Engine Mechanical: Removal & Installation Nissan Armada I

PRECAUTIONS FOR REMOVAL AND DISASSEMBLY

1. When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
2. Exercise maximum care to avoid damage to mating or sliding surfaces.
3. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials.
4. Mark and arrange disassembly parts in an organized way for easy troubleshooting and assembly.
5. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used where noted in the step.

PRECAUTIONS FOR ASSEMBLY AND INSTALLATION

1. Use torque wrench to tighten bolts or nuts to specification.
2. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
3. Replace with new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.
5. 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. 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 engine coolant, fuel, oil, and exhaust systems for leakage.

INSTALLATION

Installation is in the reverse order of removal.

Scheme 74

1. Remove the air duct and resonator assembly when inspecting the drive belt. Refer to «REMOVAL»(ref-233240-S11402286492006052500000) .
2. Make sure that the indicator (single line notch) of each auto tensioner is within the allowable working range "A" (between three line notches). NOTE: Check the auto tensioner indication when the engine is cold. When the new drive belt is installed, the range should be as shown. The indicator notch is located on the moving side of the auto tensioner.
3. Visually check entire belt for wear, damage or cracks.
4. If the indicator is out of allowable working range or belt is damaged, replace the belt.

Installation is in the reverse order of removal.

1. Rotate the crankshaft pulley several turns clockwise to equalize belt tension between pulleys.
2. Make sure belt tension is within the allowable working range, using the indicator notch on the auto tensioner. Refer to «CHECKING DRIVE BELTS»(ref-233240-S00614163472006052500000) .

Scheme 75

REMOVAL

1. Remove the air duct and resonator assembly. Refer to «REMOVAL»(ref-233240-S11402286492006052500000) .
2. Remove the drive belt. Refer to «REMOVAL»(ref-233240-S26704070312006052500000) .
3. Remove the auto tensioner and idler pulley using power tool.

Installation is in the reverse order of removal.

Scheme 76

1. Remove the engine room cover using power tool. Refer to «REMOVAL»(ref-233240-S39160149112006052500000) .
2. Disconnect the harness connector from air cleaner case (upper).
3. Remove the air duct and resonator assembly and air cleaner case. Add marks as necessary for easier installation.

Installation is in the reverse order of removal.

Installation is in the reverse order of removal.

Scheme 77

1. Tighten the intake manifold bolts in numerical order (Scheme 77)
2. Install the EVAP canister purge control solenoid valve connector with it facing front of engine.
3. Tighten the electronic throttle control actuator bolts of the electric throttle control actuator equally and diagonally in several steps.
4. After installation perform procedure in «INSPECTION AFTER INSTALLATION»(ref-233240-S36509359332006052500000).
5. Install the water hose so that its overlap width for connection is between 27 mm (1.06 in) and 32 mm (1.26 in) (target: 27 mm 1.06 in).

Scheme 78

Scheme 79

1. Remove the air duct and resonator assembly. Refer to «REMOVAL»(ref-233240-S11402286492006052500000).
2. Drain the engine coolant from the radiator. Refer to «DRAINING ENGINE COOLANT»(ref-233319-S09209346902006052500000).
3. Remove the engine undercover using power tool.
4. Remove the radiator and radiator hoses. Refer to «REMOVAL»(ref-233257-S30262370512006052500000).
5. Remove the drive belts. Refer to «REMOVAL»(ref-233240-S26704070312006052500000).
6. Remove the air fuel ratio A/F sensors (right bank, left bank). Follow steps below to remove each air fuel ratio A/F sensor. Remove the engine room cover using power tool. Refer to «REMOVAL»(ref-233240-S39160149112006052500000). Remove the harness connector of each air fuel ratio A/F sensor, and harness from bracket and middle clamp. Remove the air fuel ratio A/F sensors from both left and right exhaust manifolds using Tool. Tool number: - (J-44626) CAUTION: Do not damage the air fuel ratio A/F sensors Discard any air fuel ratio A/F sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor. Replace it with a new one.
7. Remove the front cross bar.
8. Remove the exhaust manifold (left bank) following the steps below. Remove the exhaust front tube. Refer to «REMOVAL»(ref-233272-S41515308372006052500000). Remove the exhaust manifold cover. Loosen the nuts in reverse order of (Scheme 79) using power tool. Remove the exhaust studs from positions 2, 4, 6, 8 and remove left exhaust manifold
9. Remove the exhaust manifold (right bank) following the steps below. Remove the exhaust front tube. Refer to «REMOVAL»(ref-233272-S41515308372006052500000). Remove the oil level gauge guide. Refer to «REMOVAL»(ref-233240-S04669786312006052500000). Remove the exhaust manifold cover. Loosen the nuts in reverse order of (Scheme 79) using power tool. Remove the exhaust studs from positions 2, 4, 6, 8 and remove right exhaust manifold.

Scheme 80

1. Check the flatness of each exhaust manifold flange surface using suitable tools. Flatness limit: 0.3 mm (0.012 in)
2. If measurement exceeds the limit, replace the exhaust manifold.

Installation is in the reverse order of removal.

Scheme 81

Scheme 82

1. Install new exhaust manifold gasket with the top of the triangular up mark on it facing up and its coated face (gray side) toward the exhaust manifold side.
2. Tighten the exhaust manifold nuts in the numerical order (Scheme 82) Then recheck the torque of the nuts.
3. Before installing new air fuel ration A/F sensors, clean the exhaust system threads using Tool and apply anti-seize lubricant. Tool number: ( - ) J-43879-12: ( - ) J-43897-18 CAUTION: Do not over tighten the air fuel ratio A/F sensors. Doing so may cause damage to the sensor, resulting in the MIL coming on.

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

1. Remove the engine. Refer to «REMOVAL»(ref-233240-S15370622752006052500000).
2. Remove the oil pan (lower) using the following steps. Remove the oil pan (lower) bolts in reverse order (Scheme 84)using power tool. Remove the oil pan (lower) using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage mating surface.
3. Remove the oil strainer from the oil pan (upper).
4. Remove the oil pan (upper) using the following steps. Remove the oil pan (upper) bolts in reverse order (Scheme 86) Remove the oil pan (upper) from the cylinder block by prying it at the points (Scheme 87)using suitable tool. CAUTION: Do not damage mating surface.
5. Remove the O-rings from the oil pump and front cover. NOTE: Do not reuse O-rings.

1. Remove the engine room cover using power tool. Refer to «REMOVAL»(ref-233240-S39160149112006052500000) .
2. Disconnect the harness connector from the ignition coil.
3. Remove the ignition coil. CAUTION: Do not shock ignition coil.

Installation is in the reverse order of removal.

Scheme 89

Scheme 90

1. Remove the ignition coil. Refer to «REMOVAL»(ref-233240-S23007780522006052500000) .
2. Remove the spark plug using suitable tool.

Installation is in the reverse order of removal.

Scheme 91

Scheme 92

1. Remove the engine room cover using power tool. Refer to «REMOVAL»(ref-233240-S39160149112006052500000) .
2. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233258-S23412934922006052500000) .
3. Disconnect the negative battery terminal.
4. Disconnect the fuel injector harness connectors.
5. Disconnect the fuel hose assembly from the fuel tubes (right bank and left bank). CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate the fuel connector and fuel hose.
6. Remove the fuel injectors with the fuel tube assembly.
7. Remove the fuel injector from the fuel tube using the following steps. Spread open and remove the clip. Remove the fuel injector from the fuel tube by pulling straight out. CAUTION: Be careful with remaining fuel that may leak out from fuel tube. Do not damage injector nozzles during removal. Do not bump or drop fuel injectors. Do not disassemble fuel injectors.
8. Remove the fuel damper from each fuel tube.

Scheme 93

Scheme 94

Scheme 95

1. Install the fuel damper to each fuel tube using the following steps. Apply engine oil to the new O-ring and set it into the cap of the fuel tube. CAUTION: Handle O-ring with bare hands. Never wear gloves. Lubricate new 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, do not scratch it with tool or fingernails. Do not twist or stretch the O-ring. Make sure that the backup spacer is in the O-ring connecting surface of the fuel damper. NOTE: The backup spacer is part of the fuel damper assembly. Insert the fuel damper until it seats on the fuel tube. CAUTION: Insert straight, making sure that the axis is lined up. Do not pressure-fit with excessive force. Reference value: 130 N (13.3 kg, 29.2 lb) Install the cap, and then tighten the bolts evenly. After tightening the bolts, make sure that there is no gap between the cap and fuel tube.
2. Install new O-rings to the fuel injector paying attention to the items below. CAUTION: Upper and lower O-rings are different. Fuel tube side: Blue Nozzle side: Brown Handle O-ring with bare hands. Never wear gloves. Lubricate new 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 angle or twist it.
3. Install the fuel injector to the fuel tube using the following steps. Insert new clip into clip mounting groove on the fuel injector. Insert clip so that lug "A" of fuel injector matches notch "A" of the clip. CAUTION: Do not reuse clip. Replace it with a new one. Do not allow the clip to interfere with the O-ring. If interference occurs, replace the O-ring. Insert the fuel injector into the fuel tube with the clip attached. Insert it while matching it to the axial center. Insert fuel injector so that lug "B" of fuel tube matches notch "B" of the clip. Make sure that the fuel tube flange is securely fixed in the flange fixing groove on the clip. Make sure that installation is complete by checking that the fuel injector does not rotate or come off. Make sure that the protrusions of the fuel injectors are aligned with the cutouts of the clips after installation.
4. Install the fuel tube and fuel injector assembly to the intake manifold. CAUTION: Do not let the tip of the injector nozzle come in contact with other parts. Tighten fuel tube assembly bolts "a" to "b" in (Scheme 95) in two steps. 1st step: 12.8 N.m (1.3 kg-m, 9 ft-lb) 2nd step: 24.5 N.m (2.5 kg-m, 18 ft-lb)
5. Install the fuel hose assembly. Insert connectors straight, making sure that the axis is lined up with fuel tube side to prevent O-ring from being damaged. Tighten bolts evenly in several steps. Make sure that there is no gap between the flange and fuel tube after tightening the bolts. 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 new O-ring straight into fuel tube. Do not twist it.
6. Installation of the remaining components is in the reverse order of removal.

Installation is in the reverse order of removal.

Scheme 96

1. Install the valve oil seal using Tool. Tool number: KV10115600 (J-38958)
2. Apply new engine oil on the new valve oil seal joint and seal lip.
3. Install the valve oil seal to the specified height "H". Height "H" (Without valve spring seat installed) Intake and exhaust: 14.3-14.9 mm (0.563-0.587 in)

Scheme 97

1. Remove the engine. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S15370622752006052500000) .
2. Remove the crankshaft pulley. Refer to «TIMING CHAIN»(ref-233240-S04092693052006052500000) .
3. Remove the front oil seal using suitable tool. CAUTION: Do not damage front cover and oil pump drive spacer.

Scheme 98

Scheme 99

1. Apply new engine oil to both the oil seal lip and dust seal lip of the new front oil seal.
2. Install the front oil seal. Install the front oil seal so that each seal lip is oriented (Scheme 98) Press-fit until the height of the front oil seal is level with the mounting surface using suitable tool. CAUTION: Do not damage front timing chain case and crankshaft. Press-fit straight and avoid causing burrs or tilting oil seal.
3. Installation of the remaining components is in the reverse order of removal.

Scheme 100

1. Remove the transmission assembly. Refer to «REMOVAL AND INSTALLATION (4X2)»(ref-233274-S04650071492006052500000) or «REMOVAL AND INSTALLATION (4X4)»(ref-233274-S05387574062006052500000) . Remove the drive plate. Holding the crankshaft pulley bolt, lock the crankshaft and remove the drive plate bolts. Remove the bolts diagonally. CAUTION: Do not damage the drive plate. Especially, avoid deforming and damaging the signal plate teeth (circumference position). Place the drive plate with the signal plate surface facing other than downward. Keep magnetic materials away from signal plate. Remove the engine rear plate.
2. Remove the rear oil seal using suitable tool. CAUTION: Do not damage crankshaft or oil seal retainer surface.

Scheme 101

Scheme 102

1. Apply new engine oil to both the oil seal lip and dust seal lip of the new rear oil seal.
2. Install the rear oil seal. Install the rear oil seal so that each seal lip is oriented (Scheme 101) Press-fit the rear oil seal using suitable tool. CAUTION: Do not damage the crankshaft or cylinder block. Press-fit the oil seal straight to avoid causing burrs or tilting. Do not touch grease applied onto the oil seal lip. Do not damage or scratch the outer circumference of the rear oil seal. Tap until flattened with the front edge of the oil seal retainer.
3. Installation of the remaining components is in the reverse order of removal.

Scheme 103

1. Warm up the engine thoroughly. Then stop the engine.
2. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233258-S23412934922006052500000) . CAUTION: Leave the fuel pump fuse disconnected until step 7 .
3. Remove the spark plug from each cylinder. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S36362273252006052500000) .
4. Connect the engine tachometer (not required in use of CONSULT-II).
5. Install the compression tester with Tool into the spark plug hole. Tool number: EG15050500 (J-45402)
6. With the accelerator pedal fully depressed, turn the 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. DEFERENCE LIMIT BETWEEN CYLINDERS SPECIFICATION Unit: kPa (kg/cm2, psi) /rpm Standard Minimum Deference limit between cylinders 1,520 (15.5, 220) / 200 1,324 (13.5, 192) / 200 98 (1.0, 14) / 300 CAUTION: Always use a fully charged battery to obtain specified engine speed. If the engine speed is out of the specified range, check the battery liquid for proper gravity. Check the engine speed again with normal battery gravity. If the compression pressure is below the minimum value, check the valve clearances and parts associated with the combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After checking, measure the compression pressure again. If some cylinders have low compression pressure, pour a small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. If the added engine oil improves the compression, the piston rings may be worn out or damaged. Check the piston rings and replace if necessary. If the compression pressure remains at a low level despite the addition of engine oil, the valves may be malfunctioning. Check the valves for damage. Replace the valve or valve seat accordingly. If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, the gaskets may be leaking, or a valve in adjacent cylinders may be damaged. Inspect and repair as required.
7. Install the components in the reverse order of removal.
8. Start the engine and confirm that it runs smoothly.
9. Perform trouble diagnosis. If DTC appears, erase it. Refer to «CAN COMMUNICATION»(ref-233315-S31201414622006052500000) .

Scheme 104

Scheme 105

1. Remove the engine assembly from the vehicle. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S15370622752006052500000).
2. Remove the following components and related parts: Auto tensioner of drive belts and idler pulley. Refer to «DRIVE BELTS»(ref-233240-S28365612942006052500000). Thermostat housing and hose. Refer to «REMOVAL AND INSTALLATION»(ref-233257-S35766427762006052500000). Oil pan and oil strainer. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S04669786312006052500000). Fuel tube and fuel injector assembly. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S15875093782006052500000). Intake manifold. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S38778233242006052500000). Ignition coil. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S23007780522006052500000). Rocker cover. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S19460704282006052500000).
3. Remove the crankshaft pulley, front cover, oil pump, and timing chain. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S06233824282006052500000).
4. Remove the camshaft sprockets and camshafts. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S10213585022006052500000).
5. Remove the cylinder head bolts in reverse of order (Scheme 105)

Scheme 106

1. Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace the bolt with a new one. Limit (d1-d2): 0.18 mm (0.0071 in)
2. If reduction of diameter appears in a position other than d2, use it as d2 point.

Scheme 107

Scheme 108

1. Install a new cylinder head gasket.
2. Install the cylinder head. Follow the steps below to tighten the bolts in the numerical order (Scheme 107) CAUTION: If cylinder head bolts are re-used, check their diameters before installation. Refer to «CYLINDER HEAD BOLTS DIAMETER»(ref-233240-S30493107372006052500000). Apply engine oil to threads and seating surface of the bolts. Step a: 98.1 N.m (10 kg-m, 72 ft-lb) Step b: Loosen in the reverse order of tightening. Step c: 44.1 N.m (4.5 kg-m, 33 ft-lb) Measure the tightening angle using Tool. Tool number: KV10112100 (BT-8653-A) CAUTION: Measure the tightening angle using Tool. Do not measure visually. Step d: 60° clockwise Step e: 60° clockwise
3. Installation of the remaining components is in the reverse order of removal.

Scheme 109

Scheme 110

Scheme 111

1. Remove the spark plug. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S36362273252006052500000) .
2. Remove the valve lifter. Identify the installation positions, and store them without mixing them up.
3. Remove the valve collet using Tool. Tool number: KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109220 (-) CAUTION: When working, take care not to damage valve lifter holes.
4. Remove the valve spring retainer, valve spring and valve spring seat.
5. Inspect the valve guide clearance. Refer to «VALVE GUIDE CLEARANCE»(ref-233240-S34896915122006052500000) .
6. Push the valve stem to the combustion chamber side, and remove the valve. Identify the installation positions, and store them without mixing them up.
7. Remove the valve oil seal using Tool. Tool number: KV10107902 (J-38959)
8. Replace the valve seat if necessary. Refer to «VALVE SEAT REPLACEMENT»(ref-233240-S41245851412006052500000) .
9. Replace the valve guide if necessary. Refer to «VALVE GUIDE REPLACEMENT»(ref-233240-S41526387492006052500000) .
10. Remove the spark plug tube, as necessary. Remove the spark plug tube out of the cylinder head using suitable tool. CAUTION: Do not damage the cylinder head. Do not remove the spark plug tube unless absolutely necessary. Once removed, the spark plug tube will be deformed and cannot be reused.

Scheme 112

Scheme 113

Scheme 114

Scheme 115

1. Install the valve guide if necessary. Refer to «VALVE GUIDE REPLACEMENT»(ref-233240-S41526387492006052500000) .
2. Install the valve seat if necessary. Refer to «VALVE SEAT REPLACEMENT»(ref-233240-S41245851412006052500000) .
3. Install the valve oil seal using Tool. Tool number: KV10115600 (J-38958) Apply new engine oil on the new valve oil seal joint and seal lip. Install the valve oil seal to the specified height "H". Height "H" (Without valve spring seat installed) Intake and exhaust: 14.3-14.9 mm (0.563-0.587 in)
4. Install the valves in their original position.
5. Install the valve spring seats.
6. Install the valve springs. Install the narrow pitch end (Paint mark side) to the cylinder head side.
7. Install the valve spring retainers.
8. Install the valve collet using Tool. Tool number: KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109220 (-) CAUTION: When working, take care not to damage valve lifter holes.
9. Install the valve lifters. Install the removed parts in their original locations. If installing new lifters, select the correct size lifter for proper valve clearance. Refer to «VALVE CLEARANCE»(ref-233240-S08124944862006052500000) .
10. Install the spark plug tube if necessary, following the procedure below. Remove any old liquid gasket adhering to the cylinder-head spark plug tube hole. Apply liquid gasket to area within approximately 12 mm (0.47 in) from the edge of the spark plug tube press-fit side. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233237-S23907478682006052500000) . Press-fit the spark plug tube to the specified height "H" using suitable tool. Standard press-fit height "H": 38.4-39.4 mm (1.512-1.551 in) CAUTION: When press-fitting, take care not to deform the spark plug tube. After press-fitting, wipe off any liquid gasket protruding onto the cylinder- head upper face.
11. Install the spark plugs.

Scheme 116

1. Remove any oil, scale, gasket, sealant and carbon deposits from the cylinder head surface. CAUTION: Do not allow any debris to enter the oil or coolant passages.
2. Measure the bottom surface of the cylinder head for distortion in six directions as shown, using suitable tools. Standard: 0.03 mm (0.0012 in) Limit: 0.1 mm (0.004 in) If measurement exceeds the limit, replace the cylinder head.

Scheme 117

1. Check the dimensions of each valve. Refer to «VALVE DIMENSIONS»(ref-233240-S36709291272006052500000) .
2. If the dimensions are out of the standard, replace the valve.

VALVE GUIDE REPLACEMENT

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

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

1. To remove the valve guide, heat the cylinder head to 110° to 130°C (230° to 266°F) by soaking it in heated oil.
2. Remove the valve guide using suitable tool. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
3. Ream the cylinder head valve guide hole using suitable tool. Valve guide hole diameter: Standard Intake and exhaust: 9.975-9.996 mm (0.3927-0.3935 in) Oversize (service) Intake and exhaust: 10.175-10.196 mm (0.4006-0.4014 in)
4. Heat the cylinder head to 110° to 130°C (230° to 266°F) by soaking it in heated oil.
5. Press the valve guide from the camshaft side to the dimensions as shown. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
6. Ream the cylinder head valve guide hole using suitable tool. Valve guide hole diameter: Intake and exhaust: 6.000-6.018 mm (0.2362-0.2369 in)

Scheme 124

1. After confirming that the dimensions of the valve guides and valves are within specifications, perform this procedure.
2. Apply Prussian blue (or white lead) onto the contacting surface of the 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 the valve fit and check again. If the contacting surface still has NG conditions even after the re-check, replace the valve seat.

VALVE SEAT REPLACEMENT

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

Scheme 125

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. Bore out the 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 the cylinder head recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)] (Service): 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 the valve guide center. This will enable valve seat to fit correctly.
3. Heat the cylinder head to 110° to 130°C (230° to 266°F) by soaking it in heated oil.
4. Cool the valve seats well with dry ice. Force fit the valve seat into the cylinder head. CAUTION: Avoid directly touching cold valve seats. Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
5. Finish the seat to the specified dimensions using suitable tool. Refer to «VALVE SEAT»(ref-233240-S29300248632006052500000). 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 stage valve seat.
6. Grind to obtain the dimensions indicated (Scheme 128) Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to «VALVE SEAT CONTACT»(ref-233240-S42877395862006052500000).

Scheme 130

1. Set try square along the side of valve spring and rotate the spring. Measure the maximum clearance between the top face of spring and try square. Limit: Less than 2.2 mm (0.087 in)
2. If measurement is not within specifications, replace the valve spring.

Scheme 131

1. Check the valve spring pressure at the specified spring height. Standard: Intake and exhaust Free height: 50.58 mm (1.9913 in) Installation height: 37.0 mm (1.457 in) Installation load: 165.8-187.0 N (16.9-19.1 kg, 37-42 lb) Height during valve open: 28.2 mm (1.110 in) Load with valve open: 314.8-355.0 N (32.1-36.2 kg, 71-80 lb)
2. If measurement is not within specifications, replace the valve spring.

Scheme 132

Scheme 133

Scheme 134

Scheme 135

1. Drain the engine coolant. Refer to «DRAINING ENGINE COOLANT»(ref-233257-S25347923992006052500000) .
2. Partially drain the A/T fluid. Refer to «CHANGING A/T FLUID»(ref-233274-S08338145162006052500000) .
3. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233258-S23412934922006052500000) .
4. Remove the engine hood. Refer to «REMOVAL AND INSTALLATION OF HOOD ASSEMBLY»(ref-233299-S14868019982006052500000) .
5. Remove the cowl extension. Refer to «REMOVAL AND INSTALLATION»(ref-233303-S29937724112006052500000) .
6. Remove the engine room cover using power tools.
7. Remove the air duct and air cleaner case assembly. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S11402286492006052500000) .
8. Disconnect the vacuum hose between the vehicle and engine and set it aside.
9. Remove the radiator assembly and hoses. Refer to «REMOVAL AND INSTALLATION»(ref-233257-S30262370512006052500000) .
10. Remove the drive belts. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S26704070312006052500000) .
11. Remove the fan blade. Refer to «REMOVAL AND INSTALLATION (CRANKSHAFT DRIVEN TYPE)»(ref-233257-S01743102982006052500000) .
12. Disconnect the engine room harness from the fuse box and set it aside.
13. Disconnect the ECM.
14. Disconnect the engine room harness from the engine side and set it aside.
15. Disconnect the engine harness grounds.
16. Disconnect the power steering reservoir tank from the engine and move it aside.
17. Disconnect the power steering oil pump from the engine. Move it aside and secure it using suitable wire or rope. Refer to «REMOVAL AND INSTALLATION»(ref-233296-S38988189602006052500000) .
18. Remove the A/C compressor bolts and set the compressor aside. Refer to «REMOVAL AND INSTALLATION FOR COMPRESSOR»(ref-233307-S35760121682006052500000) (ATC) or «REMOVAL AND INSTALLATION FOR COMPRESSOR»(ref-233308-S28972065502006052500000) (MTC).
19. Disconnect the brake booster vacuum line.
20. Disconnect the EVAP line.
21. Disconnect the fuel hose at the engine side connection. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S15875093782006052500000) .
22. Disconnect the heater hoses at the cowl, and install plugs to avoid leakage of engine coolant.
23. Remove the A/T oil level indicator and indicator tube upper bolts.
24. Remove the front final drive assembly (4x4 only). Refer to «REMOVAL AND INSTALLATION»(ref-233279-S27019604112006052500000) .
25. Remove the exhaust manifolds. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S28711431302006052500000) .
26. Install the engine slingers into the left bank cylinder head and right bank cylinder head. Engine slinger torque: 45.0 N.m (4.6 kg-m, 33 ft-lb)
27. Remove the A/T. Refer to «REMOVAL AND INSTALLATION (4X2)»(ref-233274-S04650071492006052500000) or «REMOVAL AND INSTALLATION (4X4)»(ref-233274-S05387574062006052500000) .
28. Lift using a hoist and secure the engine in position.
29. Remove the engine assembly from the vehicle, avoid interference with the vehicle body. CAUTION: Before and during lifting, always check if any harnesses are left connected.
30. Remove the parts that may restrict installation of the engine to the engine stand. NOTE: This procedure is described assuming that you use an engine stand mounting to the surface to which the transmission mounts. Remove the drive plate. Holding the crankshaft pulley bolt, lock the crankshaft to remove the drive plate bolts. Loosen the bolts diagonally. CAUTION: Be careful not to damage the drive plate. Especially avoid deforming and damaging of the signal plate teeth (circumference position). Place the drive plate with the signal plate surface facing other than downward. Keep magnetic materials away from the signal plate. CAUTION: Use an engine stand that has a load capacity [approximately 240 kg (529 lb) or more] large enough for supporting the engine weight. If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand. Remove the fuel tube and fuel injector assembly. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S15875093782006052500000) . Remove the intake manifold. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S38778233242006052500000) . Remove the ignition coil. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S23007780522006052500000) . Remove the rocker cover. Refer to «REMOVAL AND INSTALLATION»(ref-233240-S19460704282006052500000) . Other removable brackets. CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
31. Remove the alternator. Refer to «REMOVAL AND INSTALLATION»(ref-233309-S24863325002006052500000) .
32. Remove the engine mounting insulator and bracket using power tool.

Installation is in the reverse order of removal.