Engine Mechanical: Removal & Installation Nissan Juke I

Removal and Disassembly

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

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. After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

INSTALLATION

1. Install drive belt. CAUTION: Confirm drive belt is completely set to pulleys. Check for engine oil, working fluid and engine coolant are not adhered to drive belt and each pulley groove.
2. Release drive belt auto-tensioner, and apply tension to drive belt.
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator (notch on fixed side) is within the possible use range. Refer to " «EXPLODED VIEW»(ref-516394-S24910346932012120600000) ".

Scheme 58

1. Check that the indicator (C) (notch on fixed side) of drive belt auto-tensioner is within the possible use range (A) in the figure. NOTE: Check the drive belt auto-tensioner indication when the engine is cold. When new drive belt is installed, the indicator (notch on fixed side) should be within the range (B) in the figure.
2. Visually check entire drive belt for wear, damage or cracks.
3. If the indicator (notch on fixed side) is out of the possible use range or belt is damaged, replace drive belt.

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

1. Fixing clips shall be fixed after inserting air cleaner body protrusion to air cleaner case notch hole.
2. Make sure that whether air cleaner body has been firmly installed by shaking it.

Install in the reverse order of removal.

REMOVAL

Remove engine cover.

Install in the reverse order of removal.

Scheme 59

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

1. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
2. Remove air duct inlet (upper).
3. Remove the air cleaner filter from the air cleaner case.
4. Disconnect mass air flow sensor harness connector, and remove harness clamp from air cleaner body.
5. Remove air cleaner body assembly.
6. Remove the air duct (suction side). Add matching marks if necessary for easier installation.
7. Remove air cleaner cover assembly.
8. Remove mass air flow sensor from air cleaner cover, if necessary. CAUTION: Handle the mass air flow sensor with following cares. Never shock the mass air flow sensor. Never disassemble the mass air flow sensor. Never touch the sensor of the mass air flow sensor.
9. Remove air duct inlet (lower) with the following procedure. Remove fender protector (LH). Refer to " «EXPLODED VIEW»(ref-516396-S16406822502012120600000) ". Remove air duct inlet (lower).

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

1. Align marks. Attach each joint. Screw clamps firmly.
2. Fixing clips shall be fixed after inserting air cleaner body assembly protrusion to air cleaner case botch hole.
3. Make sure whether air cleaner body has been firmly installed by shaking it.

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

Scheme 60

Scheme 61

1. Check if gasket is not dropped from the installation groove of intake manifold.
2. Install intake manifold with the following procedure: Tighten in numerical order as shown in the figure. NOTE: Tighten bolt the No. 1 in two steps. The numerical order No. 6 shows the second step.
3. Install in the reverse order of removal after this step. CAUTION: Since check valve is built-in inside vacuum hose (1), install the vacuum hose fitting the arrow (A) to intake manifold side (2).

Install in the reverse order of removal paying attention to the following points

1. Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible).
2. Pay attention to identification mark and direction.

1. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
2. Remove cowl top extension. Refer to " «EXPLODED VIEW»(ref-516396-S00001903602012120600000) ".
3. Remove front tube. Refer to " «EXPLODED VIEW»(ref-516401-S42421858012012120600000) ".
4. Remove catalyst converter support bracket (lower).
5. Remove A/F sensor 1. Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove A/F sensor 1. CAUTION: Never damage air fuel ratio sensor 1. Discard any 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; use a new one.
6. Remove catalyst converter shroud upper.
7. Remove bolts and nut of catalyst converter turbocharger side.
8. Remove catalyst converter support bracket (upper).
9. Remove heat insulator. Refer to " «EXPLODED VIEW»(ref-516402-S02710279482012120600000) ".
10. Remove catalyst converter.
11. Remove gasket.

Scheme 62

Scheme 63

1. Install gasket between turbocharger and catalyst as shown in the figure.
2. Install catalyst converter with the following procedure. Tighten in numerical order as shown in the figure. Install catalyst converter (base on stud position 1). Temporary assemble 2 (no priority). Temporary assemble 3, 4. Tightening 5, 6 and 7. Tightening again 8, 9 and 10. Temporary assemble 11. Tightening 12, 13, 14, and 15.
3. Note the following, and install in the reverse order of removal. A/F sensor 1 Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], install A/F sensor 1. CAUTION: Before installing a new sensors, clean exhaust system threads using heated oxygen sensor thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize lubricant. Never apply excessive torque to sensor 2. Doing so may cause damage to sensor 2, resulting in the "MIL" illuminating. Prevent rust preventives from adhering to the sensor body.

Scheme 64

1. Drain engine coolant. Refer to " «DRAINING»(ref-516398-S08374559152012120600000) ".
2. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
3. Remove cowl top extension. Refer to " «EXPLODED VIEW»(ref-516396-S00001903602012120600000) ".
4. Remove front tube. Refer to " «EXPLODED VIEW»(ref-516401-S42421858012012120600000) "
5. Remove catalyst converter support bracket (lower).
6. Remove A/F sensor 1 and heated oxygen sensor 2. Use heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], remove A/F sensor 1 and heated oxygen sensor 2. CAUTION: Never damage air fuel ratio sensor 1. Discard any 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; use a new one.
7. Remove catalyst converter shroud (upper).
8. Remove bolts and nut of catalyst converter turbocharger side.
9. Remove heat insulator. Refer to " «EXPLODED VIEW»(ref-516403-S23943380952012120600000) ".
10. Remove catalyst converter support bracket (upper).
11. Remove catalyst converter. And keep a service area. NOTE: Slide the catalyst converter in a lateral direction to obtain work space for removing turbocharger.
12. Remove turbocharger. Refer to " «EXPLODED VIEW»(ref-516394-S42028742692012120600000) ".
13. Pull up and remove catalyst converter.
14. Remove gasket.

Scheme 65

Scheme 66

1. Install gasket between turbocharger and catalyst as shown in the figure.
2. Install catalyst converter with the following procedure. Tighten in numerical order as shown in the figure. Install catalyst converter (base on stud position 1). Temporary assemble 2 (no priority). Temporary assemble 3, 4. Tightening 5, 6 and 7. Tightening again 8, 9 and 10. Temporary assemble 11. Tightening 12, 13, 14, and 15.
3. Note the following, and install in the reverse order of removal. A/F sensor 1 Using heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)], install A/F sensor 1. CAUTION: Before installing a new sensors, clean exhaust system threads using heated oxygen sensor thread cleaner tool (Commercial Service Tool: J-43897-18 or J-43897-12) and apply anti-seize lubricant. Never apply excessive torque to sensor 2. Doing so may cause damage to sensor 2, resulting in the "MIL" illuminating. Prevent rust preventives from adhering to the sensor body.

Scheme 67

1. Drain engine coolant. Refer to " «DRAINING»(ref-516398-S08374559152012120600000) ".
2. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
3. Remove air cleaner cover assembly and air cleaner body assembly. Refer to " «EXPLODED VIEW»(ref-516394-S31888619102012120600000) ".
4. Remove air inlet tube 3. Refer to " «EXPLODED VIEW»(ref-516394-S42591055892012120600000) ".
5. Remove cowl top extension. Refer to " «EXPLODED VIEW»(ref-516396-S00001903602012120600000) ".
6. Disconnect heated oxygen sensor 2 harness connector.
7. Remove front tube. Refer to " «EXPLODED VIEW»(ref-516401-S42421858012012120600000) ".
8. Remove catalyst converter. Refer to " «2WD: EXPLODED VIEW»(ref-516394-S26730609962012120600000) " (2WD models) or " «AWD: EXPLODED VIEW»(ref-516394-S30349499242012120600000) " (AWD models).
9. Remove turbocharger assembly as follows: Remove heat insulator. Disconnect water hose from turbocharger. Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ". Remove oil supply tube. Remove mounting nuts of turbocharger. CAUTION: Never deform each turbocharger piping when pulling out the assembly.

Install in the reverse order of removal.

Scheme 68

Scheme 69

Scheme 70

1. Install oil pan (lower) as follows: Use a scraper (A) to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of oil pan (upper). Remove old liquid gasket from the bolt holes and threads. CAUTION: Never scratch or damage the mating surface when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket (A) with a tube presser (commercial service tool) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-516389-S27688368402012120600000) ". CAUTION: Attaching should be done within 5 minutes after liquid gasket application. Tighten bolts in numerical order as shown in the figure. NOTE: Tighten bolts the No. 1 and No. 2 in two steps. The numerical order No. 7 and No. 11 shows the second steps.
2. Install oil pan drain plug. CAUTION: Do not reuse drain plug washer. Refer to the figure of components of former page for installation direction of drain plug washer. Refer to " «EXPLODED VIEW»(ref-516394-S21352110102012120600000) ".
3. Install in the reverse order of removal after this step.

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-516395-S28376118092012120600000) ".
2. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ".
3. Remove fuel pump connector protector, and remove high pressure fuel pump insulator.
4. Disconnect quick connector (A) with the following procedure. Disconnect fuel feed hose (1) from bracket hose clamp (2). Disengage (A) and pull up (B) the pawl of the fuel feed hose connector retainer (C) to disconnect the fuel feed hose from high pressure fuel pump. NOTE: If the fuel feed hose is stuck, hold the fuel pipe by hand and disconnect it by pushing and pulling. CAUTION: Keep parts away from heat source. Especially, be careful when welding is performed around them. Never expose parts to battery electrolyte or other acids. Never bent or twist connection between quick connector and fuel feed hose (with damper) during installation/removal. Pull quick connector holding (D). Never remove the retainer. Prepare a tray and waste beforehand as fuel leaks out. Never pull with lateral force applied. O-ring inside quick connector may be damaged. Retainer color: Red To prevent damage to each joint and protect it from the entry of foreign matter, cover the joint with plastic bag (A) or an equivalent.
5. Remove intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-516394-S12508595602012120600000) ".
6. Remove fuel tube.
7. Remove fuel rail connector.
8. Remove high pressure fuel pump (1) and lifter. CAUTION: To prevent damage to high pressure fuel pump and camshaft bracket, loosen bolt (A) alternately by one turn at a time until the reaction force applied on the high pressure fuel pump disappears.

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

Scheme 80

1. Install high pressure fuel pump according to the following procedure. Check the orientation of pump cam from the mounting area (view arrow) of high pressure fuel pump. Aim pump cam at the BDC area (arrow position). NOTE: For BDC area, anywhere within the area indicated by arrow can be accepted. Install O-ring to high pressure fuel pump. When handing new O-ring, paying attention to the following caution items: CAUTION: Do not reuse O-ring. Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. Never damage O-ring with tools and fingernails during the installation. In addition, twisting or stretching O-ring is not allowed. If O-ring is stretched during the installation to high pressure fuel pump, never install high pressure fuel pump immediately. Install high pressure fuel pump lifter. Apply oil to the fitting area of high pressure fuel pump O-ring and camshaft bracket side to install high pressure fuel pump. Install high pressure fuel pump. To prevent damage to high pressure fuel pump and camshaft bracket, the following instructions must be observed. CAUTION: Temporarily tighten bolt (A) by hand. Alternately tighten bolt by one turn at a time until high pressure fuel pump reaches camshaft bracket. After a pump flange sitting, tighten the bolts to the specified torque.
2. Connect fuel feed hose with the following procedure, and them install the fuel feed hose. Check no foreign substances are deposited in and around matching pipe and quick connector, and no damage on them. Quick connector shall be inserted gradually, aligning with the axis of the matching pipe. Insert the retainer until it clicks and check the retainer is locked. After insertion, pull the connector and check that the connector is locked. CAUTION: If retainer cannot be installed smoothly, quick connector may be have not been installed correctly. Check connection again. After attaching the quick connector and fix the hose to the clamp.
3. Install new fuel rail connector (1). CAUTION: Never reuse fuel rail connector. Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. Never scratch O-ring with tools or fingernails when installing fuel rail connector. Insert new fuel rail connector straight into fuel rail. Never decenter or twist the fuel rail connector during insertion.
4. Install the fuel tube with the following procedure. CAUTION: Never reuse fuel tube. Never use fuel tube if its terminal tip is damaged. Observe the tightening order and the tightening torque. Temporarily tighten flare nut (A) and (B) of fuel tube (3) until seated. CAUTION: When temporarily tightening flare nut, place pipe in the center of the nut inner diameter. Temporarily tighten bolt (4) until the seat of bracket is seated. Tighten flare nut (A) and (B) in alphabetical order. Tighten bolt (4).
5. Install in the reverse order of removal after this step.

Removal and Installation

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

1. Release the fuel pressure. Refer to " «WORK PROCEDURE»(ref-516395-S28376118092012120600000) ".
2. Remove front bumper. Refer to " «EXPLODED VIEW»(ref-516396-S35683358922012120600000) "
3. Remove charge air cooler. Refer to " «EXPLODED VIEW»(ref-516394-S42591055892012120600000) ".
4. Remove oil level gauge. Refer to " «EXPLODED VIEW»(ref-516394-S28012697742012120600000) ".
5. Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ".
6. Remove alternator. Refer to " «EXPLODED VIEW»(ref-516405-S01517954772012120600000) "
7. Remove oil level gauge guide. Refer to " «EXPLODED VIEW»(ref-516394-S28012697742012120600000) ".
8. Remove fuel rail cover, and then remove fuel rail insulator. CAUTION: When fuel rail insulator (separated type) and adapter cover (separated type) are removed, be sure to replace them with fuel rail insulator (united type).
9. Remove fuel tube and fuel rail connector. Refer to " «EXPLODED VIEW»(ref-516394-S23624301502012120600000) ".
10. Disconnect fuel pressure sensor harness connector.
11. Disconnect fuel injector harness connector.
12. Remove fuel pressure sensor, if necessary.
13. Remove fuel rail. Loosen mounting bolts in reverse order as shown in the figure. CAUTION: When removing, be careful to avoid any interference with fuel injector. Use a shop cloth to absorb any fuel leakage from fuel rail.
14. Remove fuel injector from cylinder head as per the following. CAUTION: Be careful with remaining fuel that may go out from fuel rail. Be careful not to damage injector nozzles during removal. Never bump or drop fuel injector. Never disassemble fuel injector. Remove injector holder. Install an remover [SST: KV10119600 (-)] (A) to the injector connector side so that cutout (B) of injector remover faces the injector connector side. Hook pawl portion (B) of injector remover [SST: KV10119600 (-)] (A) to groove portion (C) of injector Press down body portion of injector remover [SST: KV10119600 (-)] (A) until it contacts cylinder head. Tighten injector remover [SST: KV10119600 (-)] clockwise and remove injector from cylinder head. Cut seal ring (1) while pinching it. Be careful not to damage injector.

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

Scheme 93

1. Install seal ring to fuel injector as per the following: CAUTION: Handle seal ring with bare hands. Never wear gloves. Never apply engine oil to seal ring. Never clean seal ring with solvent. Install an injector seal drift set [SST: KV101197S0 (-)] (A) to fuel injector (1). Set seal ring (1) to injector seal drift set [SST: KV101197S0 (-)] (A). Straightly insert seal ring (1), which is set in step 2, to fuel injector as shown in the figure and install. CAUTION: Be careful that seal ring does not exceed the groove portion of fuel injector. Insert injector seal drift set [SST: KV101197S0 (-)] (A) to injector and rotate clockwise and counterclockwise by 90° while pressing seal ring to fit it. NOTE: Compress seal ring, because this operation is for rectifying stretch of seal ring caused by installation and for preventing sticking when inserting injector into cylinder head.
2. Install O-ring and backup ring to fuel injector. When handing new O-ring and backup ring, paying attention to the following caution items: CAUTION: Do not reuse O-ring. Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. Insert new O-ring straight into fuel rail. Never decenter or twist it. Always install the back up ring (1) in the right direction as instructed.
3. Install fuel injector (1) to fuel rail (2) as per the following: Install fuel injector holder (5) to fuel injector. CAUTION: Never reuse fuel injector holder. Replace it with a new one. Be careful to keep fuel injector holder from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel rail with fuel injector holder attached. Insert it while matching it to the axial center. Insert so that protrusion (A) of fuel injector is aligned to cutout (B). Check that installation is complete by checking that fuel injector does not rotate or come off. Check that protrusions of fuel injectors and fuel rail are aligned with cutouts of clips after installation.
4. Install fuel rail and fuel injector assembly to cylinder head. Tighten mounting bolts and nuts in two steps in numerical order as shown in the figure. 1st step Torque : 10.0 N.m (1.0 kg-m, 89 in-lb) 2nd step Torque : 20.5 N.m (2.1 kg-m, 15 ft-lb)
5. Connect injector harness connector.
6. Install fuel pressure sensor, if removed.
7. Install fuel rail insulator. CAUTION: As covering part of fuel tube connector at the back end of common rail can easily move because of its shape, do not remove it before installation. Install the insulator so that it is placed under lower side of intake manifold flange.
8. Install in the reverse order of removal after this step.

Scheme 94

1. Install the rocker cover gasket to rocker cover. CAUTION: Check the gasket is not dropped.
2. Install rocker cover. Tighten bolts in two steps separately in numerical order as shown in the figure. Torque 1st step: 1.96 N.m (0.20 kg-m, 17 in-lb) Torque 2nd step: 8.33 N.m (0.85 kg-m, 74 in-lb)
3. Install in the reverse order of removal, for the rest of parts.

Scheme 95

Scheme 96

2WD: Removal and Installation

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

Outline

Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle.

Preparation

1. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-516395-S28376118092012120600000) ".
2. Drain engine coolant from radiator. Refer to " «DRAINING»(ref-516398-S08374559152012120600000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belts.
3. Remove the following parts. Engine undercover Front road wheels and tires Front fender protector (RH and LH): Refer to " «EXPLODED VIEW»(ref-516396-S16406822502012120600000) ". Drive belt: Refer to " «REMOVAL AND INSTALLATION»(ref-516394-S19439681422012120600000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ". Battery and battery tray: Refer to " «EXPLODED VIEW»(ref-516406-S08911992572012120600000) ". Air duct, and air cleaner case assembly and air cleaner body assembly: Refer to " «EXPLODED VIEW»(ref-516394-S31888619102012120600000) ". Radiator hose (upper and lower): Refer to " «EXPLODED VIEW»(ref-516398-S09436481382012120600000) ". Exhaust front tube: Refer to " «EXPLODED VIEW»(ref-516401-S42421858012012120600000) ". Radiator cooling fan assembly: Refer to " «EXPLODED VIEW»(ref-516398-S22376738012012120600000) ". Charger air cooler: Refer to " «EXPLODED VIEW»(ref-516394-S42591055892012120600000) ". Alternator: Refer to " «EXPLODED VIEW»(ref-516405-S01517954772012120600000) ".

Engine Room LH

1. Disconnect all connections of engine harness around the battery, and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors using a resin bag against foreign materials during the operation.
2. Disconnect fuel feed hose quick connector. Refer to " «EXPLODED VIEW»(ref-516394-S23624301502012120600000) ".
3. Disconnect heater hoses. Refer to " «EXPLODED VIEW»(ref-516398-S31511713162012120600000) ".
4. Remove EVAP hoses. Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ".
5. Disconnect control cable from transaxle. (CVT models) Refer to " «EXPLODED VIEW»(ref-516407-S10892226422012120600000) ".
6. Disconnect control linkage from transaxle. (M/T models) Refer to " «EXPLODED VIEW»(ref-516408-S25805612542012120600000) ".
7. Disconnect clutch tube on transaxle side from clutch damper. (M/T models) Refer to " «EXPLODED VIEW»(ref-516409-S09529281102012120600000) ".

Engine Room RH

1. Disconnect vacuum hose from intake manifold. Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ".
2. Remove A/C compressor. Refer to " «EXPLODED VIEW»(ref-516410-S11771248592012120600000) ".
3. Remove ground cable at engine side.

Vehicle Underbody

1. Remove ground cable at transaxle side.
2. Remove drive shafts (RH and LH). Refer to " «EXPLODED VIEW»(ref-516402-S02710279482012120600000) ".
3. Remove rear torque rod.
4. Remove stabilizer connecting rod. Refer to " «EXPLODED VIEW»(ref-516411-S29492245232012120600000) ".
5. Remove front suspension member. Refer to " «EXPLODED VIEW»(ref-516411-S02235269262012120600000) ".
6. Preparation for the separation work of transaxle is as follows: Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW»(ref-516394-S21352110102012120600000) ".

Removal

Scheme 97

Scheme 98

Scheme 99

1. Use a manual lift table caddy (commercial service tool) (A) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle assembly. CAUTION: Put a piece of wood or an equivalent as the supporting surface, secure a completely stable condition.
2. Remove upper torque rod (RH) (1), and engine mounting insulator (RH) (2).
3. Remove engine mounting insulator (LH). (CVT models)
4. Remove the through bolt-securing nut (B) of engine mounting bracket (LH). (M/T models)
5. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work, observe the following caution. CAUTION: Check that no part interferes with the vehicle side. Before and during this lifting, always check if any harnesses are left connected. During the removal, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. If necessary, support the vehicle by setting jack or suitable tool at the rear.

Separation

Scheme 100

1. Remove catalyst convertor. Refer to " «2WD: EXPLODED VIEW»(ref-516394-S26730609962012120600000) ".
2. Remove turbocharger. Refer to " «EXPLODED VIEW»(ref-516394-S42028742692012120600000) ".
3. Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-516394-S29282140942012120600000) ".
4. Install engine slinger to front cover front left side (A) and cylinder head rear right side (B). Slinger bolts Front cover front left side: Torque : 32.9 N.m (3.4 kg-m, 24 ft-lb) Cylinder head rear right side: Torque : 25.0 N.m (2.6 kg-m, 18 ft-lb)
5. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-516412-S42854734472012120600000) ".
6. Lift with a hoist and separate the engine from the transaxle assembly. Refer to " «EXPLODED VIEW»(ref-516408-S02341931672012120600000) ".

INSTALLATION

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

Rear torque rod bracket

Scheme 101

1. Temporarily tighten mounting bolts in the numerical order as shown in the figure.
2. Tighten mounting bolts to the specified torque in the numerical order as shown in the figure.

4WD (AWD): Removal and Installation

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

Outline

Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle.

Preparation

1. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-516395-S28376118092012120600000) ".
2. Drain engine coolant from radiator. Refer to " «DRAINING»(ref-516398-S08374559152012120600000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belts.
3. Remove the following parts. Engine undercover Front road wheels and tires Front fender protector (RH and LH): Refer to " «EXPLODED VIEW»(ref-516396-S16406822502012120600000) ". Drive belt: Refer to " «REMOVAL AND INSTALLATION»(ref-516394-S19439681422012120600000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-516394-S32227874482012120600000) ". Battery and battery tray: Refer to " «EXPLODED VIEW»(ref-516406-S08911992572012120600000) ". Air duct, air cleaner case assembly and air cleaner body assembly: Refer to " «EXPLODED VIEW»(ref-516394-S31888619102012120600000) ". Radiator hose (upper and lower): Refer to " «EXPLODED VIEW»(ref-516398-S09436481382012120600000) ". Radiator cooling fan assembly: Refer to " «EXPLODED VIEW»(ref-516398-S22376738012012120600000) ". Exhaust front tube: Refer to " «EXPLODED VIEW»(ref-516401-S42421858012012120600000) ". Alternator: Refer to " «EXPLODED VIEW»(ref-516405-S01517954772012120600000) ".

Engine Room LH

1. Disconnect all connections of engine harness around the battery, and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors using a resin bag against foreign materials during the operation.
2. Disconnect fuel feed hose quick connector. Refer to " «EXPLODED VIEW»(ref-516394-S23624301502012120600000) ".
3. Disconnect heater hoses. Refer to " «EXPLODED VIEW»(ref-516398-S31511713162012120600000) ".
4. Disconnect control cable from transaxle. Refer to " «EXPLODED VIEW»(ref-516407-S10892226422012120600000) ".
5. Remove EVAP hoses. Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ".

Engine Room RH

1. Disconnect vacuum hose from intake manifold. Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ".
2. Remove A/C compressor. Refer to " «EXPLODED VIEW»(ref-516410-S11771248592012120600000) ".
3. Remove ground cable at engine side.

Vehicle Underbody

Scheme 102

1. Remove ground cable at transaxle side.
2. Remove rear propeller shaft. Refer to " «EXPLODED VIEW»(ref-516413-S08932281062012120600000) ".
3. Remove drive shafts (RH and LH). Refer to " «EXPLODED VIEW»(ref-516402-S02710279482012120600000) ".
4. Remove rear torque rod (1). Refer to " «4WD (AWD): EXPLODED VIEW»(ref-516394-S39445883752012120600000) ".
5. Remove stabilizer connecting rod. Refer to " «EXPLODED VIEW»(ref-516411-S29492245232012120600000) ".
6. Rear front suspension member. Refer to " «EXPLODED VIEW»(ref-516411-S02235269262012120600000) ".
7. Preparation for the separation work of transaxle is as follows: Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW»(ref-516394-S28012697742012120600000) ".

Removal

Scheme 103

1. Use a manual lift table caddy (commercial service tool) (A) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle assembly. CAUTION: Put a piece of wood or an equivalent as the supporting surface, secure a completely stable condition.
2. Remove upper torque rod (RH) (1) and engine mounting insulator (RH) (2).
3. Remove engine mounting insulator (LH).
4. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work, observe the following caution. CAUTION: Check that no part interferes with the vehicle side. Before and during this lifting, always check if any harnesses are left connected. During the removal, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. If necessary, support the vehicle by setting jack or suitable tool at the rear.

Separation

Scheme 104

1. Remove catalyst convertor. Refer to " «AWD: EXPLODED VIEW»(ref-516394-S30349499242012120600000) ".
2. Remove turbocharger. Refer to " «EXPLODED VIEW»(ref-516394-S42028742692012120600000) ".
3. Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-516394-S29282140942012120600000) ".
4. Install engine slinger to front cover front left side (A) and cylinder head rear right side (B). Slinger bolts Front cover front left side: Torque : 32.9 N.m (3.4 kg-m, 24 ft-lb) Cylinder head rear right side: Torque : 25.0 N.m (2.6 kg-m, 18 ft-lb)
5. Remove starter motor. Refer to " «EXPLODED VIEW»(ref-516412-S42854734472012120600000) ".
6. Lift with a hoist and separate the engine from the transaxle assembly. Refer to " «2WD: EXPLODED VIEW»(ref-516407-S08457631982012120600000) ".

INSTALLATION

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

1. Loosen mounting bolt and remove drive belt auto-tensioner.

Install in the reverse order of removal.

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

1. Drain engine oil. Refer to " «DRAINING»(ref-516404-S29020311892012120600000) ". CAUTION: Perform this step when engine is cold.
2. Remove the following parts: Intake manifold: Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ". Rocker cover: Refer to " «EXPLODED VIEW»(ref-516394-S05642854782012120600000) ".
3. Set No. 1 cylinder at TDC on its compression stroke with the following procedure: Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover. At the same time, check that the cam noses of the No. 1 cylinder are located (<==) as shown in the figure. If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown in the figure.
4. Remove crankshaft pulley with the following procedure: Fix crankshaft pulley (1) with a pulley holder (commercial service tool) (A), loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position. CAUTION: Never remove the crankshaft pulley bolt as they will be used as a supporting point for the pulley puller [SST: KV11103000 (-)]. Attach a pulley puller [SST: KV11103000 (-)] (A) in the M6 thread hole on crankshaft pulley (1), and remove crankshaft pulley.
5. Remove oil pan (lower). Refer to " «EXPLODED VIEW»(ref-516394-S21352110102012120600000) ". NOTE: If crankshaft sprocket and oil pump drive component are not removed, this step is unnecessary.
6. Remove intake valve timing control solenoid valve and exhaust valve timing control valve.
7. Remove drive belt auto-tensioner. Refer to " «EXPLODED VIEW»(ref-516394-S03685495912012120600000) ".
8. Remove front cover with the following procedure: Loosen mounting bolts in reverse order as shown in the figure. Cut liquid gasket by prying the position (<==) shown in the figure, and then remove the front cover. CAUTION: Be careful not to damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
9. Remove front oil seal from front cover. CAUTION: Be careful not to damage front cover. Lift up front oil seal using a screwdriver.
10. Remove valve timing control cover, if necessary. Loosen mounting bolts in reverse order as shown in the figure. NOTE: Disregard the numerical order No. 1 in removal.
11. Remove timing chain tensioner with the following procedure: Insert a wire (A) (e.g. clip) into the top groove with the timing chain tensioner plunger pressed. NOTE: Timing chain tensioner plunger is securely fixed by inserting a wire (e.g. clip). Remove timing chain tensioner (1).
12. Remove slack guide (2), tension guide (3) and timing chain (1). CAUTION: Never rotate each crankshaft and camshaft individually while timing chain is removed. It causes interference between valve and piston. NOTE: If timing chain is difficult to remove, remove camshaft sprocket (EXH) first to remove timing chain.
13. Remove crankshaft sprocket and oil pump drive component with the following procedure: Push oil pump drive chain tensioner (1) in the direction show in the figure. Insert a stopper pin (A) into the body hole (B). Remove oil pump chain tensioner. When the holes on lever and tensioner body cannot be alirned, align these holes by slightly moving the oil pump chain tensioner slack guide. Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A), and then loosen the oil pump sprocket bolt and remove it. CAUTION: Secure the oil pump shaft with the WAF part. Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
14. Remove tension guide (front cover side) from front cover, if necessary.

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

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

1. Check that crankshaft key points straight up.
2. If the tension guide (front cover side) is removed, install it to the front cover. CAUTION: Check the joint condition by sound or feeling.
3. Install crankshaft sprocket (2), oil pump sprocket (3), and oil pump drive chain (1). Install it by aligning matching marks on each sprockets and oil pump drive chain. If these matching marks are not aligned, rotate the oil pump shaft slightly to correct the position. CAUTION: Check matching mark position of each sprockets after installing the oil pump drive chain.
4. Hold the WAF part of oil pump shaft [WAF: 10 mm (0.39 in)] (A), and then tighten the oil pump shaft sprocket bolt. CAUTION: Secure the oil pump shaft with the WAF part. Never loosen the oil pump shaft sprocket bolt by tightening the oil pump drive chain.
5. Install oil pump chain tensioner (1). Fix the face oil pump tensioner at the most compressed position using a stopper pin (A), and then install it. Securely pull out (<==) the stopper pin after installing the oil pump chain tensioner. Check matching mark position of oil pump drive chain and each sprockets again.
6. Align the matching marks of each sprockets with the matching marks of timing chain. If these matching marks are not aligned, rotate the camshaft slightly by holding the hexagonal portion to correct the position. CAUTION: Check matching mark position of each sprocket and timing chain again after installing the timing chain.
7. Install the slack guide (2) and the tension guide (3).
8. Install timing chain tensioner. Fix the plunger at the most compressed position using a stopper pin, and then install it. Securely pull out the stopper pin after installing the timing chain tensioner. CAUTION: After installing tensioner on the cam side, pull out lock pin. If plunger pops out after pulling out lock pin without installing the tensioner to the engine, never use the tensioner. (If used, the plunger does not slide smoothly.) To reuse tensioner on the cam side: After installation, pick up and move ratchet clip toward the tip of the plunger and position the tensioner parallel to the groove of the plunger.
9. Check matching mark position of timing chain and each sprockets again.
10. Install front oil seal. Refer to " «FRONT OIL SEAL: REMOVAL AND INSTALLATION»(ref-516394-S38049187582012120600000) ".
11. Install front cover with the following procedure: Install valve timing control cover, if removed. Apply a continuous bead of liquid gasket (E) with a tube presser (commercial service tool) to valve timing control cover as shown in the figure. NOTE: The start and end of gasket application must overlap 5mm or more one another. Tighten mounting bolts in numerical order as shown in the figure. NOTE: Tighten bolt the No. 1 in two step. The numerical order No. 6 shows the second step. Install new O-ring to cylinder block. CAUTION: Do not reuse O-rings. Apply a continuous bead of liquid gasket (D) with a tube presser (commercial service tool) to front cover as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-516389-S27688368402012120600000) ". Check that matching marks of timing chain and each sprockets are still aligned. Then install front cover. CAUTION: Check O-ring on cylinder block is correctly installed. Be careful not to damage front oil seal by interference with front end of crankshaft. Install front cover, and tighten mounting bolts in numerical order as shown in the figure. Refer to the following for the installation position of bolts. M6 bolt: No. 1 M10 bolts: No. 6, 7, 10, 13, 21 M12 bolts: No. 2, 4, 8, 11 M8 bolts: Except the above CAUTION: Attaching should be done within 5 minutes after liquid gasket application. After all bolts are tightened, retighten them to specified torque in numerical order as shown in the figure. CAUTION: Be sure to wipe off any excessive liquid gasket leaking.
12. Install crankshaft pulley with the following procedure: When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). CAUTION: Never damage front oil seal lip section. Secure crankshaft pulley (1) with a pulley holder (commercial service tool) (A). Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. Tighten crankshaft pulley bolt. Torque : 29.4 N.m (3.0 kg-m, 22 ft-lb) Put a paint mark (B) on crankshaft pulley (2), matching with any one of six easy to recognize angle marks (A) on crankshaft pulley bolt (1) flange. Turn another 60 degrees clockwise (angle tightening). Check the tightening angle with movement of one angle mark. Check that crankshaft rotates clockwise smoothly.
13. Install remaining parts in the reverse order of removal.

Scheme 126

Scheme 127

Scheme 128

Scheme 129

1. Remove the following parts. Intake manifold: Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ". Rocker cover: Refer to " «EXPLODED VIEW»(ref-516394-S05642854782012120600000) ". Front cover and timing chain related parts: Refer to " «EXPLODED VIEW»(ref-516394-S04113068152012120600000) ". NOTE: Removal of oil pump drive related part is not necessary.
2. Remove camshaft position sensor (PHASE) and exhaust valve timing control position sensor from camshaft bracket. CAUTION: Handle camshaft position sensor (PHASE) and exhaust valve timing control position sensor carefully and avoid impacts. Never disassemble camshaft position sensor (PHASE) and exhaust valve timing control position sensor. Never place sensor where it is exposed to magnetism.
3. Put the matching mark (A) on the camshaft sprocket (INT) (2), camshaft sprocket (EXH) (3) and the camshaft bracket (1) as shown in the figure. NOTE: It prevents the knock pin of the camshaft (INT) from engaging with the incorrect pin hole when installing the camshaft sprocket (INT).
4. Remove camshaft sprockets (INT and EXH). Secure hexagonal part (A) of camshaft with a wrench. Loosen camshaft sprocket mounting bolts and remove camshaft sprocket. CAUTION: Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. Never loosen the mounting bolts with securing anything other than the camshaft hexagonal part or with tensioning the timing chain.
5. Remove camshaft bracket with the following procedure: Loosen mounting bolts in reverse order as shown in the figure. Cut liquid gasket by prying the position (<==) shown in the figure, and then remove the camshaft bracket. CAUTION: Never damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
6. Remove camshafts.
7. Remove valve lifters. Identify installation positions, and store them without mixing them up.
8. Remove signal plate from camshaft, if necessary.

INSTALLATION

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

1. Install valve lifters. Install them in the original positions.
2. Install camshafts. Clean camshaft journal to remove any foreign material. Distinguish between the intake and the exhaust by looking at the different shapes of the front and rear ends of the camshaft or using the identification colors (A) and (B). Identification color A B Camshaft (EXH) - Light blue Camshaft (INT) Light blue - Install camshafts so that camshaft dowel pins (A) on the front side are positioned as shown in the figure. NOTE: Though camshaft does not stop at the positions as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
3. Install camshaft bracket with the following procedure: Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Apply liquid gasket (A) to camshaft bracket as shown in the figure. Use Genuine RTV silicone sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-516389-S27688368402012120600000) ". Tighten mounting bolts of camshaft brackets in the following steps, in numerical order as shown in the figure. There are two types of mounting bolts. Refer to the following for locating bolts. M6 bolts [thread length: 57.5 mm (2.264 in)]: 13, 14, and 15 in the figure M6 bolts [thread length: 35.0 mm (1.378 in)]: Except the above Tighten mounting bolts in numerical order. Torque : 1.96 N.m (0.20 kg-m, 17 in-lb) Tighten mounting bolts in numerical order. Torque : 5.88 N.m (0.60 kg-m, 52 in-lb) Tighten mounting bolts in numerical order. Torque : 9.5 N.m (0.97 kg-m, 84 in-lb) CAUTION: After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the mating surface of cylinder head.
4. Install the camshaft sprocket to the camshaft with the following procedure. When the camshaft sprocket (INT) (2) and camshaft sprocket (EXH) (3) is removed, refer to the paint mark (A) put according to step "3". Securely align the knock pin and the pin hole, and then install them. Tighten bolts in the following steps. Secure the hexagonal part of camshaft using wrench to tighten mounting bolt. Tighten camshaft mounting bolt. Torque : 35.0 N.m (3.6 kg-m, 26 ft-lb) Turn 30 degrees clockwise (angle tightening). CAUTION: Check the tightening angle by using an angle wrench [SST: KV10112100 (BT8653-A)] (B) or protractor. Never judge by visual inspection without an angle wrench.
5. Install timing chain and related parts. Refer to " «EXPLODED VIEW»(ref-516394-S04113068152012120600000) ".
6. Inspect and adjust valve clearance. Refer to " «INSPECTION AND ADJUSTMENT»(ref-516394-S03339711362012120600000) ".
7. Install remaining parts in the reverse order of removal.

Scheme 136

1. Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on dial indicator. (Total indicator reading) Standard and Limit: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ".
4. If it exceeds the limit, replace camshaft.

Scheme 137

1. Measure the camshaft cam height with a micrometer (A). Standard and Limit: Refer to " «CAMSHAFT»(ref-516394-S39024377212012120600000) ".
2. If it exceeds the limit, replace camshaft.

1. Remove the following parts. Front fender protector (RH): Refer to " «EXPLODED VIEW»(ref-516396-S16406822502012120600000) ". Drive belt: Refer to " «EXPLODED VIEW»(ref-516394-S24910346932012120600000) ". Crankshaft pulley: Refer to " «EXPLODED VIEW»(ref-516394-S04113068152012120600000) ".
2. Remove front oil seal with a suitable tool. CAUTION: Be careful not to damage front cover and crankshaft.

Scheme 138

1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in the figure. Press-fit front oil seal using a suitable drift with outer diameter 57 mm (2.24 in) and inner diameter 45 mm (1.77 in). Within 0.3 mm (0.012 in) toward engine front (crankshaft pulley side) Within 0.5 mm (0.020 in) toward engine rear (crankshaft sprocket side) CAUTION: Be careful not to damage front cover and crankshaft. Press-fit oil seal straight to avoid causing burrs or tilting.
3. Install in the reverse order of removal, for the rest of parts.

1. Remove transaxle assembly. Refer to " «2WD: EXPLODED VIEW»(ref-516407-S08457631982012120600000) " (CVT / 2WD models) or " «AWD: EXPLODED VIEW»(ref-516407-S30115993992012120600000) " (CVT / AWD models) or " «EXPLODED VIEW»(ref-516408-S02341931672012120600000) " (M/T models).
2. Remove clutch cover and clutch disk (M/T models). Refer to " «EXPLODED VIEW»(ref-516394-S21713881652012120600000) ".
3. Remove drive plate (CVT models) or flywheel (M/T models). Refer to " «EXPLODED VIEW»(ref-516394-S21713881652012120600000) ".
4. Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block.

Scheme 139

Scheme 140

Scheme 141

1. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine RTV silicone sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-516389-S27688368402012120600000) ".
2. Install rear oil seal so that each seal lip is oriented as shown in the figure. Press-fit rear oil seal with a suitable drift (A) outer diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in). CAUTION: Be careful not to damage crankshaft and cylinder block. Press-fit oil seal straight to avoid causing burrs or tilting. Never touch grease applied onto oil seal lip. Press in rear oil seal (1) to the position as shown in the figure.
3. Install in the reverse order of removal, for the rest of parts.

Scheme 142

1. Remove the following components and related parts. Exhaust manifold: Refer to " «EXPLODED VIEW»(ref-516394-S29282140942012120600000) ". Intake manifold: Refer to " «EXPLODED VIEW»(ref-516394-S40399315512012120600000) ". Fuel injector and fuel tube assembly: Refer to " «EXPLODED VIEW»(ref-516394-S40863151652012120600000) ". Water outlet: Refer to " «EXPLODED VIEW»(ref-516398-S31511713162012120600000) ". Rocker cover: Refer to " «EXPLODED VIEW»(ref-516394-S05642854782012120600000) ". Front cover, timing chain: Refer to " «EXPLODED VIEW»(ref-516394-S04113068152012120600000) ". Camshaft: Refer to " «EXPLODED VIEW»(ref-516394-S32610026052012120600000) ".
2. Remove cylinder head. Loosen cylinder head bolts in reverse order as shown in the figure. Using TORX socket, loosen cylinder head bolts.
3. Remove cylinder head gasket.

Scheme 143

Scheme 144

1. Install cylinder head gasket.
2. Install cylinder head, and tighten cylinder head bolts in numerical order as shown in the figure with the following procedure. CAUTION: If cylinder head bolts are reused, check their outer diameters before installation. Refer to " «INSPECTION»(ref-516394-S23181484312012120600000) ". Apply new engine oil to threads and seating surface of mounting bolts. Tighten all cylinder head bolts. Torque : 40.0 N.m (4.1 kg-m, 30 ft-lb) Turn all cylinder head bolts 100 degrees clockwise (angle tightening). CAUTION: Check and confirm the tightening angle by using an angle wrench [SST: KV10112100 (BT8653-A)] (A) or protractor. Never judge by visual inspection without the tool. Completely loosen. Torque : 0 N.m (0 kg-m, 0 ft-lb) CAUTION: In this step, loosen cylinder head bolts in reverse order that indicated in the figure. Tighten all cylinder head bolts. Torque : 40.0 N.m (4.1 kg-m, 30 ft-lb) Turn all cylinder head bolts 95 degrees clockwise (angle tightening). Turn all cylinder head bolts 95 degrees clockwise again (angle tightening).
3. Install in the reverse order of removal, for the rest of parts.

Scheme 145

Scheme 146

Scheme 147

1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter. Identify installation positions, and store them without mixing them up.
3. Remove valve collet. Compress valve spring with the valve spring compressor [SST: KV10116200 (J-26336-A)] (A), the attachment [SST: KV10115900 (J-26336-20)] (C), and the adapter [SST: KV10109220 (-)] (B). Remove valve collet with a magnet hand. CAUTION: Be careful not to damage valve lifter holes. Fit the attachment [SST: KV10115900 (J-26336-20)] in the center of valve spring retainer to press it.
4. Remove valve spring retainer and valve spring (with valve spring seat). CAUTION: Never remove valve spring seat from valve spring.
5. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store them without mixing them up.
6. Remove valve oil seal with a valve oil seal puller [SST: KV10107902 (J-38959)] (A).
7. When valve seat must be replaced. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ". CAUTION: Never bore excessively to prevent cylinder head from scratching.
8. When valve guide must be replaced. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A). Drive out valve guide with a hammer and valve guide drift (commercial service tool). CAUTION: Cylinder head contains heat, wear protective equipment to avoid getting burned.

Scheme 148

Scheme 149

Scheme 150

Scheme 151

Scheme 152

1. When valve guide is removed, install it. CAUTION: Replace with oversize [0.2 mm (0.008 in)] valve guide. Ream cylinder head valve guide hole with a valve guide reamer (commercial service tool) (A). For service parts: Oversize [0.2 mm (0.008 in)] Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ". Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A). Press valve guide (1) from camshaft side to dimensions as shown in the figure. Projection (H): Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ". CAUTION: Cylinder head contains heat, wear protective equipment to avoid getting burned. Apply reamer finish to valve guide with a valve guide reamer (commercial service tool) (A). Standard: Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ".
2. When valve seat is removed, install it. CAUTION: Replace with oversize [0.5 mm (0.020 in)] valve seat. Ream cylinder head (1) recess diameter for service valve seat (2). For service parts: Oversize [0.5 mm (0.020 in)] Refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ". Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil (A). Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head. CAUTION: Never touch cold valve seats directly. Cylinder head contains heat, wear protective equipment to avoid getting burned. Using valve seat cutter set (commercial service tool) or valve seat grinder, finish valve seat to the specified dimensions. For dimensions, refer to " «CYLINDER HEAD»(ref-516394-S22659529612012120600000) ". 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 with the cutter or cutting many different times may result in stage valve seat. Using compound, grind to adjust valve fitting. Check again for normal contact. Refer to " «INSPECTION»(ref-516394-S23181484312012120600000) ".
3. Install valve oil seal. Install with a valve oil seal drift [SST: KV10115600 (J-38958)] (A) to match dimension in the figure. NOTE: Dimension is height that measured before installing valve spring (with valve spring seat). Height (H): 15.1 - 15.7 mm (0.594 - 0.618 in)
4. Install valve. Install larger diameter to intake side.
5. Install valve spring (with valve spring seat). Install smaller pitch (valve spring seat side) to cylinder head side (B). Confirm identification color (A) of valve spring. Intake: White Exhaust: Yellow green
6. Install valve spring retainer.
7. Install valve collet. Compress valve spring with the valve spring compressor [SST: KV10116200 (J-26336-A)] (A), the attachment [SST: KV10115900 (J-26336-20)] (C), and the adapter [SST: KV10109220 (-)] (B). Install valve collet with a magnet hand. CAUTION: When working care not to damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition.
8. Install valve lifter. Install it in the original position.
9. Install spark plug with spark plug wrench (commercial service tool).

Scheme 153

1. Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between (d1) and (d2) exceeds the limit, replace them with a new one. Limit [(d1) - (d2)]: 0.15 mm (0.0059 in)
2. If reduction of outer diameter appears in a position other than (d2), use it as (d2) point.

Scheme 154

Scheme 155

Scheme 156

Scheme 157

1. Install oil pan (upper) with the following procedure: Use a scraper (A) to remove old liquid gasket from mating surfaces. Remove the old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt holes and threads. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket (D) with a tube presser (commercial service tool) as shown in the figure. Use Genuine RTV silicone sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-516389-S27688368402012120600000) ". CAUTION: Apply liquid gasket to outside of bolt hole for the positions shown by UP marks. Attaching should be done within 5 minutes after liquid gasket application. Install new O-ring at cylinder block side. CAUTION: Install avoiding misalignment of O-ring. Tighten bolts in numerical order as shown in the figure.
2. Install rear oil seal with the following procedure. CAUTION: The installation of rear oil seal should be completed within 5 minutes after installing oil pan (upper). Always replace rear oil seal with new one. Never touch oil seal lip. Wipe off liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block using a scraper. Apply engine oil to entire outside area of rear oil seal. Press-fit the rear oil seal using a suitable drift (A) with outer diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in). Press-fit to the specified dimensions as shown in the figure. CAUTION: Never touch the grease applied to the oil seal lip. Be careful not to damage the rear oil seal mounting part of oil pan (upper) and cylinder block or the crankshaft. Press-fit straight, checking that rear oil seal does not curl or tilt. NOTE: The standard surface of the dimension is the rear end surface of cylinder block.
3. Install in the reverse order of removal, for the rest of parts.