Engine Mechanical: Removal & Installation Nissan Armada I facelift

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 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.

Precaution 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.

REMOVAL

1. Remove the air duct and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S30482178812009071300000) ".
2. Install Tool on drive belt auto tensioner pulley bolt, move in the direction of arrow (loosening direction of tensioner) as shown. Tool number: - (J-46535) CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off.
3. Remove the drive belt.

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INSTALLATION

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 drive belt auto tensioner. Refer to " «CHECKING DRIVE BELTS»(ref-320185-S14954129952009071300000) ".

Scheme 41

1. Remove the air duct and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S30482178812009071300000) ".
2. Remove the drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S40419645552009071300000) ".
3. Remove the drive belt auto tensioner and idler pulley using power tool.

Installation is in the reverse order of removal.

Scheme 42

Note. The viscous paper type filter does not need cleaning between replacement intervals. Replace the air filter as necessary for periodic maintenance. Refer to " INTRODUCTION OF PERIODIC MAINTENANCE ".

1. Remove the air duct and resonator assembly.
2. Remove the air cleaner case (upper).
3. Remove the air cleaner filter from the air cleaner case (lower).

1. Install the new air cleaner filter in the air cleaner case (lower).
2. Install the air cleaner case (upper).
3. Install the air duct and resonator assembly (inlet).

Scheme 43

1. Remove engine room cover using power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S33486365092009071300000) ".
2. Remove ignition coil. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S18432381202009071300000) ".
3. Remove spark plug using suitable tool.

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1. Do not use a wire brush for cleaning.
2. If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (5.9 bar, 6 kg/cm 2 , 85 psi) Cleaning time: Less than 20 seconds
3. Checking and adjusting plug gap is not required between change intervals.

Scheme 46

Installation is in the reverse order of removal.

Spark Plug Types

SPARK PLUG REFERENCE

Installation is in the reverse order of removal.

Scheme 47

1. Remove the engine room cover using power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S33486365092009071300000) ".
2. Disconnect the harness connector from air cleaner case (upper).
3. Remove the air duct and resonator assembly and air cleaner case.
4. Remove air cleaner filter and air cleaner case (lower)

1. Add marks as necessary for easier installation.

Installation is in the reverse order of removal.

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1. Partially drain the engine coolant. Refer to " «CHANGING ENGINE COOLANT»(ref-320186-S08775799312009071300000) ". WARNING: To avoid the danger of being scalded, never drain the engine coolant when the engine is hot.
2. Remove the engine room cover using power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S33486365092009071300000) ".
3. Release the fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-320188-S03462428842009071300000) ".
4. Remove the air duct and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S30482178812009071300000) ".
5. Disconnect the fuel tube quick connector on the engine side. Perform the following steps to disconnect the quick connector using Tool. Tool number: 16441 6N210 (J-45488) Remove quick connector cap (engine side only). 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 in that position. CAUTION: Inserting the Tool hard will not disconnect quick connector. Hold Tool where it contacts and goes no further. Draw and pull out quick connector straight from fuel tube. CAUTION: Pull quick connector holding "A" position in illustration. 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.
6. Remove or disconnect harnesses, brackets, vacuum hose, vacuum gallery and PCV hose and tube from intake manifold.
7. Remove electric throttle control actuator by loosening bolts diagonally. CAUTION: Handle carefully to avoid any damage to the electric throttle control actuator. Do not disassemble.
8. Remove the fuel injectors and fuel tube assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S13716212262009071300000) ".
9. Loosen the bolts in reverse order shown using power tool.
10. Remove the intake manifold. CAUTION: Cover engine openings to avoid entry of foreign materials. Clean all gasket mating surfaces, do not reuse gaskets.

Installation is in the reverse order of removal.

1. Tighten the intake manifold bolts in numerical order as shown.
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".
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).

Connecting Quick Connector of Fuel Tube

Install quick connector as follows (the steps are the same for quick connectors on both engine side and vehicle side except for the quick connector cap).

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1. Make sure no foreign substances are deposited in and around tube and quick connector, and they are not damaged.
2. Thinly apply new engine oil around the fuel tube from tip end to the spool end.
3. Align center to insert quick connector straight into fuel tube. Insert until the paint mark for engagement identification (white) goes completely inside quick connector so that you cannot see it from the straight side of the connected part. Use a mirror to check this where it is not possible to view directly from the straight side, such as quick connector on vehicle side. Insert fuel tube into quick connector until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector on engine side. CAUTION: Hold "A" position in illustration when inserting fuel tube into quick connector. Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
4. Pull quick connector by hand holding "A" position. Make sure it is completely engaged (connected) so that it does not come out from fuel tube. NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
5. Install the quick connector cap on the quick connector joint (on engine side only).
6. Install the fuel hose and tube to hose clamps.
7. Refill the engine coolant. Refer to " «CHANGING ENGINE COOLANT»(ref-320186-S08775799312009071300000) ".

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1. Remove the air duct and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S30482178812009071300000) ".
2. Drain the engine coolant from the radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-320186-S08775799312009071300000) ".
3. Remove the engine undercover using power tool.
4. Remove the radiator and radiator hoses. Refer to " «REMOVAL AND INSTALLATION»(ref-320186-S17330192992009071300000) ".
5. Remove the drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S40419645552009071300000) ".
6. Remove the air fuel ratio A/F sensors (bank 1, bank 2). Follow steps below to remove each air fuel ratio A/F sensor. 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 LH and RH 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 (LH) following the steps below. Remove the exhaust front tube. Refer to " «REMOVAL AND INSTALLATION»(ref-320189-S29155597522009071300000) ". Remove the exhaust manifold cover. Loosen the nuts in reverse order of illustration (A) using power tool. <--: Front Remove the exhaust studs from positions 2, 4, 6, 8 and remove LH exhaust manifold
9. Remove the exhaust manifold (RH) following the steps below. Remove the exhaust front tube. Refer to " «REMOVAL AND INSTALLATION»(ref-320189-S29155597522009071300000) ". Remove the oil level gauge guide. Refer to «DISASSEMBLY AND ASSEMBLY»(ref-320185-S23393969492009071300000) . Remove the exhaust manifold cover. Loosen the nuts in reverse order of illustration (B) using power tool. Remove the exhaust studs from positions 2, 4, 6, 8 and remove RH exhaust manifold.

Scheme 57

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.

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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 shown. Then recheck the torque of the nuts both (A) and (B). <--: Front
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.

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1. Remove the engine. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S32613362772009071300000) ".
2. Remove the oil pan (lower) using the following steps. Remove the oil pan (lower) bolts using power tool. Insert Tool between the lower oil pan and the upper oil pan. Tool number: KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surface. Do not insert a screwdriver, this will damage the mating surfaces. Slide (2) the Tool by tapping (1) its side with a hammer to remove the lower oil pan from the upper oil pan.
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 as shown. Remove the oil pan (upper) from the cylinder block by prying it at the points shown, 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 AND INSTALLATION»(ref-320185-S33486365092009071300000) ".
2. Disconnect the harness connector from the ignition coil.
3. Remove the ignition coil.

Installation is in the reverse order of removal.

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Scheme 66

1. Remove the engine room cover using power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S33486365092009071300000) ".
2. Remove the air duct and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S30482178812009071300000) " (for LH only).
3. Move the harness on the upper rocker cover and its peripheral aside.
4. Remove the electric throttle control actuator, loosening the bolts diagonally (for LH only).
5. Remove the ignition coils. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S18432381202009071300000) ".
6. Remove the PCV hose from the PCV control valves. <--: Engine front
7. Loosen the bolts in reverse order shown using power tool for rocker cover (A) or (B). CAUTION: Do not hold the rocker cover (RH) (B) by the oil filler neck.

Scheme 67

1. Apply liquid gasket to the joint part of the cylinder head and camshaft bracket following the steps below. NOTE: Illustration shows an example of (LH) side (zoomed in shows No. 1 camshaft bracket). Refer to illustration "a" to apply liquid gasket to the joint part of No. 1 camshaft bracket and cylinder head. Refer to illustration "b" to apply liquid gasket 90° to illustration "a". Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-320178-S17417948952009071300000) ".
2. Install the rocker cover (A) or (B). <--: Front Make sure the new rocker cover gasket is installed in the groove of the rocker cover (A) or (B). Tighten the bolts in two steps in the numerical order shown. 1st step: 2.0 N.m (0.2 kg-m, 18 in-lb) 2nd step: 8.3 N.m (0.85 kg-m, 73 in-lb) CAUTION: Do not hold the rocker cover (RH) (B) by the oil filler neck.
3. Install the PCV hoses. NOTE: Remove foreign materials from inside the hose using compressed air. The inserted length is within 25 - 30 mm (0.98 - 1.18 in) [Target: 25 mm (0.98 in)].
4. Installation of the remaining components is in the reverse order of removal.

Scheme 68

Removal and Installation

Scheme 69

1. Remove engine room cover using power tool. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S33486365092009071300000) ".
2. Release fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-320188-S03462428842009071300000) ".
3. Disconnect the negative battery terminal.
4. Disconnect fuel injector harness connectors.
5. Disconnect fuel hose assembly from fuel tube (RH bank and LH bank). CAUTION: While hoses are disconnected, plug them to prevent fuel from draining. Do not separate fuel connector and fuel hose.
6. Remove fuel injectors with fuel tube assembly.
7. Remove fuel injector from fuel tube. Spread open to remove clip. Remove 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 fuel damper from each fuel tube.

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1. Install fuel damper to each fuel tube. Apply engine oil to O-ring and set it into the cap of fuel tube. CAUTION: Handle O-ring with bare hands. Never 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. Make sure that backup spacer is in the O-ring connecting surface of fuel damper. NOTE: Backup spacer is fuel damper assembly part. Insert fuel damper until it seats on 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 cap, and then tighten bolts evenly by turns. After tightening bolts, make sure that there is no gap between cap and fuel tube.
2. Install O-rings to fuel injector paying attention to the items below. CAUTION: Upper and lower O-ring are different. Standard model FFV model Fuel tube side: Blue Fuel tube side: Black Nozzle side: Brown Nozzle side: Green Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube. Insert O-ring straight into fuel tube. Do not angle or twist it.
3. Install fuel injector to fuel tube. Insert clip into clip mounting groove on 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. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that lug "B" of fuel tube matches notch "B" of the clip. Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by checking that fuel injector does not rotate or come off. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
4. Install 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 fuel tube assembly bolts "a" to "b" in illustration and 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 fuel hose assembly. Refer to «PRECAUTIONS»(ref-320190-S26994067242009071300000) for fuel injector when handling O-ring. 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 flange and fuel tube after tightening bolts.
6. Installation of the remaining components is in the reverse order of removal.

Note. To remove timing chain and associated parts, start with those on the LH bank. The procedure for removing parts on the RH bank is omitted because it is the same as that for removal on the LH bank. To install timing chain and associated parts, start with those on the RH bank. The procedure for installing parts on the LH bank is omitted because it is the same as that for installation on the RH bank.

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1. Remove the engine assembly from the vehicle. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S32613362772009071300000) ".
2. Remove the following components and related parts: Drive belt auto tensioner and idler pulley. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S40419645552009071300000) ". Thermostat housing and water hose. Refer to " «REMOVAL AND INSTALLATION»(ref-320186-S03198729442009071300000) ". Power steering oil pump bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-320191-S32720567222009071300000) ". Oil pan (lower), (upper) and oil strainer. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S37334637722009071300000) ". Ignition coil. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S18432381202009071300000) ". Rocker cover. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S10331236532009071300000) ".
3. Remove the Intake valve timing control solenoid valve cover (RH) (A) and Intake valve timing control solenoid valve cover (LH) (B) as follows: Loosen and remove the bolts as shown. Cut the liquid gasket and remove the covers using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage mating surfaces.
4. Obtain compression TDC of No. 1 cylinder as follows: Turn the crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with the timing indicator on the front cover. At this time, make sure both intake and exhaust cam lobes of No. 1 cylinder (top front on LH bank) point outside. If they do not point outside, turn crankshaft pulley once more.
5. Remove the crankshaft pulley. Loosen the crankshaft pulley bolts using a hammer handle to secure the crankshaft. Remove the crankshaft pulley from the crankshaft using tool. Remove the crankshaft pulley using suitable tool. Set the bolts in the two bolt holes [M6 x 1.0 mm (0.04 in)] on the front surface. NOTE: The dimension between the centers of the two bolt holes is 61 mm (2.40 in).
6. Remove the front cover. Loosen and remove the bolts in the reverse of order shown. Cut the liquid gasket and remove the covers using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage mating surfaces.
7. Remove the front oil seal using suitable tool. CAUTION: Do not damage front cover.
8. Remove the oil pump drive spacer. Hold and remove the flat space of the oil pump drive spacer by pulling it forward.
9. Remove the oil pump. Refer to " «REMOVAL AND INSTALLATION»(ref-320190-S23061481232009071300000) ".
10. Remove the chain tensioner on the LH bank using the following steps. NOTE: To remove the timing chain and associated parts, start with those on the LH bank. The procedure for removing parts on the RH bank is omitted because it is the same as that for the LH bank. Squeeze the return-proof clip ends using suitable tool and push the plunger into the tensioner body. Secure the plunger using stopper pin. Stopper pin is made from hard wire approximately 1 mm (0.04 in) in diameter. Remove the bolts and chain tensioner. WARNING: Plunger, spring, and spring seat pop out when (squeezing) return-proof clip without holding plunger head. It may cause serious injuries. Always hold plunger head when removing. NOTE: Stop the plunger in the fully extended position by using the return-proof clip (1) if the stopper pin is removed. Push the plunger (2) into the tensioner body while squeezing the return-proof clip (1). Secure it using stopper pin (3).
11. Remove the timing chain tension guide and timing chain slack guide.
12. Remove the timing chain and crankshaft sprocket.
13. Loosen the camshaft sprocket bolts as shown and remove the camshaft sprocket. CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft when timing chain is disconnected.
14. Repeat the same procedure to remove the RH timing chain and associated parts.

Note. Do not remove the engine assembly to perform this procedure.

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1. Remove the RH bank and LH bank rocker covers. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S10331236532009071300000) ".
2. Obtain compression TDC of No. 1 cylinder as follows: Turn the crankshaft pulley clockwise to align the TDC identification notch (without paint mark) with the timing indicator on the front cover. At this time, make sure both intake and exhaust cam lobes of No. 1 cylinder (top front on LH bank) point outside. If they do not point outside, turn crankshaft pulley once more.
3. Remove the intake valve timing control solenoid cover RH bank (A) and intake valve timing control solenoid cover LH bank (B) as follows: Loosen and remove the bolts as shown. Cut the liquid gasket and remove the covers using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage mating surfaces.
4. Paint alignment marks on the RH bank (A) timing chain links (C) and LH bank (B) timing chain links (D) and align with the camshaft sprocket alignment marks (E) and (F).
5. Remove the chain tensioner (LH) using the following steps. WARNING: Plunger, spring, and spring seat pop out when squeezing return-proof clip without holding plunger head. It may cause serious injuries. Always hold plunger head when removing. Squeeze return-proof clip ends using suitable tool and push the plunger into the tensioner body. Secure plunger using stopper pin. Stopper pin is made from hard wire approximately 1 mm (0.04 in) in diameter. Remove the bolts and the timing chain tensioner. NOTE: Stop plunger in the fully extended position using return-proof clip (1) if stopper pin is removed. Push the plunger (2) into the tensioner body while squeezing the return-proof clip (1). Secure it using stopper pin (3).
6. Remove the chain tensioner cover from the front cover using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage mating surfaces.
7. Remove the chain tensioner (RH) using the following steps. WARNING: Plunger, spring, and spring seat pop out when squeezing return-proof clip without holding plunger head. It may cause serious injuries. Always hold plunger head when removing. Squeeze return-proof clip ends using suitable tool and push the plunger into the tensioner body. Secure plunger using stopper pin. Stopper pin is made from hard wire approximately 1 mm (0.04 in) in diameter. Remove the bolts and the chain tensioner (RH) (A). NOTE: If it is difficult to push plunger on chain tensioner (RH) (A), remove the plunger under extended condition.
8. Loosen camshaft sprocket bolts as shown and remove camshaft sprockets. CAUTION: To avoid interference between valves and pistons, do not turn crankshaft or camshaft with timing chain disconnected.
9. Remove the RH (A) front cover bolts and LH (B) front cover bolts.
10. Remove RH (A) camshaft bracket bolts and LH (C) camshaft bracket bolts in the reverse of order shown to remove camshaft brackets. Remove No. 1 camshaft bracket. NOTE: The bottom and front surface of bracket will be stuck because of liquid gasket. <--: Engine front B: Exhaust side D: Intake side
11. Remove the camshaft.
12. Remove the valve lifters if necessary.

1. Correctly identify location where each part is removed from. Keep parts organized to avoid mixing them up.

Scheme 88

1. Put V block on precise flat work bench, and support No. 1 and No. 5 journals of the camshaft.
2. Set dial indicator vertically to No. 3 journal.
3. Turn the camshaft to one direction, and measure the camshaft runout on dial indicator (total indicator reading). Camshaft runout: Less than 0.02 mm (0.0008 in) If measurement exceeds specification, replace the camshaft.

Scheme 89

1. Measure the camshaft cam height. Standard cam height (intake): 44.865 - 45.055 mm (1.7663 - 1.7738 in) Standard cam height (exhaust): 45.075 - 45.265 mm (1.7746 - 1.7821 in) Cam wear limit (intake & exhaust): 0.02 mm (0.0008 in)
2. If measurement is not within the specifications, replace the camshaft.

Installation is in the reverse order of removal.

Scheme 90

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 installed)

Intake and exhaust: 14.300 - 14.900 mm (0.5630 - 0.5870 in)

Scheme 91

1. Remove the engine. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S32613362772009071300000) ".
2. Remove the crankshaft pulley. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S01712715042009071300000) ".
3. Remove the front oil seal using suitable tool.

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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 as shown. 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.

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1. Remove the transmission assembly. Refer to " «REMOVAL AND INSTALLATION (2WD)»(ref-320192-S40566064752009071300000) " or " «REMOVAL AND INSTALLATION (4WD)»(ref-320192-S04825389322009071300000) ".
2. Before removing the drive plate, put a match mark (A) on the crankshaft and drive plate for alignment during installation.
3. Lock the drive plate using Tool (A). Tool number: - (J-47245) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting tool. Keep magnetic materials away from signal plate. NOTE: Remove the bolts diagonally.
4. Remove the drive plate. CAUTION: Never place drive plate with signal plate facing down. When handling the signal plate, take care not to damage or scratch it. Handle the signal plate in a manner that prevents it from becoming magnetized.
5. Remove the engine rear plate.
6. Remove the rear oil seal using suitable tool.

Scheme 98

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 as shown. 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. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-320185-S23393969492009071300000) ", " «REMOVAL AND INSTALLATION (2WD)»(ref-320192-S40566064752009071300000) ", " «REMOVAL AND INSTALLATION (4WD)»(ref-320192-S04825389322009071300000) ".

Scheme 99

Scheme 100

1. Remove the engine assembly from the vehicle. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S32613362772009071300000) ".
2. Remove the following components and related parts: Drive belt auto tensioner drive belts and idler pulley. Refer to " «DRIVE BELT AUTO TENSIONER AND IDLER PULLEY»(ref-320185-S16947130322009071300000) ". Thermostat housing and hose. Refer to " «REMOVAL AND INSTALLATION»(ref-320186-S03198729442009071300000) ". Oil pan and oil strainer. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S37334637722009071300000) ". Fuel tube and fuel injector assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S13716212262009071300000) ". Intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S36423797132009071300000) ". Rocker cover. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S10331236532009071300000) ".
3. Remove the crankshaft pulley, front cover, oil pump, and timing chain. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S01712715042009071300000) ".
4. Remove the camshaft sprockets and camshafts. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S37368103112009071300000) ".
5. Remove the cylinder head bolts in reverse of order shown.

Scheme 101

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): 0.23 mm (0.0091 in)
2. If reduction of diameter appears in a position other than d2, use it as d2 point.

Scheme 102

1. Install a new cylinder head gasket.
2. Install the cylinder head. Follow the steps below to tighten the bolts in the numerical order shown. CAUTION: If cylinder head bolts are re-used, check their diameters before installation. Refer to " «CYLINDER HEAD BOLTS DIAMETER»(ref-320185-S19393269392009071300000) ". 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: 70° clockwise
3. Installation of the remaining components is in the reverse order of removal.

VALVE GUIDE REPLACEMENT

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

Scheme 103

Scheme 104

Scheme 105

Scheme 106

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 using suitable tool. Valve guide inside diameter: Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Scheme 107

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 108

Scheme 109

Scheme 110

Scheme 111

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 " «STANDARD AND LIMIT»(ref-320185-S35419514872009071300000) ". 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 as shown. Using compound, grind to adjust valve fitting.
7. Check again for normal contact.

Scheme 112

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 113

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 pressure: 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 114

Scheme 115

1. Drain the engine coolant. Refer to " «CHANGING ENGINE COOLANT»(ref-320186-S08775799312009071300000) ".
2. Partially drain the A/T fluid. Refer to " «CHANGING THE A/T FLUID (ATF)»(ref-320192-S22653366332009071300000) ".
3. Release the fuel pressure. Refer to " «FUEL PRESSURE CHECK»(ref-320188-S03462428842009071300000) ".
4. Remove the engine hood. Refer to " «REMOVAL AND INSTALLATION OF HOOD ASSEMBLY»(ref-320193-S39101194632009071300000) ".
5. Remove the cowl extension. Refer to " «REMOVAL AND INSTALLATION»(ref-320194-S36749569692009071300000) ".
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-320185-S30482178812009071300000) ".
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-320186-S17330192992009071300000) ".
10. Remove the drive belts. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S40419645552009071300000) ".
11. Remove the fan blade. Refer to " «REMOVAL AND INSTALLATION (CRANKSHAFT DRIVEN TYPE)»(ref-320186-S01285834852009071300000) ".
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-320191-S32720567222009071300000) "
18. Remove the A/C compressor bolts and set the compressor aside. Refer to " «REMOVAL AND INSTALLATION FOR COMPRESSOR»(ref-320183-S39958139482009071300000) " (ATC).
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-320185-S13716212262009071300000) ".
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 (4WD only). Refer to " «REMOVAL AND INSTALLATION»(ref-320195-S24607837002009071300000) ".
25. Remove the exhaust manifolds. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S02836758832009071300000) ".
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 (2WD)»(ref-320192-S40566064752009071300000) " or " «REMOVAL AND INSTALLATION (4WD)»(ref-320192-S04825389322009071300000) ".
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. Before removing the drive plate, put a match mark (A) on the crankshaft and drive plate for alignment during installation. Lock the drive plate using Tool (A). Tool number: - (J-47245) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting tool. Keep magnetic materials away from signal plate. NOTE: Remove the bolts diagonally. Remove the drive plate. CAUTION: Never place drive plate with signal plate facing down. When handling the signal plate, take care not to damage or scratch it. Handle the signal plate in a manner that prevents it from becoming magnetized. CAUTION: Use an engine stand that has a load capacity [approximately 240kg (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-320185-S13716212262009071300000) ". Remove the intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S36423797132009071300000) ". Remove the ignition coil. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S18432381202009071300000) ". Remove the rocker cover. Refer to " «REMOVAL AND INSTALLATION»(ref-320185-S10331236532009071300000) ". 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 generator. Refer to " «REMOVAL AND INSTALLATION»(ref-320196-S12133496912009071300000) ".
32. Remove the engine mounting insulator and bracket using power tool.

Installation is in the reverse order of removal.