Engine Mechanical: Removal & Installation Nissan Maxima A35

Precaution for Removal and Disassembly

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

Precaution for Assembly and Installation

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

INSTALLATION

Installation is in the reverse order of removal.

SPARK PLUG GAP SPECIFICATION

Scheme 87

1. Check that the indicator of drive belt auto-tensioner is within the possible use range. NOTE: Check the drive belt auto-tensioner indication when the engine is cold. When new drive belt is installed, the indicator should be within the new drive belt range.
2. Visually check entire drive belt for wear, damage or cracks.
3. If the indicator is out of the possible use range or belt is damaged, replace drive belt.

1. Install the drive belt onto all of the pulleys. CAUTION: Confirm belts are completely set on the pulleys.
2. Release tensioner, and apply tension to drive belt. WARNING: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off. CAUTION: Do not loosen the auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley.)
3. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
4. Confirm tension of drive belt at indicator is within the possible use range. Refer to " «CHECKING DRIVE BELTS»(ref-388044-S15393606542011022800000) ".

Scheme 88

REMOVAL

1. Remove the drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S22307760252011022800000) ". Insert a rod approximately 6 mm (0.24 in) in diameter through the rear of tensioner into the retaining boss to lock tensioner pulley.
2. Remove the drive belt auto-tensioner, with power tool. CAUTION: Do not loosen the auto-tensioner pulley bolt. (Don't turn it counterclockwise. If turned counterclockwise, the complete auto-tensioner must be replaced as a unit, including pulley).

Installation is in the reverse order of removal.

Scheme 89

Removal and Installation

Scheme 90

1. Remove the engine room cover bolts and engine room cover.

Installation is in the reverse order of removal.

Scheme 91

1. Remove engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
2. Remove front air duct.
3. Disconnect the tube clamp at the electric throttle control actuator and at the air duct hose.
4. Disconnect the blow-by hose.
5. Remove air duct hose and resonator assembly.
6. Disconnect mass air flow sensor.
7. Remove mass air flow sensor from air cleaner assembly, as necessary. CAUTION: Handle mass air flow sensor with care. Do not shock it. Do not disassemble it. Do not touch its sensor.
8. Remove air cleaner assembly.

Installation is in the reverse order of removal.

Scheme 92

Scheme 93

Scheme 94

1. Remove the cowl top. Refer to " «REMOVAL AND INSTALLATION»(ref-388049-S31424973292011022800000) ".
2. Remove the engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
3. Remove front air duct and air duct hose and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37478427172011022800000) ".
4. Remove the electric throttle control actuator bolts in the reverse order as shown in illustration and remove the electric throttle control actuator and position aside. CAUTION: Handle carefully to avoid any shock to the electric throttle control actuator. Do not disassemble.
5. Disconnect the following: Power brake booster vacuum hose Fuel injector electrical connectors PCV hose Electric throttle control actuator electrical connector EVAP canister purge hose CAUTION: Cover any engine openings to avoid the entry of any foreign material.
6. Remove the EVAP canister purge volume solenoid valve bracket bolt. Position the valve aside.
7. Loosen the intake manifold collector bolts in the order as shown in illustration using power tool, and remove the intake manifold collector and gasket.
8. If necessary remove the following components: VIAS control solenoid valve EVAP canister purge volume control solenoid valve

Installation is in the reverse order of removal.

Scheme 95

Scheme 96

1. Tighten intake manifold collector bolts in the order as shown in illustration.
2. Tighten electric throttle control actuator bolts in the order shown in illustration.

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 : SPECIAL REPAIR REQUIREMENT ". Perform the "Idle Air Volume Learning" when the electric throttle control actuator is replaced. Refer to " IDLE AIR VOLUME LEARNING : SPECIAL REPAIR REQUIREMENT ".

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. Release the fuel pressure. Refer to " «INSPECTION»(ref-388048-S32388389072011022800000) ".
2. Disconnect the battery negative terminal. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-388040-S08852523192011022800000) ".
3. Remove intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S24115967902011022800000) ".
4. Disconnect fuel tube quick connector at vehicle piping side.
5. To remove the quick connector cap (1), hold the sides of the connector (A), push in the tabs (2) and pull out the tube (3). 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. 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.
6. 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.
7. Loosen the bolts in the order as shown in illustration, and remove the intake manifold with power tool.

Installation is in the reverse order of removal. Follow the procedure below for specific tightening sequences and procedures.

Scheme 101

1. Install intake manifold bolts in two steps in the numerical order as shown in illustration. Step 1 : 7.3 N.m (0.74 kg-m, 65 in-lb) Step 2 : 25.5 N.m (2.6 kg-m, 19 ft-lb)

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 : SPECIAL REPAIR REQUIREMENT ". Perform the "Idle Air Volume Learning" when the electric throttle control actuator is replaced. Refer to " IDLE AIR VOLUME LEARNING : SPECIAL REPAIR REQUIREMENT ".

Scheme 102

1. 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. Install the quick connector cap on the quick connector joint. Align the arrow mark on the quick connector cap to the upper side. Install the fuel hose into the hose clamp.

Scheme 103

Scheme 104

1. Remove engine and CVT assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
2. Remove the RH and LH three way catalyst support brackets.
3. 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 (J-38365) : KV991J0050 (J-44626) 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.
4. Remove exhaust manifold and three way catalyst heat shields with power tool.
5. 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.
6. Remove the exhaust manifolds RH (A) and LH (B). Loosen the exhaust manifold nuts in the order as shown in illustration. <=: Front

Installation is in the reverse order of removal.

Scheme 105

Scheme 106

Scheme 107

1. Install the exhaust manifold nuts in the order as shown in illustration RH (A) and LH (B). <=: Front
2. Install RH (A) and LH (B) three way catalyst support brackets. Hand tighten the three way catalyst support bracket bolts to seat the support brackets. Tighten the bolts to specification in the numerical order as shown in illustration. CAUTION: Do not tighten if support brackets do not fit tightly against oil pan and three way catalysts. Three way catalyst support bracket bolts : 22.0 N.m (2.2 kg-m, 16 ft-lb)

Scheme 108

Scheme 109

Scheme 110

1. Drain the engine oil. Refer to " «CHANGING ENGINE OIL»(ref-388050-S21659641782011022800000) ".
2. Loosen the lower oil pan bolts using power tool in order as shown in illustration.
3. Remove the lower oil pan. Insert Tool between the lower oil pan and the upper oil pan. Tool number : KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surface. Do not insert a screwdriver, this will damage the mating surfaces. Slide the Tool by tapping its side with a hammer to remove the lower oil pan from the upper oil pan.
4. If re-installing the original lower oil pan, remove the old sealant from the mating surfaces using a scraper. Also remove the old sealant from mating surface of the upper oil pan. 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.

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

1. Remove the engine from the vehicle. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
2. Drain the engine oil. Refer to " «CHANGING ENGINE OIL»(ref-388050-S21659641782011022800000) ".
3. Remove the oil dipstick.
4. Remove the drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S22307760252011022800000) ".
5. Disconnect the A/C compressor harness connector.
6. Remove the A/C compressor bolts and remove the A/C compressor. Refer to " «REMOVAL AND INSTALLATION FOR COMPRESSOR»(ref-388042-S12955008922011022800000) ".
7. Remove coolant pipe bolts.
8. Disconnect the coolant lines from the engine oil cooler. NOTE: Cap or plug opening(s) to prevent fluid from spilling.
9. Remove the oil filter and engine oil cooler from the upper oil pan.
10. Remove the oil pressure switch, and the crankshaft position sensor (POS) from the upper oil pan.
11. Remove the lower oil pan. Refer to " «REMOVAL AND INSTALLATION (LOWER OIL PAN)»(ref-388044-S06020325242011022800000) ".
12. Remove the upper oil pan. Loosen the bolts in the order as shown in illustration, using power tool. Insert an appropriate size tool into the notch (1) of the upper oil pan as shown in illustration. Pry off the upper oil pan by moving the tool up and down (2) as shown in illustration.
13. Remove the O-ring seals from the bottom of the cylinder block and oil pump housing. Use new O-rings for installation.
14. Remove front cover gasket and rear oil seal retainer gasket.
15. Remove the oil strainer.
16. 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.

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

1. Install oil strainer and tighten bolt to specified torque. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
2. Apply Genuine Silicone RTV Sealant or equivalent, to the front cover gasket and the rear oil seal retainer gasket as shown in illustration. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ".
3. Install the front cover gasket and rear oil seal retainer gasket as shown in illustration.
4. Apply a bead of sealant to the cylinder block mating surface of the upper oil pan to a limited portion as shown in illustration. Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Be sure the sealant is applied 4.0 - 5.0 mm (0.157 - 0.197 in) as shown in illustration. Increase the bead to 4.5 - 5.5 mm (0.177 - 0.217 in) at the four places indicated. Attaching should be done within 5 minutes after coating. CAUTION: Wait at least 30 minutes before refilling the engine with oil.
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 as shown in illustration. Wait at least 30 minutes before refilling the engine with oil. CAUTION: Wait at least 30 minutes before refilling the engine with oil.
7. Install the lower oil pan. Refer to " «REMOVAL AND INSTALLATION (LOWER OIL PAN)»(ref-388044-S06020325242011022800000) ".
8. Installation of the remaining components is in the reverse order of removal.

1. Remove engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
2. Disconnect ignition coil connector.
3. Remove the ignition coil. CAUTION: Never shock ignition coil.

Installation is in the reverse order of removal.

1. Remove the intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S24115967902011022800000) ".
2. Disconnect ignition coil connector.
3. Remove the ignition coil. CAUTION: Never shock ignition coil.

Installation is in the reverse order of removal.

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

1. Remove engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
2. Release the fuel pressure. Refer to " «INSPECTION»(ref-388048-S32388389072011022800000) ".
3. Disconnect the battery negative terminal. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-388040-S08852523192011022800000) ".
4. Remove front wiper arm and cowl top extension. Refer to " «EXPLODED VIEW»(ref-388051-S01244656842011022800000) " and " «EXPLODED VIEW»(ref-388049-S02200598192011022800000) ".
5. Remove the electric throttle control actuator bolts in the reverse order as shown in illustration and remove the electric throttle control actuator. CAUTION: Handle carefully to avoid any shock to the electric throttle control actuator. Do not disassemble.
6. Remove intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S24115967902011022800000) ".
7. When separating fuel feed hose and fuel tube connection, disconnect quick connector using tool as follows: Tool number : 16441 6N210 (J-45488) Remove quick connector cap from quick connector. Disconnect quick connector from fuel tube as follows: CAUTION: Disconnect quick connector by using the special service tool. Not by prying out retainer tabs. With the sleeve side of tool facing to quick connector, install the tool onto fuel tube. Insert the tool (A) into quick connector (2) until sleeve (B) contacts and goes no further. Hold tool on that position. C : Insert and retain CAUTION: Inserting tool with excess force will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from fuel tube (1). CAUTION: Pull quick connector (E) holding position (D) as shown in illustration in the figure. Never pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leakage out. Avoid fire and sparks. 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 bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or something similar.
8. Disconnect harness connector from fuel injector.
9. Loosen bolts in reverse order as shown in illustration, and remove fuel tube and fuel injector assembly. <=: Engine front CAUTION: Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.
10. Remove fuel injector from fuel tube as follows: Open and remove clip (1). Remove fuel injector (2) from fuel tube (5) by pulling straight. CAUTION: Be careful with remaining fuel that may go out from fuel tube. Be careful not to damage injector nozzle during removal. Never bump or drop fuel injector. Never disassemble fuel injector.
11. Remove fuel damper from fuel tube.

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

1. Install fuel damper as follows: Install new O-ring (2) to fuel tube (1) as shown in illustration. When handling new O-ring, be careful of the following caution: CAUTION: 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 tube. Never twist it. Install spacer (3) to fuel damper (4). Insert fuel damper straight into fuel tube. CAUTION: Insert straight, checking that the axis is lined up. Never pressure-fit with excessive force. Reference value : 130 N (13.3 kg, 29.2 lb) Insert fuel damper until (B) is touching (A) of fuel tube. Tighten bolts evenly in turn. After tightening bolts, check that there is no gap between fuel damper cap (5) and fuel tube.
2. Install new O-rings to fuel injector paying attention to the following. CAUTION: Upper and lower O-ring are different. Be careful not to confuse them. Fuel tube side : Black Nozzle side : Green 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 O-ring straight into fuel injector. Never de-center or twist it.
3. Install fuel injector to fuel tube as follows: Insert clip (3) into clip groove (F) on fuel injector (5). 2 : O-ring (black) 4 : O-ring (green) Insert clip so that protrusion (E) of fuel injector matches cutout (C) of clip. CAUTION: Never reuse clip. Replace it with new one. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube (1) with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip. Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.
4. Install fuel tube and fuel injector assembly to intake manifold. CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts. Tighten bolts in two steps in numerical order as shown in illustration. 1st step : 10.1 N.m (1.0 kg-m, 7 ft-lb) 2nd step : 22.0 N.m (2.2 kg-m, 16 ft-lb)
5. Connect fuel injector harness.
6. Install intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S24115967902011022800000) ".
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure: Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them. Thinly apply new engine oil around fuel tube from tip end to spool end. Align center to insert quick connector straightly into fuel tube. Insert quick connector (1) to fuel tube until top spool (2) is completely inside quick connector, and 2nd level spool (3) exposes right below quick connector. CAUTION: Hold (A) position as shown in illustration in the figure when inserting fuel tube into quick connector. Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does not come out from fuel tube. Install quick connector cap (3) to quick connector. 1 : Fuel feed hose 2 : Fuel tube B : Upper view Install quick connector cap with arrow (A) on surface facing in direction of quick connector (fuel feed hose side). CAUTION: If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again. Secure fuel feed hose to clamp of quick connector cap.
8. Installation is in the reverse order of removal.

Installation is in the reverse order of removal.

Scheme 133

Scheme 134

1. Apply sealant to the areas on the front corners using Tool.
2. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Tool number : WS39930000 (-)
3. Tighten the rocker cover bolts in two steps in the order as shown in illustration. Rocker cover bolts Step 1 : 1.96 N.m (0.20 kg-m, 17 in-lb) Step 2 : 8.33 N.m (0.85 kg-m, 74 in-lb)

Scheme 135

Scheme 136

1. Remove the engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
2. Remove the front air duct and air duct hose and resonator assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37478427172011022800000) ".
3. Remove the intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37412770292011022800000) ".
4. Remove ignition coils. Refer to " «REMOVAL AND INSTALLATION RH»(ref-388044-S27585452232011022800000) ". CAUTION: Never shock ignition coils.
5. Remove camshaft position sensors. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip (A). Do not place sensors in a location where they are exposed to magnetism.
6. Remove RH rocker cover bolts from cylinder head as shown in illustration.

Installation is in the reverse order of removal.

Scheme 137

Scheme 138

1. Apply sealant to the areas on the front corners using Tool.
2. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Tool number : WS39930000 (-)
3. Tighten the rocker cover bolts in two steps in the order as shown in illustration. Rocker cover bolts Step 1 : 1.96 N.m (0.20 kg-m, 17 in-lb) Step 2 : 8.33 N.m (0.85 kg-m, 74 in-lb)

Scheme 139

1. Remove hood ledge cover.
2. Remove coolant reservoir and set aside.
3. Disconnect Intake valve timing control solenoid valve connector.
4. Remove Intake valve timing control solenoid valve cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S10856066392011022800000) ".
5. Remove Intake valve timing control solenoid valve and O-ring from Intake valve timing control solenoid valve cover.

Installation is in the reverse order of removal.

Intake valve timing control solenoid valve bolt : 11.3 N.m (1.2 kg-m, 8 ft-lb)

1. Remove hood ledge cover.
2. Remove coolant reservoir and set aside.
3. Remove power steering reservoir and set aside.
4. Support engine using suitable tool.
5. Remove upper engine mount and bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
6. Remove Intake valve timing control solenoid valve cover bolt behind solenoid valve. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S10856066392011022800000) ".
7. Disconnect Intake valve timing control solenoid valve connector.
8. Remove Intake valve timing control solenoid valve and O-ring from Intake valve timing control solenoid valve cover.

Installation is in the reverse order of removal.

Intake valve timing control solenoid valve bolt : 11.3 N.m (1.2 kg-m, 8 ft-lb)

Scheme 140

Note. This section describes the procedure for removal/installation of the front timing chain case without removing the oil pan (upper) from the vehicle. When rear timing chain case must be removed, remove the engine from the vehicle. Then remove front timing chain case, timing chain related parts, and rear timing chain case in this order, and install in reverse order of removal. Refer to " REMOVAL AND INSTALLATION ". Refer to " EXPLODED VIEW " for component parts location.

Scheme 141

Scheme 142

Scheme 143

Scheme 144

Scheme 145

Scheme 146

Scheme 147

Scheme 148

Scheme 149

Scheme 150

Scheme 151

1. Disconnect the battery negative terminal. Refer to " «REMOVAL AND INSTALLATION (BATTERY)»(ref-388040-S08852523192011022800000) ".
2. Remove engine under cover. Refer to " «EXPLODED VIEW»(ref-388049-S07537635232011022800000) ".
3. Drain the engine coolant from the radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-388046-S32332017542011022800000) ".
4. Drain the engine oil. Refer to " «CHANGING ENGINE OIL»(ref-388050-S21659641782011022800000) ".
5. Drain the power steering fluid. Refer to " «DRAINING»(ref-388052-S32771720742011022800000) ".
6. Remove engine room cover. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S09328238872011022800000) ".
7. Remove front air duct. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S37478427172011022800000) ".
8. Remove battery tray. Refer to " «REMOVAL AND INSTALLATION (BATTERY TRAY)»(ref-388040-S08029399692011022800000) ".
9. Remove the hood ledge covers (RH and LH).
10. Remove cowl top and cowl top extension. Refer to " «REMOVAL AND INSTALLATION»(ref-388049-S31424973292011022800000) ".
11. Remove upper radiator hose. NOTE: Cap or plug opening(s) to prevent fluid from spilling.
12. Disconnect engine coolant reservoir hose from the radiator and remove engine coolant reservoir.
13. Remove cooling fan assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388046-S01449383982011022800000) ".
14. Disconnect lower radiator hose from engine. NOTE: Cap or plug opening(s) to prevent fluid from spilling.
15. 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 " «EXPLODED VIEW»(ref-388052-S21280427522011022800000) ". NOTE: Cap or plug opening(s) to prevent fluid from spilling.
16. Remove the front RH wheel and tire. Refer to " «ADJUSTMENT»(ref-388047-S32116336402011022800000) ".
17. Remove the engine side under cover.
18. Remove the drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S22307760252011022800000) ".
19. Lock the drive plate using tool. Tool number : - (J-50288) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when setting the Tool.
20. Remove the crankshaft pulley as follows: Loosen crankshaft pulley and locate bolt seating surface at 10 mm (0.39 in) from its original position. Position a pulley puller at recess hole of crankshaft pulley to remove crankshaft pulley. CAUTION: Do not use a puller claw on crankshaft pulley periphery.
21. Remove the power steering pump. Refer to " «REMOVAL AND INSTALLATION»(ref-388052-S06195073732011022800000) ".
22. Remove the upper oil pan. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
23. Remove the generator. Refer to " «REMOVAL AND INSTALLATION»(ref-388053-S22693504302011022800000) ".
24. Disconnect the A/C tubes from the A/C compressor and position aside.
25. Remove the A/C compressor bolts and remove the A/C compressor. Refer to " «REMOVAL AND INSTALLATION FOR COMPRESSOR»(ref-388042-S12955008922011022800000) ".
26. Remove the generator bracket. Refer to " «EXPLODED VIEW»(ref-388053-S24396385342011022800000) ".
27. Support the engine with suitable jack and remove the RH engine insulator, mount and bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
28. Remove the rocker covers, if necessary. Refer to " «REMOVAL AND INSTALLATION LH»(ref-388044-S04689784852011022800000) " and " «REMOVAL AND INSTALLATION RH»(ref-388044-S28752914822011022800000) ". NOTE: Necessary only when removing timing chains.
29. If removing the timing chains, obtain compression TDC of No. 1 cylinder as follows: Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator. Check that intake and exhaust camshaft lobes on No. 1 cylinder (right bank of engine) are located as shown in illustration. If not, turn the crankshaft one revolution (360°) and align as shown in illustration.
30. Remove engine oil cooler tube bolts and bracket.
31. Disconnect the oil pressure switch harness connector.
32. Disconnect valve timing control harness connector.
33. Remove the Bank 1 (RH) (A) and Bank 2 (LH) (B) IVT covers. Loosen the IVT cover bolts in the reverse order as shown in illustration. CAUTION: The shaft in the IVT cover is inserted into the center hole of the intake camshaft sprocket. Remove the IVT cover by pulling straight out until the IVT cover disengages from the camshaft sprocket. A: Bank 1 (Conventional RH bank 1) B: Bank 2 (Conventional LH bank 2) C: Dowel pin hole Shaft is engaged with intake side camshaft sprocket center hole on inside. Pull straight out so as not to tilt until the joint is disengaged. The mating surface of magnet retarder (2) may be fitted with the exhaust side camshaft sprocket via engine oil. Open IVT cover (1) carefully. If the mating surface of the magnet retarder is fitted with the camshaft sprocket, open the IVT cover within the range that the load is not applied to the harness. Remove it so as to prevent magnet retarder from dropping. CAUTION: Be careful not to damage magnet retarder. When carrying IVT cover, face the magnet retarder side up to prevent the IVT cover from falling from magnet retarder. Never remove magnet retarder from IVT cover. (Disassembly prohibited)
34. Remove the A/C idler pulley and bracket and the drive belt auto-tensioner.
35. If necessary, remove the idler pulley and water pump cover.
36. Remove the front timing chain case. Loosen the front timing chain case bolts in the order as shown in illustration. Insert the appropriate size tool into the notch (A) at the top of the front timing chain case as shown in illustration. Pry off the case by moving the suitable tool (B) as shown in illustration. 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.
37. Remove O-rings (1) from rear timing chain case. A: Bank 1 (RH) B: Bank 2 (LH) CAUTION: Use new O-rings for installation.
38. Remove the front oil seal from the front timing chain case using a suitable tool. CAUTION: Do not damage the front cover.
39. Remove all old Silicone RTV Sealant from all the bolt holes and bolts. CAUTION: Do not damage the threads or mating surfaces.
40. Use a scraper to remove all of the old Silicone RTV Sealant from the front timing chain case and opposite mating surfaces. CAUTION: Do not damage the mating surfaces.

Scheme 152

Scheme 153

Scheme 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

Scheme 160

Scheme 161

Scheme 162

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 new front oil seal on the front timing chain case. Apply new engine oil to the oil seal edges. NOTE: Install it so that each seal lip is oriented as shown in illustration. 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.
3. Install new O-rings (1) on rear timing chain case. A: Bank 1 (RH) B: Bank 2 (LH) CAUTION: Use new O-rings for installation.
4. Apply Silicone RTV Sealant to front timing chain case as shown in illustration. A: Use Genuine Silicone RTV Sealant, or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". B: Before installation, wipe off the protruding sealant. C: 2.6 - 3.6 mm (0.102 - 0.142 in) dia.
5. Install dowel pin on the rear timing chain case into dowel pin hole in front timing chain case.
6. 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)
7. Tighten the front timing chain case bolts in the order as shown in illustration. Retighten the front timing chain case bolts in the order as shown in illustration. 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)
8. Install upper oil pan bolts as shown in illustration. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
9. Install lower oil pan. Refer to " «REMOVAL AND INSTALLATION (LOWER OIL PAN)»(ref-388044-S06020325242011022800000) ".
10. Install IVT control valve covers. Install new seal rings (1) in shaft grooves. A: Bank 2 CAUTION: When replacing seal rings, replace all rings with new ones on both RH and LH IVT control valve covers. To check the joint between dowel pins and dowel pin holes, for excessive free play. A: Mating surface of magnet retarded B: Moves slightly C: Not shaken CAUTION: Always perform this procedure when removing because the gap between dowel pins and dowel pin holes may not be caused on purpose. Install IVT covers with a new gasket to front timing chain case. 1: Valve timing control cover 2: Magnet retarder CAUTION: Never face magnet retarder side down to prevent magnet retarder from dropping. Check the mating surface of the magnet retarder and the drum of the exhaust side camshaft sprocket for foreign materials. Align center of both shaft holes of the shaft and the intake side of the intake camshaft sprocket, and then insert them. Be careful not to drop the seal ring from the shaft groove. When setting the valve timing control cover in position by hand, if valve timing control cover is not centered with the valve timing case, the dowel pin of the magnet retarder may not be aligned with the dowel pin holes of the cover. In this case, return to step " b ". Being careful not to move seal ring from the installation groove, align the dowel pins on the front timing chain case with the holes to install valve timing control covers. Tighten bolts in the numerical order as shown. in illustration IVT cover bolts 11.3 N.m (1.2 kg-m, 8 ft-lb) A: Bank 1 (Conventional RH bank) B: Bank 2 (Conventional LH bank) C: Dowel pin hole CAUTION: Discard O-ring, do not reuse.
11. 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-388039-S31807235822011022800000) ".
12. Install crankshaft pulley and tighten the bolt in two steps. Lubricate thread and seat surface of the bolt with new engine oil. For the second step angle tighten using Tool. Step 1 : 44.1 N.m (4.5 kg-m, 33 ft-lb) Step 2 : 84° - 90° degrees clockwise Tool number : KV10112100 (BT-8653-A)
13. Remove the Tool attached to the starter bolt hole. Tool number : KV10117700 (J-44716) CAUTION: Do not damage the ring gear teeth, or the signal plate teeth behind the ring gear, when removing the Tool.
14. Rotate crankshaft pulley in normal direction (clockwise when viewed from front) to confirm it turns smoothly.
15. Installation of the remaining components is in reverse order of removal.

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

Scheme 168

1. Remove front timing chain case. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S10856066392011022800000) ".
2. Remove the intake manifold collector. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S24115967902011022800000) ".
3. Remove the engine oil dipstick.
4. Place paint marks on the timing chain and sprockets to indicate the correct position of the components for installation.
5. Remove 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. Insert 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), and slack guide (2).
7. Remove timing chain (primary) and crankshaft sprocket. CAUTION: After removing timing chains, do not turn the crankshaft and camshaft separately, or the valves will strike the pistons.
8. Attach a suitable stopper pin (2) to the right and left timing chain tensioners (secondary) (1). A: Bank 1 B: Bank 2
9. Remove the timing chains (secondary) with camshaft sprockets (INT) and (EXH). Insert metal or resin plate [0.5 mm (0.020 in)] into guide between timing chain (secondary) and timing chain tensioner (secondary) plunger. Remove camshaft sprocket and timing chain (secondary) with timing chain removed from guide groove. CAUTION: Timing chain tensioner plunger can move while stopper pin is inserted in timing chain tensioner. Plunger can come out of tensioner when timing chain is removed. Use caution during removal. Apply paint to the timing chain and camshaft sprockets for alignment during installation. Remove the camshaft sprocket (INT) and (EXH) bolts. Secure the hexagonal portion of the camshaft using a wrench to loosen the bolts. Handle the sprockets as an assembly. Remove timing chains (secondary). CAUTION: Avoid impact or dropping the camshaft sprockets. Do not disassemble the camshaft sprockets (never loosen bolts (A) and (B) as shown in illustration).
10. Remove the tension guide.

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

Scheme 169

Scheme 170

Scheme 171

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

1. Install the tension guide.
2. Position the crankshaft so No. 1 piston is set at TDC on the compression stroke. Make sure that the dowel pin hole, dowel pin and crankshaft key are located as shown in illustration. 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 RH bank. CAUTION: Hole on small diameter side must be used for intake camshaft sprocket dowel pin. Do not misidentify (ignore big diameter side).
3. Install the timing chains (secondary) and camshaft sprockets. CAUTION: Matching marks between the timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process. Push the sleeve of the chain tensioner (secondary) and keep it pressed in with a stopper pin. Align the matching marks (4), (5), (7) and (10) on the timing chain (secondary) (8) (orange link) (2) with the ones on the camshaft sprockets (INT) and (EXH) (stamped), and install them. Matching marks for the camshaft sprocket (INT) are on the back side of the secondary sprocket. There are two types of matching marks, round (7) and (10) oval (4) and (5) types. They should be used for the RH and LH banks, respectively. RH bank: use round type (7) and (10). LH bank (6): use oval type (4) and (5). Align the dowel pin (3) with and pin hole on the camshaft sprocket (INT) side (1), and dowel pin groove (11) with the dowel pin on the camshaft sprocket (EXH) side, and install them. On the intake side, align the pin hole on the small diameter side of the camshaft front end with the dowel pin (3) on the back side of the camshaft sprocket (1), and install them. On the exhaust side, align the dowel pin on the camshaft front end with the dowel pin groove (11) on the camshaft sprocket (9), and install them. Camshaft sprocket bolts must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of the dowel pins (3) and dowel pin grooves (11). Check mating mark (punched) (D) on each camshaft sprocket are positioned on the mating marks (orange link) (C) on timing chain (secondary). Intake side Exhaust side NOTE: Mating mark (punched) in the figure is for checking loose at this step.
4. After confirming the mating marks are aligned, tighten the camshaft sprocket bolts. Secure the camshaft using a wrench at the hexagonal portion to tighten the bolts.
5. Pull the stopper pins (2) out from the timing chain tensioners (secondary) (1). A: RH bank B: LH bank
6. Install the crankshaft sprocket on the crankshaft. Make sure the mating marks on the crankshaft sprocket face the front of the engine.
7. Install the timing chain (primary). Install timing chain (primary) so the mating mark (punched) (B) on camshaft sprocket (C) is aligned with the pink link (A) on the timing chain, while the mating mark (notched) (E) on the crankshaft sprocket (D) is aligned with the orange one (F) on the timing chain, as shown in illustration. When it is difficult to align mating marks of the timing chain (primary) with each sprocket, gradually turn the camshaft using a wrench on the hexagonal portion to align it with the mating marks. During alignment, be careful to prevent dislocation of mating mark alignments of the secondary timing chains. (G): Water pump
8. Install the internal chain guide (1), slack guide (2) and timing chain (primary). CAUTION: Do not overtighten the slack guide bolts. It is normal for a gap to exist under the bolt seats when the bolts are tightened to specification.
9. Install the timing chain tensioner (primary) for the slack guide. When installing the timing chain tensioner (primary), push in the sleeve and keep it pressed in with the stopper pin. Remove any dirt and foreign materials completely from the back and the mounting surfaces of the timing chain tensioner (primary). After installation, pull out the stopper pin while pressing the slack guide.
10. Reconfirm that the matching marks on the sprockets and the timing chain have not slipped out of alignment.
11. Install the front timing chain case. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S10856066392011022800000) ".

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

1. Remove the engine assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".
2. Remove the oil pan lower and upper. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
3. Remove the front timing chain case. Refer to " «EXPLODED VIEW»(ref-388044-S00494834172011022800000) ".
4. Remove the timing chains (primary) and (secondary). Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S33483831572011022800000) ".
5. Remove the rear timing chain case. CAUTION: Do not remove the plate metal cover for the oil passage. After removing the chain case, do not apply any load to the case that might bend it. Loosen and remove the rear timing chain case bolts in the order as shown in illustration. Cut the sealant using Tool and remove the rear timing chain case. Tool number : KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surface. Do not insert a screwdriver, this will damage the mating surfaces. Slide the Tool by tapping its side with a hammer to remove the rear timing chain case from the cylinder block.
6. Remove O-rings to timing chain case and cylinder block.
7. Use a scraper to remove all of the old Silicone RTV Sealant from the front and rear timing chain case and opposite mating surfaces. CAUTION: Do not damage the mating surfaces.
8. Remove all old Silicone RTV Sealant from all the bolt holes and bolts. CAUTION: Do not damage the threads or mating surfaces.

Scheme 187

Scheme 188

Scheme 189

1. Install O-rings on cylinder block.
2. Apply Genuine Silicone RTV Sealant or equivalent, to the rear timing chain case using Tool as shown in illustration. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-388039-S31807235822011022800000) ". Tool number : WS39930000 (-) CAUTION: For "a", completely wipe out liquid gasket extended on a portion touching at engine coolant. Apply liquid gasket on installation position of water pump and cylinder completely.
3. Align the rear timing chain case and water pump assembly with the dowel pins (RH and LH) on the cylinder block and install the case. Make sure the O-rings stay in place during installation. Tighten the bolts in the numerical order as shown in illustration. There are two bolt lengths used. Follow the chart below for proper bolt length specifications. BOLT LENGTH SPECIFICATION Bolt length Bolt position Torque specification 20 mm (0.79 in) 1, 2, 3, 6, 7, 8, 9, 10 12.7 N.m (1.3 kg-m, 9 ft-lb) 16 mm (0.63 in) 4, 5, 11 12.7 N.m (1.3 kg-m, 9 ft-lb) 16 mm (0.63 in) 12 - 25 12.7 N.m (1.3 kg-m, 9 ft-lb) After all bolts are initially tightened, retighten them to the specification in the numerical order as shown in illustration.
4. Install the primary and secondary timing chains. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S33483831572011022800000) ".
5. Install the front timing chain case. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S10856066392011022800000) ".
6. Install the oil pan upper and lower. Refer to " «REMOVAL AND INSTALLATION (UPPER OIL PAN)»(ref-388044-S20358380952011022800000) ".
7. Install the engine assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S31213686922011022800000) ".

Scheme 190

Scheme 191

Scheme 192

Scheme 193

Scheme 194

1. Remove the timing chains. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S33483831572011022800000) ".
2. Remove camshaft position brackets (RH shown in illustration, LH similar).
3. 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 numerical order as shown in illustration.
4. Remove valve lifters, if necessary. NOTE: Identify installation positions to ensure proper installation.
5. Remove secondary timing chain tensioner from cylinder head. Remove secondary tensioner with its stopper pin attached. NOTE: Stopper pin was attached when secondary timing chain was removed.

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

Scheme 202

Scheme 203

Scheme 204

Scheme 205

Scheme 206

Scheme 207

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 front cam 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 in illustration.
4. Install camshaft chain tensioners on both sides of cylinder head. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S10856066392011022800000) ".
5. Install valve lifters, if removed. 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. INTAKE/EXHAUST PAINT MARKS CHART Bank INT/EXH ID mark Drill mark Paint marks M1 M2 RH INT 1A Yes Blue No EXH 1C No No Blue LH INT 1B Yes Blue No EXH 1D No No Blue 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-388039-S31807235822011022800000) ". Before installation, wipe off any protruding sealant. Refer to " «PRECAUTION FOR LIQUID GASKET»(ref-388044-S20989129222011022800000) ". Install camshaft brackets in their original positions and direction. Align the stamp marks as shown in illustration. If checking and adjusting any part of valve assembly or camshaft, check valve clearance according to the reference data. Refer to " «VALVE CLEARANCE»(ref-388044-S22359624852011022800000) ". Valve clearance (cold) Intake : 0.26 - 0.34 mm (0.010 - 0.013 in) Valve clearance (cold) Exhaust : 0.29 - 0.37 mm (0.011 - 0.015 in) Tighten the camshaft brackets in the three steps, in numerical order as shown in illustration. CAMSHAFT BRACKETS TORQUE SPECIFICATION 1 1.96 N.m (0.2 kg-m, 17 in-lb) Tighten No. 7 - 10, then tighten 1 - 6 in numerical order as shown in illustration. 2 5.88 N.m (0.6 kg-m, 52 in-lb) Tighten in numerical order as shown in illustration. 3 10.41 N.m (1.10 kg-m, 8 ft-lb) Tighten No. 1 - 6 in the numerical order as shown in illustration.
8. Measure difference in levels between front end faces of No. 1 camshaft bracket and cylinder head. Standard : - 0.14 mm (- 0.0055 in) If measurement is outside the specified range, re-install camshaft and camshaft bracket.
9. Install camshaft position sensors (PHASE) (RH and LH bank.)
10. Install the fuel rail and injectors. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S28770987952011022800000) ".
11. Install the timing chains. Refer to " «REMOVAL AND INSTALLATION»(ref-388044-S33483831572011022800000) ".

VALVE GUIDE REPLACEMENT

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

Scheme 208

Scheme 209

Scheme 210

Scheme 211

Scheme 212

1. To remove valve guide, heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil.
2. Drive out the valve guide with a press [under a 20 kN (2.2 US ton) pressure] or hammer and suitable tool.
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° to 130°C (230° to 266°F) by soaking in heated oil and press new valve guide from camshaft side into the cylinder head to the dimensions as shown in illustration. 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 213

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 214

Scheme 215

Scheme 216

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 : 32.100 - 32.116 mm (1.2638 - 1.2644 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° to 130°C (230° to 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 " «CYLINDER HEAD»(ref-388044-S38525453412011022800000) ".
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition. Seat face angle "α" : 45° 15' - 45° 45' degrees/minutes Contacting width "W" for intake : 1.18 - 1.22 mm (0.0465 - 0.0480 in) Contacting width "W" for exhaust : 1.38 - 1.42 mm (0.0543 - 0.0559 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 : 41.16 - 41.76 mm (1.6205 - 1.6441 in) Valve seat resurface limit "L" exhaust : 41.09 - 41.69 mm (1.6177 - 1.6413 in)

Installation is in the reverse order of removal.

1. Tighten transmission bolts to specification. Refer to " «REMOVAL AND INSTALLATION»(ref-388054-S01022948512011022800000) ".

Installation is in the reverse order of removal.

Scheme 217

Scheme 218

1. When installing the drive plate to the crankshaft, use the match mark (A) as shown in illustration to correctly align the crankshaft side dowel pin to the drive plate side dowel pin hole.
2. Install the drive plate and the reinforcement plate in the direction as shown in illustration.
3. Tighten the drive plate bolts in a diagonal pattern in two steps. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-388044-S39693684222011022800000) ". Use a suitable tool to lock the drive plate.