Engine Mechanical: Diagnosis Nissan Murano Z50

Precautions for Inspection, Repair and Replacement

Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary.

INSPECTION AFTER REMOVAL

Inspect air duct assembly for crack or tear.

1. If anything found, replace air duct assembly.

Clean oil strainer if any object attached.

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

1. Install oil pan (upper) as follows: Use a scraper to remove old liquid gasket from mating surfaces. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket. Also remove old liquid gasket from mating surface of cylinder block. Remove oil liquid gasket from bolt holes and threads. Install new oil pan gaskets. Apply liquid gasket to new oil pan gaskets as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . To install, align protrusion of oil pan gasket with notches of front timing chain case and rear oil seal retainer. Install oil pan gasket with smaller arc to front timing chain case side. Install new O-rings on the bottom of cylinder block and oil pump. Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . CAUTION: For bolt holes with marks (5 locations), apply liquid gasket outside the holes. Apply a bead of 4.5 to 5.5 mm (0.177 to 0.217 in) diameter to area "A". Attaching should be done within 5 minutes after coating. Install oil pan (upper). CAUTION: Install avoiding misalignment of both oil pan gasket and O-rings. Tighten mounting bolts in numerical order as shown in the figure. There are two types of mounting bolt. Refer to the following for locating bolts. M8 x 100 mm (3.97 in): 5, 7, 8, 11 M8 x 25 mm (0.98 in): Except the above Install transaxle joint bolts. (2WD models) Refer to «TRANSAXLE ASSEMBLY»(ref-234000-S38984770662006052700000) .
2. Install oil strainer to oil pump.
3. Install oil pan (lower) as follows: Use scraper to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of oil pan (upper). Remove old liquid gasket from the bolt holes and thread. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to oil pan (lower) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . CAUTION: Attaching should be done within 5 minutes after coating. Install oil pan (lower). Tighten mounting bolts in numerical order as shown in the figure.
4. Install oil pan drain plug. Refer to the figure of components of former page for installation direction of drain plug washer. Refer to «REMOVAL AND INSTALLATION»(ref-233993-S10182447012006052800000) .
5. Install in the reverse order of removal after this step.

Note. At least 30 minutes after oil pan is installed, pour engine oil.

Inspection for Leaks

The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-234032-S17417855162006052700000) .
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary. SUMMARY OF THE INSPECTION ITEMS Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid (1) Level Leakage Level Fuel Leakage Leakage Leakage Exhaust gases --- Leakage --- (1) Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.

Scheme 20

Use the standard type spark plug for normal condition.

The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as

1. Frequent engine starts
2. Low ambient temperatures

The cold type spark plug is suitable when spark plug knock occurs with the standard type spark plug under conditions such as

1. Extended highway driving
2. Frequent high engine revolution SPARK PLUG REFERENCE Make NGK Standard type PLFR5A-11 Hot type PLFR4A-11 Cold type PLFR6A-11 Gap (Nominal): 1.1 mm (0.043 in)

Scheme 21

Scheme 22

The followings are procedures for checking fluid leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-234032-S17417855162006052700000) .
2. Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
3. Warm up engine thoroughly to make sure there is no leakage of exhaust gases, or any oil/fluids including engine oil and engine coolant.
4. Bleed air from lines and hoses of applicable lines, such as in cooling system.
5. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

Summary Of the Inspection Items

ENGINE OIL REFERENCE

Scheme 23

Note. This article describes procedures for removal/installation front timing chain case and timing chain related parts, and rear timing chain case, when oil pan (upper) needs to be removed/installed for engine overhaul, etc. To removal/installation front timing chain case, timing chain, and its related parts without removing oil pan (upper), Refer to FRONT TIMING CHAIN CASE .

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Remove engine assembly from the vehicle, and separate front suspension member and transaxle from engine. Refer to «ENGINE ASSEMBLY»(ref-233993-S16501809062006052800000) .
2. Install engine sub-attachment with engine stand shaft [SST: KV10117001 ( - ) and KV10106500 ( - )] to right side of cylinder block, then lift engine, and mount it onto engine stand [SST: ST0501S000 ( - )]. Refer to «CYLINDER BLOCK»(ref-233993-S21665934002006052800000) .
3. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-233994-S33124697692006052700000) .
4. Drain engine coolant from inside engine. Refer to «DISASSEMBLY»(ref-233993-S09363877202006052800000) .
5. Remove intake manifold collectors (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
6. Remove rocker covers (right and left banks). Refer to «ROCKER COVER»(ref-233993-S41118776802006052800000) .
7. Remove oil pans (lower and upper) and oil strainer. Refer to «OIL PAN AND OIL STRAINER»(ref-233993-S25354294872006052800000) .
8. Remove idler pulley and bracket.
9. Separate engine harness removing their brackets from front timing chain case
10. Remove intake valve timing control covers. Loosen mounting bolts in reverse order as shown in the figure. Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal. CAUTION: Shaft is internally jointed with camshaft sprocket (INT) center hole. When removing, keep it horizontal until it is completely disconnected.
11. Remove collared O-ring from front timing chain case oil hole (left and right sides).
12. Obtain No. 1 cylinder at TDC of its compression stroke as follows: Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure. If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure.
13. Remove crankshaft pulley as follows: Fix crankshaft with the pulley holder [SST]. Loosen crankshaft pulley bolt and locate bolt seating surface at 10 mm (0.39 in) from its original position. CAUTION: Do not remove crankshaft pulley bolt as it will be used as a supporting point for suitable puller. Place suitable puller tab on holes of crankshaft pulley, and pull crankshaft pulley through. CAUTION: Do not put suitable puller tab on crankshaft pulley periphery, as this will damage internal damper.
14. Remove front timing chain case as follows: Loosen mounting bolts in reverse order as shown in the figure. Insert a suitable tool into the notch at the top of front timing chain case as shown (1). Pry off case by moving the tool as shown (2). Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal. CAUTION: Do not use screwdrivers or something similar. After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
15. Remove O-rings from rear timing chain case.
16. Remove water pump cover and chain tensioner cover from front timing chain case. Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
17. Remove front oil seal from front timing chain case using a suitable tool. Use a screwdriver for removal. CAUTION: Be careful not to damage front timing chain case.
18. Remove timing chain tensioner (primary) as follows: Pull lever down and release plunger stopper tab. Plunger stopper tab can be pushed up to release (coaxial structure with lever). Insert a stopper pin into tensioner body hole to hold lever, and keep tab released. NOTE: An Allen wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example. Insert plunger into tensioner body by pressing slack guide. Keep slack guide pressed and hold it by pushing stopper pin through the lever hole and body hole. Remove mounting bolts and remove timing chain tensioner (primary).
19. Remove internal chain guide, tension guide and slack guide. NOTE: Tension guide can be removed after removing timing chain (primary).
20. Remove timing chain (primary) and crankshaft sprocket. CAUTION: After removing timing chain (primary), do not turn crankshaft and camshaft separately, or valves will strike the piston heads.
21. Remove timing chain (secondary) and camshaft sprockets as follows: Attach a suitable stopper pin to the right and left timing chain tensioners (secondary). NOTE: Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin. For removal of timing chain tensioner (secondary), Refer to «CAMSHAFT»(ref-233993-S24061581132006052800000) . [Removing camshaft bracket (No. 1) is required.] Remove camshaft sprockets (INT and EXH) mounting bolts. Secure the hexagonal portion of camshaft using a wrench to loosen mounting bolts. CAUTION: Do not loosen mounting bolts with securing anything other than the camshaft hexagonal portion or with tensioning the timing chain. Remove timing chain (secondary) together with camshaft sprockets. Turn camshaft slightly to secure slackness of timing chain on timing chain tensioner (secondary) side. Insert 0.5 mm (0.020 in)- thick metal or resin plate between timing chain and timing chain tensioner plunger (guide). Remove timing chain (secondary) together with camshaft sprockets with timing chain loose from guide groove. CAUTION: Be careful of plunger coming-off when removing timing chain (secondary). This is because plunger of timing chain tensioner (secondary) moves during operation, leading to coming-off of fixed stopper pin. NOTE: Camshaft sprocket (INT) is two-for-one structure of sprockets for timing chain (primary) and for timing chain (secondary). When handling camshaft sprocket (INT), be careful of the following caution: CAUTION: Handle carefully to avoid any shock to camshaft sprocket. Do not disassemble. (Do not loosen bolts "A" as shown in the figure).
22. Remove water pump. Refer to «WATER PUMP»(ref-233995-S33089933962006052700000) .
23. Remove rear timing chain case as follows: Loosen and remove mounting bolts in reverse order as shown in the figure. Cut liquid gasket using the seal cutter [SST: KV10111100 (J37228)] and remove rear timing chain case. CAUTION: Do not remove plate metal cover of oil passage. After removal, handle rear timing chain case carefully so it does not tilt, cant, or warp under a load.
24. Remove O-rings from cylinder head.
25. Remove O-rings from cylinder block.
26. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary. Remove camshaft brackets (No. 1). Refer to «REMOVAL»(ref-233993-S00513617832006052800000) . Remove timing chain tensioners (secondary) with a stopper pin attached.
27. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and opposite mating surfaces. Remove old liquid gasket from bolt hole and thread.
28. Use a scraper to remove all traces of old liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.

The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-234032-S17417855162006052700000) .
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
4. Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

ENGINE OIL REFERENCE

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Remove engine assembly from the vehicle, and separate front suspension member, transaxle and transfer (AWD models) assembly from engine. Refer to «ENGINE ASSEMBLY»(ref-233993-S16501809062006052800000) .
2. Install engine sub-attachment with engine stand shaft [SST: KV10117001 ( - ) and KV10106500 ( - )] to right side of cylinder block, then lift engine, and mount it onto engine stand [SST: ST0501S000 ( - )]. Refer to «CYLINDER BLOCK»(ref-233993-S21665934002006052800000) .
3. Remove front timing chain case, camshaft sprocket, timing chain and rear timing chain case. Refer to «TIMING CHAIN»(ref-233993-S27825796252006052800000) .
4. Remove camshaft position sensor (PHASE) (right and left banks) from cylinder head back side. CAUTION: Handle carefully to avoid dropping and shocks. Do not disassemble. Do not allow metal powder to adhere to magnetic part at sensor tip. Do not place sensors in a location where they are exposed to magnetism.
5. Remove intake valve timing control solenoid valves. Discard intake valve timing control solenoid valve gaskets and use new gaskets for installation.
6. Remove camshaft brackets. Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for installation. Equally loosen camshaft bracket bolts in several steps in reverse order as shown in the figure.
7. Remove camshafts.
8. Remove valve lifters. Identify installation positions, and store them without mixing them up.
9. Remove chain tensioner (secondary) from cylinder head. Remove timing chain tensioner (secondary) with its stopper pin attached.

Note. Stopper pin was attached when timing chain (secondary) was removed.

Scheme 52

Scheme 53

1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft. CAUTION: Do not support journal No. 1 (on the side of camshaft sprocket) because it has a different diameter from the other three locations.
2. Set a dial indicator vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on dial indicator. (Total indicator reading) Standard: Less than 0.02 mm (0.001 in) Limit: 0.05 mm (0.002 in)
4. If it exceeds the limit, replace camshaft.

Scheme 54

1. Measure the camshaft cam height with a micrometer. Standard cam height (intake and exhaust): 44.865 - 45.055 mm (1.7663 - 1.7738 in) Cam wear limit: 0.2 mm (0.008 in)
2. If wear is beyond the limit, replace camshaft.

Scheme 55

1. Measure the outer diameter of camshaft journal with a micrometer. Standard: No. 1: 25.935 - 25.955 mm (1.0211 - 1.0218 in) No. 2, 3, 4: 23.445 - 23.465 mm (0.9230 - 0.9238 in)

Scheme 56

1. Tighten camshaft bracket bolt with the specified torque. Refer to «INSTALLATION»(ref-233993-S24112159802006052800000) for the tightening procedure.
2. Measure inner diameter "A" of camshaft bracket with a bore gauge. Standard: No. 1: 26.000 - 26.021 mm (1.0236 - 1.0244 in) No. 2, 3, 4: 23.500 - 23.521 mm (0.9252 - 0.9260 in)

Inspection of Camshaft Sprocket (INT) Oil Groove

Scheme 57

1. Check the engine oil level. Refer to «ENGINE OIL»(ref-233994-S16173938422006052700000) .
2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233996-S05768987042006052700000) . Disconnect ignition coil and injector harness connectors.
3. Remove intake valve timing control solenoid valve. Refer to «CAMSHAFT»(ref-233993-S24061581132006052800000) .
4. Crank the engine, and then make sure that engine oil comes out from camshaft bracket (No. 1) oil hole. End crank after checking. WARNING: Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.). CAUTION: Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking. Use a shop cloth to prevent the engine components and the vehicle. Do not allow engine oil to get on rubber components such as drive belt or engine mount insulators. Immediately wipe off any splashed engine oil. Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from camshaft bracket (No. 1) oil hole. Refer to «LUBRICATION SYSTEM»(ref-233994-S37039275372006052700000) .
5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. Clean oil groove if necessary. Refer to «LUBRICATION SYSTEM»(ref-233994-S37039275372006052700000) .
6. After inspection, install removed parts.

The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-234032-S17417855162006052700000) .
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
4. Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

ENGINE OIL REFERENCE

INSPECTION

In cases of removing/installing or replacing camshaft and valve-related parts, or of unusual engine conditions due to changes in valve clearance (found malfunctions during stating, idling or causing noise), perform inspection as follows

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

1. Remove rocker covers (right and left banks). Refer to «ROCKER COVER»(ref-233993-S41118776802006052800000) .
2. Measure the valve clearance as follows: Set No. 1 cylinder at TDC of its compression stroke. Rotate crankshaft pulley clockwise to align timing mark (grooved line without color) with timing indicator. Make sure that intake and exhaust cam noses on No. 1 cylinder (engine front side of right bank) are located as shown in the figure. If not, turn crankshaft one revolution (360 degrees) and align as shown in the figure. Use a feeler gauge, measure the clearance between valve lifter and camshaft. VALVE CLEARANCE Items Cold Hot (1) (reference data) Intake 0.26-0.34 (0.010-0.013) 0.304-0.416 (0.012-0.016) Exhaust 0.29-0.37 (0.011-0.015) 0.308-0.432 (0.012-0.016) (1) This data is reference value and is measured between ECM terminal 107 (Fuel tank temperature sensor) and ground. By referring to the figure, measure the valve clearances at locations marked "x" as shown in the table below (locations indicated in the figure). No. 1 cylinder at compression TDC
3. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 3 cylinder at TDC of its compression stroke. NOTE: Crankshaft pulley mounting bolt flange has a stamped line every 60 degrees. They can be used as a guide to rotation angle.
4. By referring to the figure, measure the valve clearances at locations marked "x" as shown in the table below (locations indicated in the figure).
5. No. 3 cylinder at compression TDC
6. Rotate crankshaft by 240 degrees clockwise (when viewed from engine front) to align No. 5 cylinder at TDC of compression stroke. By referring to the figure, measure the valve clearances at locations marked "x" as shown in the table below (locations indicated in the figure). No. 5 cylinder at compression TDC
7. For the measured value are out of the standard, perform adjustment. Refer to «ADJUSTMENT»(ref-233993-S04289899112006052800000) .

The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-234032-S17417855162006052700000) .
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

ENGINE OIL REFERENCE

Scheme 70

Scheme 71

Scheme 72

1. Remove spark plug with spark plug wrench (commercial service tool).
2. Remove valve lifter. Identify installation positions, and store them without mixing them up.
3. Remove valve collet. Compress valve spring with the valve spring compressor, the attachment and the adapter [SST]. Remove valve collet with a magnet hand. CAUTION: When working, take care not to damage valve lifter holes.
4. Remove valve spring retainer, valve spring and valve spring seat.
5. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store them without mixing them up.
6. Remove valve oil seal with the valve oil seal puller [SST].
7. If valve seat must be replaced, Refer to «VALVE SEAT REPLACEMENT»(ref-233993-S22800445722006052800000) .
8. If valve guide must be replaced, Refer to «VALVE GUIDE REPLACEMENT»(ref-233993-S14759751022006052800000) .
9. Remove spark plug tube, as necessary. Using a pliers, pull spark plug tube out of cylinder head.

Scheme 73

Scheme 74

Scheme 75

Scheme 76

1. When valve guide is removed, install it. Refer to «VALVE GUIDE REPLACEMENT»(ref-233993-S14759751022006052800000) .
2. When valve seat is removed, install it. Refer to «VALVE SEAT REPLACEMENT»(ref-233993-S22800445722006052800000) .
3. Install new valve oil seals as follows: Apply new engine oil on valve oil seal joint and seal lip. Install with the valve oil seal drift [SST] to match dimension in the figure. Height "H" (Without valve spring seat installed) Intake and exhaust: 14.3 - 14.9 mm (0.563 - 0.587 in)
4. Install valve spring seat.
5. Install valve. Install it in the original position. NOTE: Larger diameter valves are for intake side.
6. Install valve spring (uneven pitch type). Install narrow pitch end (paint mark) to cylinder head side (valve spring seat side). Intake side and exhaust side valve springs are different. Install them referring to the following paint mark collar. Paint mark collar Intake: White Exhaust: Blue
7. Install valve spring retainer.
8. Install valve collet. Compress valve spring with the valve spring compressor, the attachment and the adapter [SST]. Install valve collet with a magnet hand. CAUTION: When working, take care not to damage valve lifter holes. Tap valve stem edge lightly with plastic hammer after installation to check its installed condition.
9. Install valve lifter. Install it in the original position.
10. Install spark plug tube. Press-fit spark plug tube as follows: Remove old liquid gasket adhering to cylinder head mounting hole. Apply sealant to area within approximately 12 mm (0.47 in) from edge of spark plug tube press-fit side. Use Genuine High Strength Locking Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . Using a drift, press-fit spark plug tube so that its height "H" is as specified in the figure. Standard press-fit height "H": 38.1 - 39.1 mm (1.500 - 1.539 in) CAUTION: When press-fitting, take care not to deform spark plug tube. After press-fitting, wipe off liquid gasket protruding onto cylinder-head upper face.
11. Install spark plug with the spark plug wrench (commercial service tool).

The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

1. Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to «RECOMMENDED FLUIDS AND LUBRICANTS»(ref-234032-S17417855162006052700000) .
2. Use procedure below to check for fuel leakage. Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points.
3. Run engine to check for unusual noise and vibration.
4. Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
5. Bleed air from lines and hoses of applicable lines, such as in cooling system.
6. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.

ENGINE OIL REFERENCE

Scheme 77

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

Scheme 91

Scheme 92

1. Remove engine assembly from the vehicle, and separate front suspension member, transaxle and transfer (AWD models) assembly from engine. Refer to «ENGINE ASSEMBLY»(ref-233993-S16501809062006052800000) .
2. Remove exhaust manifolds (right and left banks). Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-233993-S37636481532006052800000) .
3. Remove oil cooler, water pipes and water hoses. Refer to «OIL COOLER»(ref-233994-S25994909912006052700000) . When removing water drain plug, engine coolant remaining in the engine is drained. Use tray to collect it.
4. Install engine sub-attachment with engine stand shaft [SST] to right side of cylinder block. Use a spacer to engine front side.
5. Lift engine, and mount it onto engine stand [SST]. A widely use engine stand can be used. CAUTION: Use an engine stand that has a load capacity [approximately 220 kg (441 lb) or more] large enough for supporting the engine weight. NOTE: This example is an engine stand for holding at transaxle mounting side with drive plate removed.
6. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-233994-S33124697692006052700000) .
7. Drain engine coolant by removing water drain plug "A", "B" and connector bolt "D" from cylinder block as shown in the figure. NOTE: For Canada, "A" in the figure is not water drain plug but block heater.
8. Remove drive plate. Fix crankshaft pulley with the pulley holder [SST: KV10109300 ( - )], and remove mounting bolts. Loosen mounting bolts in diagonal order. CAUTION: Do not disassemble drive plate. Never place drive plate with signal plate facing down. When handling signal plate, take care not to damage or scratch it. Handle signal plate in a manner that prevents it from becoming magnetized.
9. Remove the following parts: Intake manifold collectors (upper and lower); Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) . Intake manifold; Refer to «INTAKE MANIFOLD»(ref-233993-S12366549612006052800000) . Oil pans (lower and upper); Refer to «OIL PAN AND OIL STRAINER»(ref-233993-S25354294872006052800000) . Front and rear timing chain case; Refer to «TIMING CHAIN»(ref-233993-S27825796252006052800000) . Cylinder head; Refer to «CYLINDER HEAD»(ref-233993-S28508778912006052800000) .
10. Remove knock sensor. CAUTION: Carefully handle sensor avoiding shocks.
11. Remove pilot converter using the pilot bushing puller [SST] as necessary.
12. Remove rear oil seal retainer. Remove by inserting screwdriver between main bearing cap and rear oil seal retainer. CAUTION: If rear oil seal retainer is removed, replace it with new one. NOTE: Regard both rear oil seal and retainer as an assembly.
13. Remove piston and connecting rod assembly with the following procedure: Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to «CONNECTING ROD SIDE CLEARANCE»(ref-233993-S20641643362006052800000) . CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod bearing cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
14. Remove connecting rod bearings from connecting rod and connecting rod bearing cap. CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. Identify installation positions, and store them without mixing them up.
15. Remove piston rings form piston. Before removing piston rings, check the piston ring side clearance. Refer to «PISTON RING SIDE CLEARANCE»(ref-233993-S42579727492006052800000) . Use a piston ring expander (commercial service tool). CAUTION: When removing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expanding them excessively.
16. Remove piston from connecting rod as follows: Using a snap ring pliers, remove snap rings. Heat piston to 60 to 70°C (140 to 158°F) with an industrial use drier or equivalent. Push out piston pin with stick of outer diameter approximately 20 mm (0.79 in).
17. Remove main bearing cap bolts. NOTE: Use TORX socket (size E14). Before loosening main bearing cap bolts, measure the crankshaft end play. Refer to «CRANKSHAFT END PLAY»(ref-233993-S26237811292006052800000) . Loosen main bearing cap bolts in the reverse order shown in the figure in several different steps.
18. Remove main bearing beam.
19. Remove main bearing caps. CAUTION: Be careful not to drop main bearing, and to scratch the surface. Using main bearing cap bolts, remove main bearing cap while shaking it back-and-forth. Remove crankshaft. Remove main bearings and thrust bearings from cylinder block and main bearing caps. CAUTION: Be careful not to drop main bearing, and to scratch the surface. Identify installation positions, and store them without mixing them up. Remove oil jet.

Scheme 93

Scheme 94

Scheme 95

Scheme 96

Scheme 97

Scheme 98

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

1. Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. CAUTION: Use a goggles to protect your eye.
2. Install each plug to cylinder block as shown in the figure. Apply sealant to the thread of water drain plug "A". Use Anaerobic Liquid Gasket or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . NOTE: For Canada, "A" in the figure is not water drain plug but block heater. Refer to «DISASSEMBLY AND ASSEMBLY»(ref-233993-S14266442882006052800000) . Apply sealant to the thread of water drain plug "B" and connector bolt "D". Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . Apply sealant to the thread of plug "C". Use Genuine High Strength Locking Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . Replace washers with new one. Tighten each plug and connector bolt as specified below. PLUG AND CONNECTOR BOLT SPECIFICATION Part Washer Tightening torque A Yes 62.0 N.m (6.3 kg-m, 46 ft-lb) B No 9.8 N.m (1.0 kg-m, 87 in-lb) C Yes 62.0 N.m (6.3 kg-m, 46 ft-lb) D No 39.2 N.m (4.0 kg-m, 29 ft-lb)
3. Install oil jet. Insert oil jet dowel pin into cylinder block dowel pin hole, and tighten mounting bolts.
4. Install main bearings and thrust bearings as follow: CAUTION: Be careful not to drop main bearing, and to scratch the surface. Remove dust, dirt, and engine oil on bearing mating surfaces of cylinder block and main bearing caps. Install thrust bearings to the both sides of the No. 3 journal housing on cylinder block and main bearing cap. Install thrust bearings with the oil groove facing crankshaft arm (outside). Install thrust bearing with a projection on one end on cylinder block, and thrust bearing with a projection at center on main bearing cap. Align each projection with mating notch. Install main bearings paying attention to the direction. Main bearing with oil hole and groove goes on cylinder block. The one without them goes on main bearing cap. Before installing main bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align main bearing stopper protrusion to cutout of cylinder block and main bearing caps. Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned.
5. Install crankshaft to cylinder block. While turning crankshaft by hand, check that it turns smoothly.
6. Install main bearing caps. Main bearing caps are identified by identification mark cast on them. For installation, face front mark to front side. NOTE: Main bearing cap cannot be replaced as a single part, because it is machined together with cylinder block.
7. Install main bearing beam. Install main bearing beam with front mark facing downward (oil pan side). Install main bearing beam with front mark facing front of the engine.
8. Install main bearing cap bolts in numerical order as shown in the figure as follows: Inspect the outer diameter of main bearing cap bolt. Refer to «MAIN BEARING CAP BOLT OUTER DIAMETER»(ref-233993-S27740278662006052800000) . Apply new engine oil to threads and seat surfaces of main bearing cap bolts. Tighten main bearing cap bolts in several different steps. 35.3 N.m (3.6 kg-m, 26 ft-lb) Turn all main bearing cap bolts 90 degrees clockwise (Angle tightening). CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] to check tightening angle. Do not make judgment by visual inspection. After installing main bearing cap bolts, make sure that crankshaft can be rotated smoothly by hand. Check the crankshaft end play. Refer to «CRANKSHAFT END PLAY»(ref-233993-S26237811292006052800000) .
9. Install piston to connecting rod as follows: Using snap ring pliers, install new snap ring to the groove of piston rear side. Insert it fully into groove to install. Install piston to connecting rod. Using an industrial drier or similar tool, heat piston until piston pin can be pushed in by hand without excess force [approx. 60 to 70°C (140 to 158°F)]. From the front to the rear, insert piston pin into piston and connecting rod. Assemble so that the front mark on the piston crown and the cylinder number on connecting rod are positioned as shown in the figure. Install new snap ring to the groove of the piston front side. Insert it fully into groove to install. After installing, make sure that connecting rod moves smoothly.
10. Using a piston ring expander (commercial service tool), install piston rings. CAUTION: When installing piston rings, be careful not to damage piston. Be careful not to damage piston rings by expending them excessively. If there is stamped mark on ring, mount it with marked side up. NOTE: If there is no stamp on ring, no specific orientation is required for installation. Stamped mark: Top ring: - Second ring: R Position each ring with the gap as shown in the figure referring to the piston front mark. Check the piston rings side clearance. Refer to «PISTON RING SIDE CLEARANCE»(ref-233993-S42579727492006052800000) .
11. Install connecting rod bearings to connecting rod and connecting rod bearing cap. CAUTION: Be careful not to drop connecting rod bearing, and to scratch the surface. Before installing connecting rod bearings, apply engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. When installing, align connecting rod bearing stopper protrusion with cutout of connecting rod and connecting rod bearing cap to install. Ensure the oil hole on connecting rod and that on the corresponding bearing are aligned.
12. Install piston and connecting rod assembly to crankshaft. Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. Apply engine oil sufficiently to the cylinder bore, piston and crankshaft pin journal. Match the cylinder position with the cylinder number on connecting rod to install. Be sure that front mark on piston crown is facing front of engine. Using a piston ring compressor [SST] or suitable tool, install piston with the front mark on the piston crown facing the front of the engine. CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end.
13. Install connecting rod bearing cap. Match the stamped cylinder number marks on connecting rod with those on connecting rod bearing cap to install. Be sure that front mark on connecting rod bearing cap is facing front of the engine.
14. Tighten connecting rod bolt as follows: Inspect the outer diameter of connecting rod bolt. Refer to «CONNECTING ROD BOLT OUTER DIAMETER»(ref-233993-S05035340672006052800000) . Apply engine oil to the threads and seats of connecting rod bolts. Tighten connecting rod bolts. 19.6 N.m (2.0 kg-m, 14 ft-lb) Then tighten all connecting rod bolts 90 degrees clockwise (Angle tightening). CAUTION: Always use the angle wrench [SST: KV10112100 (BT8653-A)]. Avoid tightening based on visual check alone. After tightening connecting rod bolts, make sure that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to «CONNECTING ROD SIDE CLEARANCE»(ref-233993-S20641643362006052800000) .
15. Install new rear oil seal retainer to cylinder block. Apply new engine oil to both oil seal lip and dust seal lip. Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to rear oil seal retainer as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . CAUTION: Replace with a new parts. Attaching should be done within 5 minutes after coating. Make sure the garter spring is in position and seal lips not inverted. NOTE: Regard both rear oil seal and retainer as an assembly.
16. Install pilot converter. With drift [outer diameter: approx. 33 mm (1.30 in)], press-fit as far as it will go. Press-fit pilot converter with its chamfer facing crankshaft as shown in the figure.
17. Install knock sensor. Install knock sensor so that connector faces front of the engine. After installing knock sensor, connect harness connector, and lay it out to rear of engine. CAUTION: Do not tighten mounting bolts while holding connector. If any impact by dropping is applied to knock sensor, replace it with new one. NOTE: Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. Make sure that knock sensor does not interfere with other parts.
18. Note the following, assemble in the reverse order of disassembly after this step.

Scheme 113

1. When installing drive plate to crankshaft, be sure to correctly align crankshaft side guide pin and drive plate side guide pin hole. If these are not aligned correctly, engine runs roughly and "MIL" turns on.
2. Install drive plate and reinforcement plate as shown in the figure.
3. Holding ring gear with the pulley holder [SST: KV10109300 ( - )]
4. Tighten mounting bolts crosswise over several times.