Engine Mechanical: Removal & Installation Nissan Maxima A34

Precautions for Removal and Disassembly

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

Precautions for Assembly and Installation

1. Use torque wrench to tighten bolts or nuts to specification.
2. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
3. Replace with new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage.
5. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
6. Release air within route after draining coolant.
7. Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections.
8. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.

REMOVAL

1. Remove engine undercover.
2. Fully loosen each belt. Refer to «POWER STEERING OIL PUMP BELT»(ref-233644-S30107960682006052600000) . Remove generator and air conditioner compressor belt and then power steering oil pump belt. CAUTION: Grease is applied to idler pulley adjusting bolt. Be careful to keep grease away from the belts.

INSTALLATION

1. Installation is in the reverse order of removal. CAUTION: Make sure belts are correctly engaged with the pulley groove. Clean off any for oil and coolant on belts and each pulley groove.
2. Adjust belt tension. Refer to «POWER STEERING OIL PUMP BELT»(ref-233644-S30107960682006052600000) .

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1. Remove the grille top cover.
2. Remove the fresh air duct.
3. Disconnect the harness connector from the mass air flow sensor.
4. Disconnect the tube clamp at the electric throttle control actuator.
5. Remove air cleaner to electric throttle control actuator tube, air cleaner case (upper) with the mass air flow sensor attached.
6. Remove mass air flow sensor from air cleaner case (upper), as necessary. CAUTION: Handle mass air flow sensor with care. Do not shock it. Do not disassemble it. Do not touch its sensor.
7. Remove the air cleaner case (lower).
8. Remove resonator in the fender, lifting left fender protector, as necessary.

Installation is in the reverse order of removal.

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1. Remove the cowl top. Refer to «REMOVAL AND INSTALLATION»(ref-233645-S31308520782006052600000) .
2. Remove the windshield wiper assembly. Refer to «REMOVAL AND INSTALLATION OF WIPER MOTOR AND LINKAGE»(ref-233646-S28715745702006052600000) .
3. Remove the engine cover using power tool.
4. Remove air cleaner case lid and mass air flow sensor, and air intake tube as an assembly. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S23956234542006052600000) .
5. Partially drain the coolant when the engine is cool. Refer to «DRAINING ENGINE COOLANT»(ref-233644-S13037486022006052600000) .
6. Disconnect the following: Power brake booster vacuum hose Coolant hoses from the intake manifold collector Swirl control vacuum lines to power valve and intake manifold collector upper Fuel injector electrical connectors PCV hose Electric throttle control actuator electrical connector EVAP canister purge hose EGR temperature sensor electrical connector CAUTION: Cover any engine openings to avoid the entry of any foreign material.
7. Remove the EGR tube (to lower intake manifold collector) nuts.
8. Disconnect the power steering hose bracket from the rear of the intake manifold collector.
9. Remove the EVAP canister purge volume solenoid valve bracket bolt. Position the valve aside.
10. Remove the VIAS control solenoid valve bracket bolt. Position the valve aside.
11. Remove the vacuum tank.
12. Remove the intake manifold collector support bracket from the back of the intake manifold collector using power tool.
13. Loosen the intake manifold collector bolts in the order shown using power tool, and remove the intake manifold collector and gasket.
14. If necessary, remove the electric throttle control actuator bolts in the order shown and remove the electric throttle control actuator. CAUTION: Handle carefully to avoid any shock to the electric throttle control actuator. Do not disassemble.
15. If necessary, remove the intake manifold collector (upper) bolts in the order shown, using power tool and remove the intake manifold collector. CAUTION: Handle carefully to avoid any shock to the electric throttle control actuator, if installed.
16. If necessary, remove power valve bolts in the order shown and remove the power valve.
17. If necessary remove the following components: Vacuum tank VIAS control solenoid valve EVAP canister purge volume control solenoid valve

Installation is in the reverse order of removal, paying attention to the following.

Note. After installation, it is necessary to re-calibrate the electric throttle control actuator as follows: Perform the "Throttle Valve Closed Position Learning" when harness connector of the electric throttle control actuator is disconnected. Refer to THROTTLE VALVE CLOSED POSITION LEARNING . Perform the "Idle Air Volume Learning" when the electric throttle control actuator is replaced. Refer to IDLE AIR VOLUME LEARNING .

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1. If necessary, install power valve bolts in the order shown. Power valve bolts : 17.6 - 21.6 N.m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
2. If necessary, tighten the intake manifold collector pipe bolts in the order shown. Intake manifold collector pipe bolts : 17.6 - 21.6 N.m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)
3. If necessary, install the electric throttle control actuator bolts in the order shown. Install gasket with three protrusions facing down. Electric throttle control actuator bolts : 7.2 - 9.6 N.m (0.74 - 0.97 kg-m, 64 - 84 in-lb)
4. Install the intake manifold collector bolts in the order shown. Intake manifold collector bolts : 17.6 - 21.6 N.m (1.8 - 2.2 kg-m, 13 - 15 ft-lb)

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1. Remove the engine cover using power tool.
2. Remove air cleaner case lid and mass air flow sensor, and air intake tube as an assembly. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S23956234542006052600000) .
3. Partially drain the coolant when the engine is cool. Refer to «DRAINING ENGINE COOLANT»(ref-233644-S13037486022006052600000) . CAUTION: Cover any engine openings to avoid the entry of any foreign material.
4. Disconnect the EGR temperature sensor electrical connector and bracket.
5. If necessary, remove the EGR temperature sensor.
6. Disconnect the EGR volume control valve electrical connector.
7. Remove the EGR tube (to intake manifold collector) bolts at the intake manifold collector.
8. Remove the EGR tube (to intake manifold collector) bolts at the EGR volume control valve and remove the tube.
9. Loosen the EGR tube (to exhaust manifold) to EGR volume control valve fitting.
10. If necessary remove the EGR tube (to exhaust manifold) as follows: Remove the front cowl grille. Refer to «REMOVAL AND INSTALLATION»(ref-233645-S31308520782006052600000) . Remove the windshield wiper assembly. Refer to «REMOVAL AND INSTALLATION OF WIPER MOTOR AND LINKAGE»(ref-233646-S28715745702006052600000) . Remove the EGR tube (to exhaust manifold) to EGR volume control valve fitting. Disconnect the air fuel ratio (A/F) sensor 1 (bank 1). Remove the RH heat shield. Remove the EGR tube (to exhaust manifold) to exhaust manifold fitting.
11. Disconnect the coolant lines at the EGR volume control valve.
12. Remove the EGR volume control valve bolts and the valve.

Installation is in the reverse order of removal.

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1. Install the RH heat shield bolts. RH heat shield bolts: 5.1 - 6.5 N.m (0.52 - 0.66 kg-m, 46 - 57 in-lb)

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1. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233647-S14261418062006052600000) .
2. Remove the intake manifold collector. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S18595903042006052600000) .
3. Remove the fuel rail with the fuel injectors. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S24437408532006052600000) .
4. Loosen the intake manifold nuts and bolts in the order shown using power tool, and remove the intake manifold.

Installation is in the reverse order of removal.

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1. If necessary, install the stud bolts. Stud bolts : 9.8 - 11.8 N.m (1.0 - 1.2 kg-m, 87 - 104 in-lb)
2. Install intake manifold bolts in three steps in the order shown. Step 1 : 4.9 - 9.8 N.m (0.5 - 0.99 kg-m, 44 - 86 in-lb) Step 2 : 26.5 - 31.4 N.m (2.7 - 3.2 kg-m, 20 - 23 ft-lb) Step 3 : 26.5 - 31.4 N.m (2.7 - 3.2 kg-m, 20 - 23 ft-lb)

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1. Remove the front wheel and tires using power tool.
2. Remove the engine undercover.
3. Remove the inner wheel well splash shields.
4. Remove the radiator and cooling fan assembly. Refer to «REMOVAL»(ref-233648-S29776269262006052600000) .
5. Remove the front exhaust tube. Refer to «REMOVAL AND INSTALLATION»(ref-233649-S22833986492006052600000) .
6. Remove the front suspension member. Refer to «REMOVAL AND INSTALLATION»(ref-233650-S01688699322006052600000) .
7. Remove the RH and LH three way catalyst support bolts in the order shown.
8. Remove heated oxygen sensor 2 (bank 1), heated oxygen sensor 2 (bank 2), air fuel ratio (A/F) sensor 1 (bank 1) and air fuel ratio (A/F) sensor 1 (bank 2). Remove harness connector of each sensor, and disconnect the harness from the bracket and middle clamp. Remove both heated oxygen sensors and air fuel ratio (A/F) sensors using Tool. Tool numbers: KV10114400 (J38365) : KV10117100 (J3647-A) CAUTION: Be careful not to damage heated oxygen sensors or air fuel ratio (A/F) sensors. Discard any heated oxygen 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 with a new sensor.
9. Remove exhaust manifold and three way catalyst heat shields with power tool.
10. Remove the three way catalyst (manifold) (bank 1) and three way catalyst (manifold) (bank 2) by loosening the bolts first and then removing the nuts and through bolts.
11. Remove the exhaust manifolds. Loosen the exhaust manifold nuts in the order shown.

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1. Use a reliable straightedge and feeler gauge to check the flatness of the exhaust manifold mating surfaces. Limit : 0.3 mm (0.012 in)

Installation is in the reverse order of removal.

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1. Install the exhaust manifold nuts in the order shown. Exhaust manifold nuts : 28.4 - 33.3 N.m (2.9 - 3.3 kg-m, 21 - 24 lb-ft) CAUTION: When using the heated oxygen sensor wrench, tighten to the middle of specified torque range, because the length of the Tool may increase the actual tightness. Do not tighten to the maximum specified torque range. Tool numbers: KV10114400 (J38365) : KV10117100 (J3647-A) Before installing a heated oxygen sensor or air fuel ratio (A/F) sensor, clean the exhaust manifold threads using the oxygen sensor thread cleaner tool, and apply anti-seize lubricant. Tool numbers: J-43897-18 : J-43897-12 Do not over-tighten the air fuel ratio (A/F) sensor or heated oxygen sensors. Doing so may cause damage.
2. Install the RH and LH three way catalyst support bolts in the order shown. Three way catalyst support bolts: 19 - 28 N.m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
3. Install the exhaust manifold heat shield bolts. Exhaust manifold heat shield bolts: 5.1 - 6.5 N.m (0.52 - 0.66 kg-m, 46 - 57 in-lb)
4. Install the three way catalyst heat shield bolts. Three way catalyst heat shield bolts: 6.7 - 9.8 N.m (0.69 - 0.99 kg-m, 60 - 86 in-lb)

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1. Remove the front RH wheel and tire using power tool. Refer to «WHEEL AND TIRE ASSEMBLY»(ref-233651-S14782790692006052600000) .
2. Disconnect the battery negative terminal.
3. Remove the oil dipstick.
4. Drain the engine coolant. Refer to «DRAINING ENGINE COOLANT»(ref-233644-S13037486022006052600000) .
5. Remove the engine undercover.
6. Remove the RH inner fender splash shield.
7. Remove the A/C drive belt. Refer to «REMOVAL»(ref-233643-S17836745932006052600000) .
8. Remove the front exhaust tube. Refer to «REMOVAL AND INSTALLATION»(ref-233649-S22833986492006052600000) .
9. Remove coolant pipe bolts.
10. Remove the A/C compressor with piping attached, and position it out of the way securely with wire. CAUTION: Do not pull on or crimp the A/C lines and hoses.
11. Disconnect the coolant lines from the engine oil cooler and plug them to prevent coolant loss.
12. Remove the oil filter and engine oil cooler from the upper oil pan.
13. Remove the oil pressure switch, and the crankshaft position sensor (POS) from the upper oil pan.
14. Remove the front drive shafts. Refer to «REMOVAL AND INSTALLATION»(ref-233652-S33721208742006052600000) .
15. Remove the front suspension member. Refer to «REMOVAL AND INSTALLATION»(ref-233650-S01688699322006052600000) .
16. Disconnect the heated oxygen sensors and air flow ratio (A/F) sensors and remove the two catalytic convertors from the exhaust manifolds using power tool. Refer to «REMOVAL AND INSTALLATION»(ref-233649-S22833986492006052600000) .
17. Remove the rear plate cover from the upper oil pan.
18. Loosen the lower oil pan bolts using power tool in order shown. Remove the lower oil pan. Insert Tool between the lower oil pan and the upper oil pan. Tool number: KV10111100 (J37228) Be careful not to damage the mating surface. Do not insert a screwdriver, this will damage the mating surfaces. Slide the Tool by tapping its side with a hammer to remove the lower oil pan from the upper oil pan.
19. Remove the four upper oil pan to transaxle bolts.
20. Remove the upper oil pan. Loosen the bolts in the order shown, using power tool. Insert an appropriate size tool into the notch (1) of the upper oil pan as shown. Pry off the upper oil pan by moving the tool up and down (2) as shown.
21. Remove the O-ring seals from the bottom of the cylinder block and oil pump housing, use new O-rings for installation.
22. Remove front cover gasket and rear oil seal retainer gasket.
23. Remove the oil strainer.
24. If re-installing the original oil pan, remove the old sealant from the mating surfaces using a scraper. Also remove the old sealant from mating surface of the cylinder block. Remove the old sealant from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off the old sealant.

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1. Install oil strainer. Oil strainer bolts: 19.6 - 22.5 N.m (2.0 - 2.2 kg-m, 15-16 ft-lb)
2. Apply Genuine Silicone RTV Sealant or equivalent, to the front cover gasket and the rear oil seal retainer gasket as shown. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) .
3. Install the front cover gasket and rear oil seal retainer gasket as shown.
4. Apply a bead of sealant to the cylinder block mating surface of the upper oil pan to a limited portion as shown. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Be sure the sealant is applied to a limited portion as shown, and the sealant is 4.0 - 5.0 mm (0.157 - 0.197 in) or 4.5 - 5.5 mm (0.177 - 0.217 in) wide. Attaching should be done within 5 minutes after coating.
5. Install new O-rings on the cylinder block and oil pump body.
6. Install the upper oil pan. Tighten upper oil pan bolts in the order shown. Upper oil pan bolts: 15.7 - 18.6 N.m (1.6 - 1.8 kg-m, 12 - 13 ft-lb) Wait at least 30 minutes before refilling the engine with oil.
7. Install the four upper oil pan to transaxle bolts. Refer to «INSTALLATION»(ref-233643-S40551544322006052600000) .
8. Apply a continuous bead of sealant to the lower oil pan. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Be sure the sealant is 4.5 - 5.5 mm (0.177 - 0.217 in) wide. Installation must be done within 5 minutes after applying sealant.
9. Install the lower oil pan. Tighten the lower oil pan bolts in order shown. Lower oil pan bolts: 9.22 - 10.6 N.m (0.94 - 1.00 kg-m, 82 - 93 in-lb) Wait at least 30 minutes before refilling the engine with oil.
10. Install rear plate cover. Rear plate cover bolt: 6.37 - 7.45 N.m (0.65 - 0.75 kg-m, 57 - 65 in-lb)
11. Installation of the remaining components is in the reverse order of removal.

1. Remove the engine cover using power tool.
2. Drain engine coolant. Refer to «DRAINING ENGINE COOLANT»(ref-233644-S13037486022006052600000) .
3. Disconnect the mass air flow sensor electrical connector and remove the air cleaner assembly and air intake tubes. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S23956234542006052600000) .
4. Remove the intake manifold collector, gasket, and electric throttle control actuator. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S18595903042006052600000) .
5. Remove the six ignition coils. CAUTION: Do not shock it.

Installation is in the reverse order of removal.

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1. Remove the engine cover, using power tool.
2. Drain engine coolant. Refer to «DRAINING ENGINE COOLANT»(ref-233644-S13037486022006052600000) .
3. Disconnect the mass air flow sensor electrical connector and remove the air cleaner assembly and air intake tubes. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S23956234542006052600000) .
4. Remove the intake manifold collector, gasket, and electric throttle control actuator. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S18595903042006052600000) .
5. Remove the six ignition coils. CAUTION: Do not shock it.
6. Remove the six spark plugs using a suitable tool. If replacing the spark plugs use the correct spark plug for maximum performance. Refer to «CHANGING SPARK PLUGS (PLATINUM - TIPPED TYPE)»(ref-233644-S03725006502006052600000) .

Installation is in the reverse order of removal.

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1. Remove the intake manifold collector. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S18595903042006052600000) .
2. Disconnect fuel tube quick connector at vehicle piping side.
3. To remove the quick connector cap, hold the sides of the connector, push in the tabs and pull out the tube. NOTE: If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling. CAUTION: The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. Do not use any tools to remove the quick connector. Keep the resin tube away from heat. Be especially careful when welding near the tube. Prevent acid liquids such as battery electrolyte, etc. from getting on the resin tube. Do not bend or twist the tube during removal or installation. Do not remove the remaining retainer on the tube. When the tube is replaced, also replace the retainer with a new one. To keep the connecting portion clean and to avoid damage and foreign materials entering, cover the ends of the fuel tubes with plastic bags or something similar.
4. Remove the fuel rail with the fuel injectors attached, from the intake manifold. Remove the fuel injector O-rings and use new O-rings for installation.
5. If necessary, remove fuel damper bolts and the fuel dampers. Remove fuel damper O-rings and use new O-rings for installation.

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1. If necessary, Install fuel damper bolts. Use new O-rings for installation. Fuel damper bolts: 7.2 - 10.8 (0.8 - 1.1 kg-m, 64 - 95 in-lb)
2. Install the fuel rails with fuel injectors attached. NOTE: Carefully install new O-rings. Lubricate O-rings by lightly coating with new engine oil. Be careful not to damage the O-rings and surfaces for O-ring sealing surfaces. Do not expand or twist O-rings. Discard old clips; replace with new ones. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation. Position clips in grooves on the fuel injectors. Align the protrusions of the fuel tube assembly with those of the fuel injectors. After properly inserting the fuel injectors onto the fuel tube assembly, check that the fuel tube protrusions are engaged with those of fuel injectors, and the flanges of the fuel tube assembly are fully engaged with the clips.
3. Tighten fuel tube assembly bolts in the order shown, in two steps: Fuel tube assembly bolts Step 1: 9.3 - 10.8 N.m (0.95 - 1.1 kg-m, 6.2 - 7.9 ft-lb) Step 2: 20.6 - 26.5 N.m (2.1 - 2.7 kg-m, 16 - 19 ft-lb) CAUTION: After properly connecting fuel tube assembly to injector and fuel hose, check connection for fuel leakage.
4. Install the quick connector as follows: Make sure no foreign substances are deposited in and around the fuel tube and quick connector and that there is no damage. Align the center to insert the quick connector straight onto the fuel tube. Insert the fuel tube until a click is heard.
5. Installation of the remaining components is in the reverse of removal.

Installation is in the reverse order of removal.

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1. Apply sealant to the areas on the front corners. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S15386963742006052600000) .
2. Use Genuine Silicone RTV Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) .
3. Tighten the rocker cover bolts in two steps in the order shown. Rocker cover bolts Step 1 : 0.96 - 2.96 N.m (0.10 - 0.30 kg-m, 9 - 26 in-lb) Step 2 : 7.33 - 9.33 N.m (0.75 - 0.95 kg-m, 65 - 82 in-lb)
4. Install engine cover.

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1. Remove engine under cover. Refer to «MUDGUARD»(ref-233645-S02829373362006052600000) .
2. Drain the engine oil. Refer to «ENGINE OIL»(ref-233656-S34400740082006052600000) .
3. Drain the engine coolant from the radiator. Refer to «ENGINE COOLANT»(ref-233648-S31618211132006052600000) .
4. Drain the power steering fluid. Refer to «POWER STEERING FLUID»(ref-233655-S19212831832006052600000) .
5. Remove engine room cover.
6. Remove front air duct..
7. Remove battery tray.
8. Remove upper radiator hose.
9. Disconnect engine coolant reservoir hose from the radiator and remove engine coolant reservoir.
10. Remove cooling fan assembly. Refer to «COOLING FAN»(ref-233648-S35857417692006052600000) .
11. Disconnect lower radiator hose from engine.
12. Disconnect the power steering fluid reservoir tank hose from the power steering pump and fluid cooler and remove the power steering fluid reservoir tank. Refer to «HYDRAULIC LINE»(ref-233655-S00828690882006052600000) .
13. Remove the front RH wheel and tire.
14. Remove the fender protector side cover RH. Refer to «FENDER PROTECTOR»(ref-233645-S03287839192006052600000) .
15. Remove the drive belt. Refer to «DRIVE BELTS»(ref-233643-S31230987292006052600000) .
16. Remove the power steering pump. Refer to «HYDRAULIC LINE»(ref-233655-S00828690882006052600000) .
17. Remove the lower oil pan. Loosen the lower oil pan bolts using power tool in order as shown. Cut the sealant using Tool and remove the lower oil pan. CAUTION: * Be careful not to damage the mating surface. * Do not insert a screwdriver, this will damage the mating surfaces. Slide the Tool by tapping its side with a hammer to remove the lower oil pan.
18. Remove upper oil pan bolts in reverse order as shown.
19. Remove the generator. Refer to «REMOVAL AND INSTALLATION»(ref-233654-S19301859372006052600000) .
20. Remove the A/C compressor bolts and position the A/C compressor aside. Refer to «REMOVAL AND INSTALLATION FOR COMPRESSOR»(ref-233653-S29634147182006052600000) .
21. Remove the generator bracket. Refer to «REMOVAL AND INSTALLATION»(ref-233654-S19301859372006052600000) .
22. Support the engine with suitable jack and remove the RH engine, mount and bracket. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S15386963742006052600000) .
23. Remove the crankshaft pulley as follows: CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the Tool. Remove access plate and install Ring Gear Stopper Tool. Tool number : - (J-50288) CAUTION: Do not remove crankshaft pulley bolt. Keep loosened crankshaft pulley bolt in place to protect the crankshaft pulley from dropping. Loosen crankshaft pulley bolt so that there is a 10 mm (0.39 in) gap between bolt and crankshaft pulley. CAUTION: Do not use a puller claw on the outside edge of the crankshaft pulley. Position a suitable tool at recess hole of crankshaft pulley to remove crankshaft pulley.
24. Disconnect the oil pressure switch harness connector.
25. Disconnect valve timing control harness connector.
26. Remove the A/C idler pulley and bracket and the drive belt auto-tensioner.
27. If necessary, remove the idler pulley and water pump cover.
28. Remove the front timing chain case. Loosen the front timing chain case bolts in the order as shown. Insert the appropriate size tool into the notch (1) at the top of the front timing chain case as shown. Pry off the case by moving the suitable tool (2) as shown. Cut liquid gasket for removal using Tool. CAUTION: Do not use a screwdriver or similar tool. After removal, handle carefully so it does not bend, or warp under a load.
29. Remove O-rings from rear timing chain case. Use new O-rings for installation.
30. Remove the front oil seal from the front timing chain case using a suitable tool. Do not damage the front cover.
31. Remove all old Silicone RTV Sealant from all the bolt holes and bolts. Do not damage the threads or mating surfaces.
32. Use a scraper to remove all of the old Silicone RTV Sealant from the front timing chain case and opposite mating surfaces. Do not damage the mating surfaces.

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1. Install dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
2. Install the front oil seal on the front timing chain case. Apply new engine oil to the oil seal edges. Install it so that each seal lip is oriented as shown.
3. Install the new front oil seal so that it becomes flush with the face with front timing chain case using suitable drift. CAUTION: Press fit straight and avoid causing burrs or tilting the oil seal. NOTE: Make sure the garter spring is in position and seal lip is not inverted.
4. Install new collared O-rings on front timing chain case oil hole (left and right sides).
5. Apply Silicone RTV Sealant to front timing chain case as shown. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Before installation, wipe off the protruding sealant.
6. Apply Silicone RTV Sealant to top surface of oil pan (upper) as shown. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) .
7. Install front timing chain case. Install lower end of front timing chain case tightly onto top surface of oil pan (upper). CAUTION: Be careful that oil pan gasket is in place. While pressing front timing chain case from its front and top as shown, hammer dowel pin until the outer end becomes flush with surface using suitable tool. Install dowel pin on the rear timing chain case into dowel pin hole in front timing chain case.
8. Loosely install the front timing chain case bolts. Bolt position - Bolt diameter 1, 2 : 8 mm (0.31 in) 3 - 22 : 6 mm (0.24 in)
9. Tighten the front timing chain case bolts in the order as shown. Retighten the front timing chain case bolts in the order as shown. Bolt position - Tightening specification 1, 2 : 28.5 N.m (2.9 kg-m, 21 ft-lb) 3 - 22 : 12.8 N.m (1.3 kg-m, 9 ft-lb)
10. Install the upper oil pan front bolts in the order as shown. Upper oil pan front bolts : 22.0 Nm (2.2 kg-m, 16 ft-lb)
11. Install lower oil pan. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S42259334642006052600000) .
12. Install IVT control valve covers as follows: Install new collared O-rings in front cover oil hole (LH and RH sides). Install new seal rings on the IVT control covers. Apply Silicone RTV Sealant to the IVT control covers. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case with the holes to install the IVT control covers. Tighten the intake valve timing control cover bolts in the order as shown. Intake valve timing control cover bolts : 11.3 N.m (1.2 kg-m, 100 in-lb)
13. Apply liquid gasket and install the water pump cover, if removed. Use Genuine Silicone RTV Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) .
14. Install crankshaft pulley and tighten the bolt in two steps. Lubricate thread and seat surface of the bolt with new engine oil. Apply a paint mark for the second step of angle tightening. Step 1 : 44 N.m (4.5 kg-m, 32 ft-lb) Step 2 : 84° - 90° degrees clockwise
15. Remove the Ring Gear Stopper Tool. Tool number : - (J-50288) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when removing the Tool.
16. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
17. Installation of the remaining components is in reverse order of removal.

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Scheme 131

1. Before removing the upper oil pan, remove the crankshaft position sensor (POS).
2. Be careful not to damage sensor edges.
3. Do not spill engine oil or coolant on drive belts.

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1. Set No. 1 cylinder at TDC on its compression stroke. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator.
2. Remove front timing chain case. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S16453194412012022700000) .
3. Check timing chain markings to confirm No. 1 cylinder is at TDC of its compression stroke. If not, remove Ring Gear Stopper Tool and turn crankshaft clockwise 360° (one revolution). * Re-install Ring Gear Stopper Tool (J-50288). NOTE: If the original timing chain markings are not legible, use paint or equivalent to mark the timing chains to the sprockets.
4. If removing the timing chains (secondary), loosen camshaft sprocket bolts.
5. Compress the timing chain tensioner (primary). Pull lever down and release plunger stopper tab. Plunger stopper tab can be pushed up to release (coaxial structure with lever). Insert stopper pin into timing chain tensioner (primary) body hole to hold lever, and keep the tab released. An Allen wrench [1.2 mm (0.047 in)] is used for a stopper pin as an example. Depress plunger into tensioner body by pressing the slack guide. Keep the slack guide pressed and hold it by pushing the stopper pin through the lever hole and body hole. Remove the bolts and remove the timing chain tensioner (primary).
6. Remove the internal chain guide (1). Slack guide (2) does not need to be removed.
7. Remove primary timing chain and crankshaft sprocket. CAUTION: After removing timing chain, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.
8. Attach a suitable stopper pin (1) to the RH (2) and LH (3) secondary timing chain tensioners.
9. Remove the intake and exhaust camshaft sprocket bolts. Apply paint to the timing chain and camshaft sprockets for alignment during installation. Secure the hexagonal portion of the camshaft using a wrench to loosen the bolts as shown.
10. Remove the secondary timing chains (3) with camshaft sprockets. Illustration shows RH (1) secondary timing chain (3), refer to side view (7) if needed. Rotate camshaft slightly, and loosen secondary timing chain (3) on secondary timing chain tensioner side. Insert metal or resin plate (5) [0.5 mm (0.020 in)] into plunger (6) between secondary timing chain (3) and secondary timing chain tensioner plunger (6). Remove camshaft sprocket and secondary timing chain (3) with secondary timing chain removed from plunger (6) groove. Intake camshaft sprocket is two-for-one structure of primary and secondary sprockets. Handle the intake sprockets as an assembly. CAUTION: Secondary timing chain tensioner plunger (6) can move while stopper pin (4) is inserted in timing chain tensioner (2). Plunger can come out of tensioner when timing chain is removed. Use caution during removal. Avoid impact or dropping the intake sprockets. Do not disassemble the intake sprockets (never loosen bolts A and B as shown).

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

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1. Make sure that dowel pin hole, dowel pin and crankshaft key are located as shown in the figure. (No. 1 cylinder at compression TDC) NOTE: Though camshaft does not stop at the position as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure. Camshaft dowel pin hole (intake side) : At cylinder head upper face side in each bank Camshaft dowel pin (exhaust side) : At cylinder head upper face side in each bank Crankshaft key : At cylinder head side of right bank CAUTION: Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big dia. side).
2. Install timing chain (secondary) and camshaft sprockets (INT and EXH) as follows: CAUTION: Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process. Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin (Tool J-50246). Before installing timing chains (secondary) and camshaft sprockets, confirm mating marks are visible. If necessary, use paint or equivalent to re-mark the camshaft sprockets at each mating mark. Install timing chain (secondary) and camshaft sprockets (INT and EXH). Align the mating marks on timing chain (secondary) (gold link) with the ones on camshaft sprockets (INT and EXH) (punched), and install them. NOTE: Mating marks for camshaft sprocket (INT) are on the back side of camshaft sprocket (secondary). There are two types of mating mark, circle and oval types. They should be used for the right and left banks, respectively. Right bank: Use circle type. Left bank: Use oval type. Align dowel pin and pin hole on camshafts with the groove and dowel pin on sprockets, and install them. On the intake side, align pin hole on the small diameter side of the camshaft front end with dowel pin on the back side of camshaft sprocket, and install them. On the exhaust side, align dowel pin on camshaft front end with pin groove on camshaft sprocket, and install them. In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent. Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins. It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint. Confirm the mating marks are aligned, then finger tighten camshaft sprocket bolts. Final tightening will be done with all timing chains installed. Pull stopper pins out from timing chain tensioners (secondary).
3. Install timing chain (primary) as follows: Install crankshaft sprocket. Make sure the mating marks on crankshaft sprocket face the front of the engine. Install timing chain (primary). Install timing chain (primary) so the mating mark (punched) on camshaft sprocket (INT) is aligned with the copper link on timing chain, while the mating mark (notched) on crankshaft sprocket is aligned with the Yellow one on timing chain, as shown in the figure. When it is difficult to align mating marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the mating marks. During alignment, be careful to prevent dislocation of mating mark alignments of timing chains (secondary).
4. Install internal chain guide, slack guide and timing chain tensioner (primary). CAUTION: Do not overtighten slack guide mounting bolt. It is normal for a gap to exist under the bolt seat when mounting bolt is tightened to specification.
5. Remove stopper pin from timing chain tensioner (primary).
6. After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts. Secure the camshaft using a wrench at the hexagonal portion to tighten the mounting bolts. Tighten camshaft sprocket bolts to specification with all timing chains installed and Ring Gear Stopper Tool ((J-50288)) holding the crankshaft.
7. Install the front timing chain case. Refer to «INSTALLATION»(ref-233643-S05464291852012022700000) .

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Scheme 151

1. Remove the front RH wheel and tire.
2. Remove the fender protector side cover RH. Refer to «FENDER PROTECTOR»(ref-233645-S03287839192006052600000) .
3. Support the engine with suitable jack and remove the RH engine insulator, mount and bracket. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S15386963742006052600000) .
4. Remove the Bank 1 (RH) IVT control covers, right and left. Loosen the bolts in the numerical order as shown. NOTE: The shaft in the cover is inserted into the center hole of the intake camshaft sprocket. Remove the cover by pulling straight out until the cover disengages from the camshaft sprocket.
5. Remove the timing chain tensioner (primary) as follows: Pull the lever (C) down to release the plunger stopper tab (B). Insert the stopper pin A into the tensioner body hole to hold the lever (C) and keep the plunger stopper tab (B) released. NOTE: An Allen wrench [(1.2 mm (0.047 in)] is used for a stopper pin A as an example. Compress the plunger (D) into the tensioner body (1) by pressing the slack guide (2). Keep the slack guide (2) pressed and lock the plunger (D) in by pushing the stopper pin A through the lever (C) and into the chain tensioner body hole. Remove timing chain tensioner bolts and then remove the timing chain tensioner. CAUTION: Be careful not to drop timing chain tensioner bolts inside timing chain case.

Installation is in the reverse order of removal.

1. When installing primary timing chain tensioner, push in plunger and keep it pressed in with stopper pin.
2. Remove any dirt and foreign materials completely from the back and the mounting surfaces of primary timing chain tensioner.
3. After installation, pull out stopper pin.
4. When installing the IVT control valve covers perform the following steps.

Scheme 152

1. Install IVT control valve covers as follows: Install new collared O-rings in front timing chain case oil hole (left and right sides). Install new seal rings on the IVT control covers. Apply Silicone RTV Sealant to the IVT control covers. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case with the holes to install the IVT control covers. Tighten the intake valve timing control cover bolts in the order as shown. Intake valve timing control cover bolts : 11.3 N.m (1.2 kg-m, 100 in-lb)

Scheme 153

1. Remove the timing chains (secondary). Refer to " «REMOVAL»(ref-233643-S13804956682006052600000) ".
2. Remove the secondary timing chain tensioner shoe by evenly prying at base of shoe with suitable tool as shown.

Scheme 154

1. Install new secondary timing chain tensioner shoe using Tool (A) as shown. Tighten the bolt until the secondary timing chain tensioner shoe is fully seated on the secondary timing chain tensioner. CAUTION: Do not overtighten bolt. Tool number : - (J-50246)
2. Installation of the remaining components is in the reverse order of removal.

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1. Remove the timing chains. Refer to «REMOVAL»(ref-233643-S13804956682006052600000) .
2. If necessary, remove camshaft position sensor (PHASE) (right and left bank) from cylinder head back side. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow any metal particles to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
3. Remove the IVT control solenoid valves. Discard the IVT control solenoid valve gaskets and use new gaskets for installation.
4. Remove the intake and exhaust camshaft brackets and the camshafts. Mark the camshafts, camshaft brackets, and bolts so they are placed in the same position and direction for installation. Equally loosen the camshaft bracket bolts in several steps in the order shown.
5. Remove valve lifters. NOTE: Identify installation positions to ensure proper installation.
6. Remove camshaft timing chain tensioner from cylinder head with the stopper pin inserted. NOTE: Stopper pin was installed when secondary timing chain was removed.

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1. Before installation, remove any old Silicone RTV Sealant from component mating surfaces using a scraper. Remove the old Silicone RTV Sealant from the bolt holes and threads. Do not scratch or damage the mating surfaces.
2. Before installing the No. 1 camshaft bracket, remove the old Silicone RTV Sealant from the mating surface using a scraper. Do not scratch or damage the mating surface.
3. Turn the crankshaft until No. 1 piston is set at TDC on the compression stroke. The crankshaft key should line up with the right bank cylinder center line as shown.
4. Install camshaft chain tensioners on both sides of cylinder head. Camshaft chain tensioner bolts : 7 - 10 N.m (0.8 - 1.0 kg-m, 62 - 88 in-lb)
5. Install valve lifters. NOTE: Install them in original positions.
6. Install exhaust and intake camshafts and camshaft brackets. Intake camshaft has a drill mark on camshaft sprocket mounting flange. Follow your identification marks made during removal, or follow the identification marks that are present on the new camshafts components for proper placement and direction of the components. Position the camshafts: RH exhaust camshaft dowel pin at about 10 o'clock. LH exhaust camshaft dowel pin at about 2 o'clock.
7. Before installing camshaft brackets, apply sealant to mating surface of No. 1 camshaft bracket. Use Genuine Silicone RTV Sealant, or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233642-S07555866002006052600000) . Before installation, wipe off any protruding sealant. Refer to «LIQUID GASKET APPLICATION PROCEDURE»(ref-233643-S02277520802006052600000) . Install camshaft brackets in their original positions and direction. Align the stamp marks as shown. If checking and adjusting any part of valve assembly or camshaft, check valve clearance according to the reference data. Refer to «VALVE CLEARANCE»(ref-233643-S23371903282006052600000) .
8. Tighten the camshaft brackets in the four steps, in the order shown. NOTE: Lubricate the threads and seat surfaces of the camshaft bracket bolts with new engine oil before installation. Camshaft bracket bolts Step 1: (bolts 7 - 10) 1.96 N.m (0.2 kg-m, 17 in-lb) Step 2: (bolts 1 - 6) 1.96 N.m (0.2 kg-m, 17 in-lb) Step 3: 5.88 N.m (0.6 kg-m, 52 in-lb) Step 4: (bolts 1 - 6) 10.4 N.m (1.1 kg-m, 92 in-lb)
9. Measure difference in levels between front end faces of camshaft No. 1 bracket and cylinder head. Standard: - 0.14 (- 0.0055 in) If measurement is outside the specified range, re-install camshaft and camshaft bracket.
10. Install the IVT control solenoid valves with new gaskets. IVT control solenoid valve bolts: 9.81 - 12.7 N.m (1.0 - 1.2 kg-m, 87 - 112 in-lb)
11. If necessary, install camshaft position sensor (PHASE) (RH and LH bank.) Camshaft position sensor (PHASE) bolt: 8.4 - 10.8 N.m (0.9 - 1.1 kg-m, 15 - 95 in-lb)
12. Install the fuel rail and injectors. Refer to «REMOVAL AND INSTALLATION»(ref-233643-S24437408532006052600000) .
13. Install the timing chains. Refer to «INSTALLATION»(ref-233643-S39433827032012022700000) .

VALVE GUIDE REPLACEMENT

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

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1. To remove valve guide, heat cylinder head to 110° - 130°C (230° - 266°F) by soaking in heated oil.
2. Drive out the valve guide with a press [under a 20 kN (2.2 US ton) pressure] or hammer and suitable tool. WARNING: Cylinder head is hot. Wear protective equipment to prevent getting burned.
3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts), intake and exhaust : 10.175 - 10.196 mm (0.4006 - 0.4014 in)
4. Heat cylinder head to 110° - 130°C (230° - 266°F) by soaking in heated oil and press new valve guide from camshaft side into the cylinder head to the dimensions as shown. Projection "L": 12.6 - 12.8 mm (0.496 - 0.504 in)
5. Using a valve guide reamer, apply a reamer finish to the valve guide. Intake and exhaust finished size: 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Scheme 180

1. After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure.
2. Apply Prussian blue onto contacting surface of 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 valve fitting and check again. If the contacting surface still has N.G conditions even after the re-check, replace valve seat.

Scheme 181

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1. 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.
2. Ream cylinder head recess for service valve seat. Oversize: 0.5 mm (0.020 in) 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 cylinder head to 110° - 130°C (230° - 266°F) by soaking in heated oil.
4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool to the specified dimensions. Refer to «VALVE»(ref-233643-S27642505732006052600000) .
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Seat face angle "a": 45° 25' - 45° 75' degrees/minutes Contacting width "W" for intake: 1.09 - 1.31 mm (0.0429 - 0.0516 in) Contacting width "W" for exhaust: 1.29 - 1.51 mm (0.0508 - 0.0594 in)
8. Use a depth gauge to measure the distance between the mounting surface of the cylinder head spring seat and the valve stem end. If the distance is shorter than specified, repeat step 5 to adjust it. If it is longer, replace the valve seat with a new one. Valve seat resurface limit "L" intake: 41.07 - 41.67 mm (1.6169 - 1.6405 in) Valve seat resurface limit "L" exhaust: 41.00 - 41.60 mm (1.6142 - 1.6378 in)

Installation is in the reverse order of removal.