector straight out from the fuel tube. CAUTION: Pull quick connector holding it at the (A) position, as shown above. 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. Be sure to cover openings of disconnected pipes with plug or plastic bag to avoid fuel leakage and entry of foreign materials. Do not reuse O-ring.
9. When removing fuel hose quick connector at vehicle piping side, perform as follows. Remove quick connector cap. Hold the sides of the connector, push in tabs and pull out the tube. (The figure is shown below for reference only.) If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling. CAUTION: The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. Do not use any tools to remove the quick connector. Keep the resin tube away from heat. Be especially careful when welding near the tube. Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. Do not bend or twist the tube during installation and removal. Do not remove the remaining retainer on tube. When the tube is replaced, also replace the retainer with a new one. Retainer color: Green. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
10. Loosen bolts diagonally, remove the electric throttle control actuator, and position it aside. CAUTION: Handle carefully to avoid any damage.
11. Remove the bolts and nuts in the order shown below and remove the intake manifold assembly and gasket, using power tools. CAUTION: Cover engine openings to avoid entry of foreign materials.

Installation is in the reverse order of removal. Follow the tightening sequences below.

Tightening Intake Manifold Bolts and Nuts

Scheme 604

1. Tighten in numerical order as shown below. CAUTION: After tightening the five bolts in the order shown below, the 1, 6 position designates that the first bolt tightened is to be retightened to specification.
2. Installation of Electric Throttle Control Actuator: Tighten the bolts of electric throttle control actuator equally and diagonally in several steps. After installation perform procedure in . «INSPECTION AFTER INSTALLATION»(ref-592016-S18196729992014010800000)

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Scheme 606

1. Make sure no foreign substances are deposited in and around the fuel tube and quick connector, and there is no damage to them.
2. Thinly apply new engine oil around the fuel tube tip end.
3. Align center to insert quick connector straight into fuel tube. Insert fuel tube into quick connector until the top spool on fuel tubes is inserted completely and the second level spool is positioned slightly below the quick connector bottom end. CAUTION: Hold at position (A) as shown below, when inserting the fuel tube into the quick connector. Carefully align to center to avoid inclined insertion to prevent damage to the O-ring inside the quick connector. Insert the fuel tube 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. Do not reuse O-ring.
4. Before clamping the fuel hose with the hose clamp, pull the quick connector hard by hand, holding at the (A) position, as shown below. Make sure it is completely engaged (connected) so that it does not come off of the fuel tube. NOTE: Recommended pulling force is 50 N (5.1 kg-f, 11.2 lb-f).
5. Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap to upper side (fuel hose side).
6. Install fuel hose to hose clamp.

Scheme 607

1. Make sure no foreign substances are deposited in and around the fuel tube and quick connector, and there is no damage to them.
2. Align center to insert quick connector straight into fuel tube. Insert fuel tube until a click is heard. Install quick connector cap on quick connector joint. Direct arrow mark on quick connector cap upper side. Install fuel hose to hose clamp.

Installation is in the reverse order of removal.

Tightening Exhaust Manifold Nuts

Scheme 608

1. Tighten the nuts to specification in the numerical order shown below, on the exhaust manifold and three way catalyst assembly.

Installation of Air Fuel Ratio (A/F) Sensor 1

Clean the air fuel ratio (A/F) sensor 1 threads with the suitable tool, then apply the anti-seize lubricant to the threads before installing the air fuel ratio (A/F) sensor 1.

Oxygen sensor thread cleaner: J-43897 - 18

Oxygen sensor thread cleaner: J-43897 - 12

Scheme 609

Note. When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

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1. Drain engine oil. Refer to " «CHANGING ENGINE OIL»(ref-592029-S25315628712014010800000) ". WARNING: To avoid the danger of being scalded, never drain the engine oil when the engine is hot.
2. Remove the front exhaust tube. Refer to " «EXPLODED VIEW»(ref-592028-S05924199902014010800000) ".
3. Remove power steering cooler hose bracket from suspension member.
4. Disconnect the power steering hose and tube from the power steering gear. Refer to " «EXPLODED VIEW»(ref-592021-S24031104982014010800000) ".
5. Remove oil level gauge guide.
6. Remove the front suspension member for clearance to remove the oil pan. Refer to " «REMOVAL AND INSTALLATION»(ref-592024-S24625802692014010800000) ".
7. Disconnect the A/C compressor electrical connector.
8. Remove the A/C compressor bolts and position the A/C compressor aside. Refer to " «REMOVAL AND INSTALLATION»(ref-592013-S40509849192014010800000) ".
9. Remove the rear engine mount torque rod bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S00521159162014010800000) ".
10. Remove the center drive shaft bearing bracket from the oil pan, if necessary.
11. Remove the lower oil pan bolts in the order as shown below, using power tool.
12. Remove the lower oil pan using Tool. NOTE: Tap gently to cut sealant around the pan; do not damage the mating surface using Tool. Tool number: KV10111100 (J-37228)
13. Remove the oil strainer.
14. Remove rear plate cover, and four engine-to transaxle bolts, using power tool.
15. Loosen the upper oil pan bolts in the order shown below to remove upper oil pan, using power tool.
16. Remove upper oil pan using Tool. Remove the three O-rings from the upper oil pan and front cover. CAUTION: Do not reuse O-rings. NOTE: Tap gently to cut sealant around the pan; do not damage the mating surface using Tool. Tool number: KV10111100 (J-37228)

Installation is in the reverse order of removal.

Scheme 614

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1. Apply Genuine Silicone RTV Sealant or equivalent to the upper oil pan at the specified sealant bead diameter (A) as shown below. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ". Sealant bead diameter (A): 4.0 - 5.0 mm (0.157 - 0.197 in) CAUTION: Install two new O-rings in the upper oil pan and a new O-ring in the front cover. Do not reuse O-rings.
2. Tighten the upper oil pan bolts in the order as shown below.
3. Apply Genuine Silicone RTV Sealant or equivalent to the lower oil pan at the specified sealant bead diameter (A) as shown below. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ". Sealant bead diameter (A): 4.0 - 5.0 mm (0.157 - 0.197 in)
4. Tighten the lower oil pan bolts in the numerical order shown below. CAUTION: Wait at least 30 minutes after the oil pans are installed before filling the engine with oil.

1. Remove the engine room cover.
2. Disconnect the harness connector from the ignition coil.
3. Remove the ignition coil. CAUTION: Do not drop or shock it.

Installation is in the reverse order of removal.

Scheme 618

Scheme 619

1. Remove engine room cover.
2. Release the fuel pressure. Refer to " «INSPECTION»(ref-592022-S08111032412014010800000) " (California), " «INSPECTION»(ref-592023-S21357902862014010800000) " (Except California).
3. Disconnect the battery negative terminal. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-592011-S06046231102014010800000) ".
4. Remove the front air duct. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S14803150462014010800000) ".
5. Disconnect the fuel hose quick connector at the fuel tube side. CAUTION: Prepare a container and cloth for catching any spilled fuel. This operation should be performed in a place that is free from any open flames. While hoses are disconnected seal their openings with vinyl bag or similar material to prevent foreign material from entering them.
6. Remove the intake manifold. Refer to «INTAKE MANIFOLD»(ref-592016-S05382354022014010800000) .
7. Disconnect sub-harness for injector at engine front side, and remove it from bracket.
8. Loosen the bolts in the reverse order shown below, then remove fuel tube and fuel injectors as an assembly.
9. Remove the fuel injectors from the fuel tube. Release the clip and remove the fuel injector. Pull fuel injector straight out of the fuel tube. CAUTION: Be careful not to damage the nozzle. Avoid any impact, such as dropping the fuel injector. Do not disassemble or adjust the fuel injector.

Scheme 620

Scheme 621

1. Install new O-rings on the fuel injector, the fuel side black O-ring and the nozzle side green O-ring. CAUTION: Do not reuse O-rings. Upper and lower O-rings are different. Be careful not to confuse them. Fuel tube side: black O-ring Nozzle side: green O-ring Lubricate the O-rings lightly with new engine oil. Handle O-rings with bare hands only. Do not wear gloves. Do not clean O-rings with solvent. Make sure that O-ring and its mating part are free of foreign material. Be careful not to scratch O-rings during installation. Do not twist or stretch the O-ring. If the O-ring was stretched while it is attached, do not insert it into the fuel tube immediately.
2. Install the fuel injector (5) into the fuel tube (1) with the following procedure: Do not reuse the clip (3), replace it with a new one. Insert the new clip (3) into the clip mounting groove (F) on fuel injector (5). Insert the clip (3) so that projection (E) of fuel injector (5) matches notch (C) of the clip (3). Fuel tube side: black O-ring (2) Nozzle side: green O-ring (4)
3. Insert fuel injector (5) into fuel tube (1) with clip (3) attached. Insert it while matching it to the axial center. Insert fuel injector (5) so that projection (A) of fuel tube (1) matches notch (B) of the clip (3). Make sure that fuel tube flange (G) is securely fixed in flange fixing groove (D) on the clip (3). Make sure that installation is complete by checking that fuel injector (5) does not rotate or come off.
4. Install fuel tube assembly. Insert the tip of each fuel injector (5) into intake manifold. Tighten the bolts in two steps in the numerical order as shown below. Fuel tube assembly bolts Step 1: 10 N.m (1.0 kg-m, 7 ft-lb) Step 2: 22 N.m (2.2 kg-m, 16 ft-lb) CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.
5. Install the intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S29799204272014010800000) ".
6. Connect the fuel hose quick connector.
7. Installation of the remaining components is in the reverse order of removal.

Installation is in the reverse order of removal.

Scheme 622

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Scheme 633

1. Remove the engine and transaxle assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S00521159162014010800000) ".
2. Remove the upper and lower oil pan, and oil strainer. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S01467858682014010800000) ".
3. Remove generator. Refer to " «REMOVAL AND INSTALLATION»(ref-592027-S14904319922014010800000) ".
4. Disconnect variable timing control solenoid harness connector.
5. Loosen IVT (intake valve timing) control cover bolts in the numerical order as shown below. Remove the IVT control cover using Tool. Tool number: KV10111100 (J-37228)
6. Set the No. 1 cylinder at TDC on the compression stroke with the following procedure: Rotate the crankshaft pulley clockwise and align the mating marks to the timing indicator on the front cover. At the same time, make sure that the mating marks on the camshaft sprockets are lined up as shown below. If not lined up, rotate the crankshaft pulley one more turn to line up the mating marks to the positions as shown below.
7. Remove crankshaft pulley with the following procedure: Hold the crankshaft pulley using suitable tool, then loosen the crankshaft pulley bolt, and pull the pulley out about 10 mm (0.39 in). Attach suitable pulley puller in the M 6 (0.24 in diameter) thread hole on crankshaft pulley, and remove crankshaft pulley using a suitable puller.
8. Remove the front cover with the following procedure: Loosen the bolts in the numerical order as shown below, and remove them. Remove the front cover. CAUTION: Be careful not to damage the mounting surface.
9. Remove front oil seal using suitable tool, if necessary.
10. Remove timing chain with the following procedure: Push in the tensioner plunger. Insert a stopper pin into the hole on the tensioner body to secure the chain tensioner plunger and remove chain tensioner. Use a wire of 0.5 mm (0.02 in) diameter as a stopper pin. Remove the timing chain. Secure hexagonal part of the camshaft with a wrench and loosen the camshaft sprocket bolt and remove the camshaft sprocket for both camshafts. CAUTION: Do not rotate the crankshaft or camshafts while the timing chain is removed. It can cause damage to the valve and piston.
11. Remove the chain slack guide, tension guide, timing chain, and oil pump drive spacer.
12. Press stopper tab (A) in the direction shown below to push the timing chain slack guide (B) toward timing chain tensioner (for balancer unit) (1). The slack guide (B) is released by pressing the stopper tab (A). As a result, the slack guide (B) can be moved.
13. Insert stopper pin (D) into tensioner body hole (C) to secure timing chain slack guide (B). NOTE: Use a hard metal pin with a diameter of approximately 1.2 mm (0.047 in) as a stopper pin.
14. Remove timing chain tensioner (for balancer unit) (1).
15. Secure width across flats of the balancer LH side shaft using a suitable tool. Loosen the balancer sprocket bolt.
16. Remove balancer unit timing chain, balancer unit sprocket and crankshaft sprocket.
17. Loosen bolts in order as shown below, and remove balancer unit. Use socket (size E14) CAUTION: Do not disassemble balancer unit.

Note. There may be two color variations of the link marks (link colors) on the timing chain. There are 26 links between the blue mating marks on the timing chain; and 64 links between the camshaft sprocket blue link and the crankshaft sprocket orange link, on the timing chain side without the tensioner.

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1. Make sure the crankshaft key points straight up.
2. Install the balancer unit and tighten the bolts in the numerical order as shown below: CAUTION: When reusing a bolt, check its outer diameter before installation. Follow the Balancer Unit Bolt Outer Diameter procedure. Apply new engine oil to threads and seating surfaces of bolts. Check tightening angle with an angle wrench (A) or a protractor. Do not make judgment by visual check alone. Tool number: KV10112100 (BT-8653-A) Balancer unit bolts Step 1 Bolts 1-5: 42 N.m (4.3 kg-m, 31 ft-lb) Bolt 6: 36 N.m (3.7 kg-m, 27 ft-lb) Step 2 Bolts 1-5: 120° + 5° Bolt 6: 90° + 5° Step 3 (Loosen in everse order or tightening): 0 N.m (0 kg-m, 0 ft-lb) Step 4 Bolts 1-5: 42 N.m (4.3 kg-m, 31 ft-lb) Bolt 6: 36 N.m (3.7 kg-m, 27 ft-lb) Step 5 Bolts 1-5: 120° + 5° Bolt 6: 90° + 5°
3. Install the crankshaft sprocket (1) and timing chain (2) for the balancer unit. Make sure that the crankshaft sprocket (1) is positioned with mating marks (A) on the block and sprocket meeting at the top. Install it by lining up mating marks on each sprocket (A), (C) and timing chain (B), (D). B: Blue link D: Orange link
4. Install timing chain tensioner (for balancer unit) (1). Fix the plunger at the most compressed position using a stopper pin (A), and then install it. Securely pull out (<==) the stopper pin after installing the timing chain tensioner (for balancer unit). Check matching mark position of balancer unit drive chain and each sprocket again.
5. Install timing chain (1) and related parts. Install by lining up mating marks on each sprocket and timing chain as shown below. Before and after installing chain tensioner (3), check again to make sure the mating marks have not slipped. After installing timing chain tensioner (3), remove the stopper pin, and make sure that the tensioner moves freely. CAUTION: For the following note, after the mating marks are aligned, keep them aligned by holding them by hand. To avoid skipped teeth, do not move crankshaft and camshaft until front cover is installed. NOTE: Before installing chain tensioner (3), it is possible to change the position of mating mark on timing chain for that of each sprocket for alignment. 2: Camshaft sprocket (INT) 4: Timing chain slack guide 5: Crankshaft key 6: Crankshaft sprocket 7: Balancer unit sprocket 8: Balancer unit chain tensioner 9: Balancer unit timing chain 10: Timing chain tension guide 11: Camshaft sprocket (EXH) 12: Chain guide A: Mating mark (peripheral stamp line) B: Blue link C: Mating mark (lug) D: Mating mark (stamp) E: Orange link F: Blue link G: Mating mark (stamp) H: Mating mark (stamp) J: Orange link K: Mating mark (stamp) L: Blue link
6. Install new front oil seal to front cover, using suitable tool Install new oil seal in until it is flush with front end surface of front cover. CAUTION: Do not reuse oil seal. Be careful not to cause damage to circumference of oil seal.
7. Install front cover with the following procedure: Install O-rings (B) to cylinder head and cylinder block. CAUTION: Do not reuse O-rings. Apply Genuine Silicone RTV Sealant or equivalent, to positions (A) specified as shown below. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ". Sealant diameter (C): 3.9 mm (0.154 in) Make sure the mating marks on the timing chain and each sprocket are still aligned. Then install the front cover. CAUTION: Be careful not to damage the front oil seal during installation with the front end of the crankshaft. Tighten front cover bolts in the numerical order as shown below. After all bolts are tightened, retighten them to the specified torque. Front cover bolts Bolts (A): 49 N.m (5.0 kg-m, 36 ft-lb) Bolts (B): 12.7 N.m (1.3 kg-m, 9 ft-lb) Bolts (C): 12.7 N.m (1.3 kg-m, 9 ft-lb) Bolts (D): 49 N.m (5.0 kg-m, 36 ft-lb) (E) Dowel pins CAUTION: Wipe off any excess sealant leaking at the surface for installing the oil pan.
8. Install the chain guide between the camshaft sprockets.
9. Install IVT cover with the following procedure: Install IVT solenoid valve to IVT cover. Install new O-ring to front cover. CAUTION: Do not reuse O-ring. Apply Silicone RTV Sealant to the IVT cover as shown below. Apply Genuine Silicone RTV Sealant or equivalent, to positions specified as shown below. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ". Diameter (A): 3.0 - 4.0 mm (0.118 - 0.157 in) Tighten the IVT cover bolts in the numerical order as shown below.
10. Insert crankshaft pulley by aligning with crankshaft key. Tap its center with a plastic hammer to insert. Do not tap the belt hook.
11. Tighten crankshaft pulley bolts. Secure crankshaft pulley with tool to tighten the bolt. Perform angle tightening with the following procedure: Apply new engine oil to threads and seat surfaces of bolts. Tighten to initial specifications: Crankshaft bolt: 42.1 N.m (4.3 kg-m, 31 ft-lb) Apply a paint mark on the front cover, mating with any one of six easy to recognize stamp marks on bolt flange. Turn crankshaft pulley bolt another 60° to 66° degrees [Target: 60° degrees]. Check vertical mounting angle with movement of one stamp mark.
12. Installation of the remaining components is in the reverse order of removal.

Scheme 645

Scheme 646

1. Remove camshaft. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S00554203142014010800000) ".
2. Remove valve lifter. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S00554203142014010800000) ".
3. Rotate crankshaft, and set piston whose oil seal is to removed to top dead center. This prevents valve from dropping inside cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring the front cover with the timing chain.
4. Remove valve collet, valve spring retainer and valve spring using Tool. Tool number : KV10116200 (J-26336-B) : KV10115900 (J-26336-20)
5. Remove valve oil seal using Tool. Tool number: KV10107902 (J-38959)

Scheme 647

1. Apply new engine oil to new valve oil seal joint surface and seal lip.
2. Press in valve oil seal to the position shown below using Tool. Oil seal installed height (A): 12.1 mm (0.476 in) Tool number: KV10115600 (J-38958)
3. Installation of the remaining components is in the reverse order of removal.

1. Remove the following parts: RH front wheel. Refer to " «ADJUSTMENT»(ref-592020-S33110986762014010800000) ". Fender protector side cover RH. Refer to " «REMOVAL AND INSTALLATION»(ref-592019-S24442268552014010800000) ". Drive belts. Refer to «DRIVE BELTS»(ref-592016-S25039129232014010800000) . Crankshaft pulley. Refer to «TIMING CHAIN»(ref-592016-S40364969022014010800000) .
2. Remove front oil seal from front cover. CAUTION: Be careful not to scratch front cover.

Scheme 648

Scheme 649

1. Install new front oil seal to front cover using suitable tool. Install new oil seal in until it is flush with front end surface of front cover. CAUTION: Do not reuse oil seal. Be careful not to cause damage to circumference of oil seal. Install new oil seal in the direction shown below.
2. Installation of the remaining components is in the reverse order of removal.

Scheme 650

1. Remove the transaxle. Refer to " «UNIT REMOVAL AND INSTALLATION»(ref-592030-S29683858582014010800000) ".
2. Remove drive plate.
3. Remove rear oil seal using suitable tool. CAUTION: Be careful not to scratch rear oil seal retainer.

Scheme 651

Scheme 652

Scheme 653

1. Apply new engine oil to new oil seal and install it using a suitable tool. Install new oil seal in the direction shown below. Press fit new oil seal straight using a suitable drift, to avoid causing burrs or tilting. Press in the new oil seal to the specified depth as shown below.
2. Installation of the remaining components is in the reverse order of removal.

Scheme 654

1. Remove the timing chain. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S04717953372014010800000) ".
2. Remove the camshafts. Refer to «CAMSHAFT»(ref-592016-S12834092042014010800000) .
3. Remove spark plugs. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S14052902852014010800000) ".
4. Remove the exhaust manifold and three way catalyst. Refer to " «REMOVAL AND INSTALLATION»(ref-592016-S06035965652014010800000) ".
5. Remove cylinder head loosening bolts in the order as shown below, using power tool.
6. Remove cylinder head.
7. Remove cylinder head gasket.
8. If necessary to transfer to new cylinder head or remove for reconditioning, remove the intake manifold collector, intake manifold, and fuel tube assembly. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-592016-S41596357442014010800000) ".

Scheme 655

1. Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace the bolts with new ones. Limit (d1 - d2): 0.23 mm (0.0091 in) or more
2. If reduction of outer diameter appears in a position other than d2, use it as d2 point.

Scheme 656

Scheme 657

Scheme 658

1. Install a new cylinder head gasket.
2. Install the cylinder head.
3. Follow the steps below to tighten the cylinder head bolts in the numerical order as shown below. Apply new engine oil to the threads and the seating surfaces of bolts. CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. Follow the Outer Diameter of Cylinder Head Bolts measurement procedure. Check and confirm the tightening angle by using angle wrench or protractor. Avoid judgment by visual inspection without the tool. Tool number: KV10112100 (BT-8653-A) Step a: 55 N.m (5.6 kg-m, 41 ft-lb) Step b: Loosen to 0 N.m in the reverse order of tightening. Step c: 39.2 N.m (4.0 kg-m, 29 ft-lb) Step d: 75° clockwise Step e: 75° clockwise
4. Installation of the remaining components is in the reverse order of removal.

Scheme 659

Scheme 660

Scheme 661

1. Remove the valve lifter. Confirm installation point.
2. Remove the valve collet, valve spring retainer and valve spring using Tool. Tool number: KV10116200 (J-26336-B) : KV10115900 (J-26336-20) CAUTION: Do not remove valve spring seat from valve spring.
3. Push valve stem to combustion chamber side, and remove valve. Inspect valve guide clearance before removal. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-592016-S18448970532014010800000) ". Confirm installation point.
4. Remove valve oil seal using Tool. Tool number: KV10107902 (J-38959)
5. When valve seat must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-592016-S18448970532014010800000) ".
6. When valve guide must be replaced, refer to " «INSPECTION AFTER DISASSEMBLY»(ref-592016-S18448970532014010800000) ".
7. Remove spark plug using suitable tool.
8. Remove spark plug tubes, if necessary using suitable tool. CAUTION: Be careful not to damage cylinder head. Do not remove spark plug tube if not necessary. Once removed, the spark plug tube cannot be reused because of deformation during removal.

Scheme 662

Scheme 663

1. Install valve guide. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-592016-S18448970532014010800000) ".
2. Install valve seat. Refer to " «INSPECTION AFTER DISASSEMBLY»(ref-592016-S18448970532014010800000) ".
3. Install new valve oil seal using Tool as shown below. Oil seal installed height (A): 12.1 mm (0.476 in) Tool number: KV10115600 (J-38958)
4. Install valve. Install larger diameter to intake side.
5. Install valve spring. Install valve spring so that the identification color faces upwards. Confirm the identification color of the valve spring. Intake: pink Exhaust: green
6. Install valve spring retainer.
7. Install valve collet using Tool. Compress valve spring with valve spring compressor. Install valve collet with magnet hand. Tap stem edge lightly with plastic hammer after installation to check its installed condition. Tool number: KV10116200 (J-26336-B) : KV10115900 (J-26336-20)
8. Install valve lifter.
9. Install spark plug tube. Remove old liquid gasket from cylinder head side mounting hole. Apply liquid gasket all around on spark plug tube with a 12 mm (0.47 in) width from edge of spark plug tube on the press fit side. Use Three Bond or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-592010-S39097878722014010800000) ". Press fit spark plug tube so that height is to (H) as shown below. Press fit height (H) standard value: 41.7 mm (1.642 in) CAUTION: When press fitting be careful not to deform spark plug tube. After press fitting, wipe off any protruding liquid gasket on top surface of cylinder head.
10. Install spark plug using suitable tool.

Scheme 664

1. Wipe off oil and remove water scale deposits, old gasket, old sealer, and carbon with a scraper. CAUTION: Use care not to allow gasket debris to enter passages for oil or water.
2. At each of several locations on bottom surface of cylinder head, measure distortion in six directions. Limit: 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head.

VALVE GUIDE REPLACEMENT

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

Scheme 665

Scheme 666

Scheme 667

Scheme 668

Scheme 669

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 (2.2 ton-force) pressure] or hammer and suitable tool.
3. Ream cylinder head valve guide hole using suitable reamer. Intake and exhaust valve guide hole diameter (Service): 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. Press valve guide from camshaft side to dimensions as shown below.
6. Apply finish to valve guide using suitable reamer. Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

VALVE SEAT REPLACEMENT

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

Scheme 670

Scheme 671

Scheme 672

1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in the cylinder head. Set the machine depth stop to ensure this.
2. Ream cylinder head recess diameter for service valve seat. Intake: 37.000 - 37.016 mm (1.4567 - 1.4573 in) Exhaust: 32.000 - 32.016 mm (1.2598 - 1.2605 in) Be sure to ream in circles concentric to the valve guide center. This will enable the valve seat to fit correctly.
3. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.
4. Use valve seats cooled well with dry ice. Force fit valve seat into cylinder head. CAUTION: Avoid directly touching the cold valve seats.
5. Finish the seat to the specified dimensions using suitable tool. Refer to " «STANDARD AND LIMIT»(ref-592016-S42035231992014010800000) ". CAUTION: When using valve seat cutter, firmly grip the cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on the cutter or cutting many different times may result in a defective valve seat.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact.

Installation is in the reverse order of removal.

Note. Tighten the transmission bolts to specification. Refer to " UNIT REMOVAL AND INSTALLATION ".

Scheme 673

1. Do not allow oil to get on mounting insulators. Be careful not to damage mounting insulators.
2. If parts have a direction mark (arrow) this indicates front of the vehicle, and the parts must be installed according to the identification mark.
3. Install the RH engine mounting bracket bolts in the following steps: First install bolts (A) and (B) loosely. Install and tighten the five RH engine mounting bracket bolts to specification in the order as shown below. RH engine mounting bracket bolt: 48.2 N.m (4.9 kg-m, 36 ft-lb)