Engine Mechanical: Removal & Installation Nissan Murano Z50

Precautions for Removal and Disassembly

1. When instructed to use SST, 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. Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, make sure that dowel pins are installed in the original position.
4. Cover openings of engine system with a tape or the equivalent, if necessary, to seal out foreign materials.
5. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly.
6. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

Precautions for Assembly and Installation

1. Use torque wrench to tighten bolts or nuts to specification.
2. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
3. Replace with new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check engine oil or engine coolant passages for any restriction and blockage.
5. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
6. Release air within route when refilling after draining engine coolant.
7. After repairing, start the engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gases for leakage.

REMOVAL

1. Remove splash guard (RH).
2. Fully loosen each belt by following the guidelines in «Tension Adjustment»(ref-233993-S17514305412006052800000) . Remove alternator and A/C compressor belt and then power steering oil pump belt.

INSTALLATION

1. Install each belt to pulley in the reverse order of removal. CAUTION: Make sure belt is correctly engaged with the pulley groove. Make sure that for engine oil, working fluid and engine coolant do not adhere to belt and each pulley groove.
2. Adjust belt tension. Refer to «TENSION ADJUSTMENT»(ref-233993-S17514305412006052800000) .
3. Tighten each nuts and bolts to the specified torque.
4. Make sure that tension of each belt is within the standard. Refer to «CHECKING DRIVE BELTS»(ref-233993-S00247116512006052800000) .

Scheme 114

1. Remove radiator cover grills (right and left side).
2. Remove air duct (inlet).
3. Disconnect harness connector from mass air flow sensor.
4. Disconnect PCV hose.
5. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly disconnecting their joints. Add mating marks as necessary for easier installation.
6. Remove mass air flow sensor from air cleaner case (upper), as necessary. CAUTION: Handle mass air flow sensor with following cares. Do not shock it. Do not disassemble it. Do not touch its sensor.
7. Remove resonator, removing left side fender protector (front), as necessary.

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

1. Align marks. Attach each joint. Screw clamps firmly.

Scheme 115

1. Unhook air cleaner case (lower) side clips and lift up air cleaner case (upper).
2. Remove air cleaner filter.

Install in the reverse order of removal.

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1. Remove engine cover. CAUTION: Be careful not to damage or scratch engine cover.
2. Remove air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-233993-S13601402462006052800000) .
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage. Refer to «CHANGING ENGINE COOLANT»(ref-233995-S01322841342006052700000) . CAUTION: Perform this step when the engine is cold.
4. Remove front wiper arm and extension cowl top panel (lower and upper). Refer to «FRONT WIPER AND WASHER SYSTEM»(ref-234026-S29844305442006052700000) and «COWL TOP»(ref-234018-S27219738992006052700000) .
5. Remove electric throttle control actuator as follows: Disconnect harness connector. Loosen mounting bolts in reverse order as shown in the figure. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Do not disassemble.
6. Disconnect water hoses from intake manifold collector (upper). When engine coolant is not drained from radiator, attach plug to water hoses to prevent engine coolant leakage.
7. Remove the following parts: Vacuum hose PCV hose Power steering hose bracket Intake manifold collector support Harness bracket
8. Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve.
9. Remove EVAP canister purge volume control solenoid valve.
10. Remove VIAS control solenoid valve and vacuum tank. Add mating marks as necessary for easier installation.
11. Loosen mounting nuts and bolts in reverse order as shown in the figure with power tool, and remove intake manifold collector (upper and lower) assembly and gasket. CAUTION: Cover engine openings to avoid entry of foreign materials.
12. Loosen mounting bolts in reverse order as shown in the figure to remove intake manifold collector (upper) from intake manifold collector (lower) with power tool.
13. Loosen mounting bolts in reverse order as shown in the figure to remove power valve from intake manifold collector (lower).

Scheme 123

1. Check the surface distortion of intake manifold collector (lower) with a straightedge and a feeler gauge. Limit: 0.1 mm (0.004 in)
2. If it exceeds the limit, replace intake manifold collector (lower).

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

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

Scheme 124

1. If stud bolts were removed, install them and tighten to the specified torque below. 10.8 N.m (1.1 kg-m, 8 in-lb)
2. Tighten all mounting nuts and bolts to the specified torque in two or more steps in numerical order shown in figure. 1st step 7.4 N.m (0.8 kg-m, 5 ft-lb) 2nd step and after 29.0 N.m (3.0 kg-m, 21 ft-lb)

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1. Drain engine coolant. Refer to «CHANGING ENGINE COOLANT»(ref-233995-S01322841342006052700000) . CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belts.
2. Remove following parts: Engine cover; Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) . Radiator cover grilles, air duct (inlet), air cleaner cases (upper) with mass air flow sensor and air duct assembly; Refer to «AIR CLEANER AND AIR DUCT»(ref-233993-S13601402462006052800000) . Undercover Radiator and radiator cooling fan assembly; Refer to «RADIATOR»(ref-233995-S41746158612006052700000) . Front wiper arm; Refer to «FRONT WIPER AND WASHER SYSTEM»(ref-234026-S29844305442006052700000) . Extension cowl top panel (lower and upper); Refer to «COWL TOP»(ref-234018-S27219738992006052700000) . Intake manifold collectors (upper and lower); Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
3. Remove exhaust front tube mounting bracket and then remove exhaust front tube. Refer to «EXHAUST SYSTEM»(ref-233998-S33151466512006052700000) .
4. Remove heat insulator.
5. Disconnect harness connector and remove air fuel ratio sensor 1 on both banks with the heated oxygen sensor wrench [SST]. Put marks to identify installation positions of each air fuel ratio sensor 1. CAUTION: Be careful not to damage air fuel ratio sensor 1. Discard any air fuel ratio sensor 1 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. NOTE: Figure is shown as an example of left bank.
6. Disconnect harness connector and remove heated oxygen sensor 2 on both banks with the heated oxygen sensor wrench [SST]. Put marks to identify installation positions of each heated oxygen sensor 2. CAUTION: Be careful not to damage heated oxygen sensor 2. Discard any heated oxygen sensor 2 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.
7. Remove exhaust manifold covers (right and left banks) and three way catalyst covers.
8. Remove mounting bolts in reverse order as shown in the figure to remove three way catalyst supports (right and left banks).
9. Remove three way catalysts (right and left banks) by loosening bolts first and then removing nuts. CAUTION: Handle carefully to avoid any shock to three way catalyst.
10. Loosen mounting nuts in reverse order as shown in the figure to remove exhaust manifolds (right and left banks).
11. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

Scheme 131

1. Check the surface distortion of the exhaust manifold mating surfaces with a straightedge and a feeler gauge. Limit: 0.3 mm (0.012 in)
2. If it exceeds the limit, replace exhaust manifold.

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

1. Remove engine cover. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
2. Remove front wiper arm and extension cowl top (lower and upper). Refer to «FRONT WIPER AND WASHER SYSTEM»(ref-234026-S29844305442006052700000) and «COWL TOP»(ref-234018-S27219738992006052700000) .
3. Remove intake manifold collectors (upper and lower). (At the right bank side, remove ignition coil) Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
4. Move aside harness, harness bracket, and hoses located above ignition coil.
5. Disconnect harness connector from ignition coil.
6. Remove ignition coil. CAUTION: Do not drop or shock it.

Install in the reverse order of removal.

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1. Remove engine cover. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
2. Remove ignition coil. Refer to «IGNITION COIL»(ref-233993-S03131100382006052800000) .
3. Remove spark plug using spark plug wrench (commercial service tool). CAUTION: Do not drop or shock it.

Install in the reverse order of removal.

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1. Remove engine cover. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
2. Release the fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233996-S05768987042006052700000) .
3. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage. Refer to «CHANGING ENGINE COOLANT»(ref-233995-S01322841342006052700000) and «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) . CAUTION: Perform this step when the engine is cold.
4. Remove front wiper arm and extension cowl top panel (lower and upper). Refer to «FRONT WIPER AND WASHER SYSTEM»(ref-234026-S29844305442006052700000) and «COWL TOP»(ref-234018-S27219738992006052700000) .
5. Remove radiator cover grilles, air duct (inlet), air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-233993-S13601402462006052800000) .
6. Remove intake manifold collectors (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) . Intake manifold collector (upper) should be moved aside with water hoses connected.
7. Remove fuel feed hose (with damper) from fuel tube. CAUTION: While hose disconnected, plug it to prevent fuel from draining. Do not separate fuel damper and fuel feed hose.
8. When separating fuel feed hose (with damper) and centralized under-floor piping connection, disconnect quick connector as follows: Remove quick connector cap from quick connector. Disconnect quick connector from centralized under-floor piping as follows: CAUTION: Disconnect quick connector by using the quick connector release [SST: J-45488], not by picking out retainer tabs. With the sleeve side of quick connector release facing to quick connector, install the quick connector release onto fuel tube. Insert the quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from centralized under-floor piping. CAUTION: Pull quick connector holding "A" position as shown in the figure. Do not pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leak out. Avoid fire and sparks. Keep parts away from heat source. Especially, be careful when welding is performed around them. Do not expose parts to battery electrolyte or other acids. Do not 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 or something similar.
9. Disconnect harness connector from fuel injector.
10. Loosen mounting bolts in reverse order as shown in the figure, and remove fuel tube and fuel injector assembly. CAUTION: Do not tilt it, or remaining fuel in pipes may flow out from pipes.
11. Remove spacers on intake manifold.
12. Remove fuel injector from fuel tube as follows: Open and remove clip. Remove fuel injector from fuel tube 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. Do not bump or drop fuel injector. Do not disassemble fuel injector.
13. Remove fuel damper from fuel tube.

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1. Install fuel damper. When handling new O-rings, be careful of the following caution: CAUTION: Handle O-ring with bare hands. Do not wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube. Insert new O-ring straight into fuel damper. Do not decenter or twist it. Insert fuel damper straight into fuel tube. Tighten mounting bolts evenly in turn. After tightening mounting bolts, make sure that there is no gap between flange 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: Blue Nozzle side: Brown Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Do not clean O-ring with solvent. Make sure that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it quickly into fuel tube. Insert O-ring straight into fuel injector. Do not decenter or twist it.
3. Install fuel injector to fuel tube as follows: Insert clip into clip mounting groove on fuel injector. Insert clip so that protrusion "A" of fuel injector matches cutout "A" of clip. CAUTION: Do not 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 with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that protrusion "B" of fuel tube matches cutout "B" of clip. Make sure that fuel tube flange is securely fixed in flange fixing groove on clip. Make sure that installation is complete by checking that fuel injector does not rotate or come off. Make sure that protrusions of fuel injectors are aligned with cutouts of clips after installation.
4. Install spacers on intake manifold.
5. 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 mounting bolts in two steps in numerical order as shown in figure. 1st step 10.1 N.m (1.0 kg-m, 7 ft-lb) 2nd step 23.6 N.m (2.4 kg-m, 17 ft-lb)
6. Connect fuel injector harness.
7. Install intake manifold collectors (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
8. Connect fuel feed hose (with damper). Handling procedure of O-ring is the same as that of fuel damper. Insert fuel damper straight into fuel tube. Tighten mounting bolts evenly in turn. After tightening mounting bolts, make sure that there is no gap between flange and fuel tube.
9. Connect quick connector between fuel feed hose (with damper) and centralized under-floor piping connection with the following procedure: Make sure no foreign substances are deposited in and around centralized under-floor piping and quick connector, and no damage on them. Thinly apply new engine oil around centralized under-floor piping from tip end to spool end. Align center to insert quick connector straightly into centralized under-floor piping. Insert quick connector to centralized under-floor piping until top spool is completely inside quick connector, and 2nd level spool exposes right below quick connector. CAUTION: Hold "A" position as shown in the figure when inserting centralized under-floor piping 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 mis-identification of engagement with a similar sound, be sure to perform the next step. Pull quick connector by hand holding "A" position. Make sure it is completely engaged (connected) so that it does not come out from centralized under-floor piping. Install quick connector cap to quick connector. Install quick connector cap with arrow on surface facing in direction of quick connector [fuel feed hose (with damper) 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 (with damper) to clamp of quick connector cap.
10. Install in the reverse order of removal after this step.

Removal and Installation

Note. This article describes removal/installation procedure of front timing chain case and timing chain related parts without removing oil pan (upper) on vehicle. When upper oil pan needs to be removed or installed, or when rear timing chain case is removed or installed, remove oil pans (lower and upper) first. 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 TIMING CHAIN . Refer to TIMING CHAIN for component parts location.

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1. Remove engine cover. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
2. Remove air duct (inlet), air cleaner case (upper) with mass air flow sensor and air duct assembly. Refer to «AIR CLEANER AND AIR DUCT»(ref-233993-S13601402462006052800000) .
3. Remove undercover and splash guard (RH).
4. Remove right side front road wheel and tire.
5. Drain engine oil. Refer to «CHANGING ENGINE OIL»(ref-233994-S33124697692006052700000) . CAUTION: Perform this step when the engine is cold. Do not spill engine oil on drive belts.
6. Drain engine coolant from radiator. Refer to «CHANGING ENGINE COOLANT»(ref-233995-S01322841342006052700000) . CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belts.
7. Remove intake manifold collectors (upper and lower). Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
8. Remove drive belts. Refer to «DRIVE BELTS»(ref-233993-S14607392772006052800000) .
9. Remove alternator. Refer to «CHARGING SYSTEM»(ref-234023-S04076612042006052700000) .
10. Remove power steering oil pump from bracket with piping connected, and temporarily secure it to aside. Refer to «POWER STEERING OIL PUMP»(ref-234012-S27486162762006052700000) .
11. Remove power steering oil pump bracket. Refer to «POWER STEERING OIL PUMP»(ref-234012-S27486162762006052700000) .
12. Remove idler pulley and bracket. Refer to «TIMING CHAIN»(ref-233993-S27825796252006052800000) .
13. Separate engine harnesses removing their brackets from front timing chain case.
14. Remove rocker covers (right and left banks). Refer to «ROCKER COVER»(ref-233993-S41118776802006052800000) . NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed.
15. Obtain No. 1 cylinder at TDC of its compression stroke as follows: NOTE: When timing chain is not removed/installed, this step is not required. 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. NOTE: When only timing chain (primary) is removed, rocker cover does not need to be removed. To make sure that No. 1 cylinder is at its compression TDC, remove front timing chain case first. Then check mating marks on camshaft sprockets. Refer to «INSTALLATION»(ref-233993-S02076788762006052800000) .
16. 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.
17. Remove oil pan (lower). Refer to «OIL PAN AND OIL STRAINER»(ref-233993-S25354294872006052800000) .
18. Loosen two mounting bolts in front of oil pan (upper) in reverse order as shown in the figure.
19. Install oil pan (lower) temporarily. Applying liquid gasket is unnecessary.
20. Support the oil pan (lower) bottom with jack. Perform following operations with engine front-side supported with jack. CAUTION: Put a piece of wood or something similar as the supporting surface, be careful not to damage oil pan (lower).
21. 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.
22. Remove collared O-rings from front timing chain case oil holes (left and right sides).
23. Remove engine mounting insulator (RH) and engine mounting bracket (RH). Refer to «ENGINE ASSEMBLY»(ref-233993-S16501809062006052800000) .
24. Raise engine front-side with jack. (This secures work space to remove front timing chain case.)
25. 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 a screwdriver or something similar. After removal, handle front timing chain case carefully so it does not tilt, cant, or warp under a load.
26. Remove oil pan gasket (front). Refer to «OIL PAN AND OIL STRAINER»(ref-233993-S25354294872006052800000) .
27. Remove O-rings from rear timing chain case.
28. Remove water pump cover and chain tensioner cover from front timing chain case, if necessary. Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.
29. 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.
30. Remove timing chain and related parts. Refer to «TIMING CHAIN»(ref-233993-S27825796252006052800000) .
31. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases and oil pan (upper), and liquid gasket mating surfaces. CAUTION: Be careful not to allow gasket fragments to enter oil pan. Remove old liquid gasket from bolt hole and thread.
32. Use a scraper to remove all traces of liquid gasket from water pump cover, chain tensioner cover and intake valve timing control covers.

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1. Install timing chain and related parts. Refer to «TIMING CHAIN»(ref-233993-S27825796252006052800000).
2. Hammer dowel pins (right and left) into front timing chain case up to a point close to taper in order to shorten protrusion length.
3. Install new front oil seal on front timing chain case. Apply new engine oil to both oil seal lip and dust seal lip. Install it so that each seal lip is oriented as shown in the figure. Using a suitable drift [outer diameter: 60 mm (2.36 in)], press-fit oil seal until it becomes flush with front timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted.
4. Install water pump cover and chain tensioner cover to front timing chain case, if removed. Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to front timing chain case as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000).
5. Install front timing chain case as follows: Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to front timing chain case back side as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000). Install new oil pan gasket (front). Apply liquid gasket to oil pan gasket as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000). Align notch of front timing chain case with protrusion of oil pan gasket. Apply liquid gasket with the tube presser [SST: WS39930000 ( - )] to top surface of oil pan (upper) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000). Install new O-rings on rear timing chain case. Assemble front timing chain case as follows: Fit lower end of front timing chain case tightly onto top face of oil pan (upper). From the fitting point, make entire front timing chain case contact rear timing chain case completely. CAUTION: Be careful that oil pan gasket is in place. Since front timing chain case is offset for difference of bolt holes, tighten bolts temporarily with holding front timing chain case from front and top as shown in the figure. For bolt length and positions, refer to step e. Same as the step ii, insert dowel pin with holding front timing chain case from front and top completely. Tighten mounting bolts to the specified torque in numerical order as shown in the figure. There are two types of mounting bolt. Refer to the following for locating bolts. M8 bolts: 1,2 28.4 N.m (2.9 kg-m, 21 ft-lb) M6 bolts: Except the above 12.7 N.m (1.3 kg-m, 9 ft-lb) After all bolts tightening, retighten them to the specified torque in numerical order as shown in the figure.
6. Install engine mounting bracket (RH) and engine mounting insulator (RH). Refer to «ENGINE ASSEMBLY»(ref-233993-S16501809062006052800000).
7. Remove jack which supports the oil pan (lower) bottom.
8. Remove oil pan (lower).
9. Install two mounting bolts in front of oil pan (upper) in numerical order as shown in the (Scheme 114).2 N.m (1.8 kg-m, 13 ft-lb)
10. Install oil pan (lower). Refer to «OIL PAN AND OIL STRAINER»(ref-233993-S25354294872006052800000).
11. Install intake valve timing control covers as follows: Install new seal rings in shaft grooves. Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to intake valve timing control covers as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000). Install new collared O-rings in front timing chain case oil holes (left and right sides). Being careful not to move seal rings from the installation grooves, align dowel pins on front timing chain case with the holes to install intake valve timing control covers. Tighten mounting bolts in numerical order as shown in the figure.
12. Install crankshaft pulley as follows: Install crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with plastic hammer, tap on its center portion (not circumference). Fix crankshaft with the pulley holder [SST: KV10109300 ( - )]. Tighten crankshaft pulley bolt. 44.1 N.m (4.5 kg-m, 33 ft-lb) Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by 60 degrees. (Angle tightening)
13. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
14. Install in the reverse order of removal after this step.

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

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Scheme 204

1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Refer to «INSTALLATION»(ref-233993-S24112159802006052800000) . Install timing chain tensioners (secondary) with a stopper pin attached and new O-ring. Install camshaft brackets (No. 1). Refer to «INSTALLATION»(ref-233993-S24112159802006052800000) .
2. Install rear timing chain case as follows: Install new O-rings onto cylinder block. Install new O-rings to cylinder head. Apply liquid gasket with the tube presser [SST: WS39930000 ( - )] to rear timing chain case back side as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . CAUTION: For "A" in the figure, completely wipe out liquid gasket extended on a portion touching at engine coolant. Apply liquid gasket on installation position of water pump and cylinder head very completely. Align rear timing chain case and water pump assembly with dowel pins (right and left) on cylinder block and install rear timing chain case. Make sure O-rings stay in place during installation to cylinder block and cylinder head. 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. Bolt length: Bolt position 20 mm (0.79 in): 1, 2, 3, 6, 7, 8, 9, 10 16 mm (0.63 in): Except the above 12.7 N.m (1.3 kg-m, 9 ft-lb) After all bolts tightening, retighten them to the specified in numerical order as shown in the figure. If liquid gasket protrudes, wipe it off immediately. After installing rear timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface. Standard Rear timing chain case to cylinder block: -0.24 to 0.14 mm (-0.009 to 0.006 in) If not within the standard, repeat the installation procedure. Install water pump with new O-rings. Refer to «WATER PUMP»(ref-233995-S33089933962006052700000) . Make sure that dowel pin hole, dowel pin and crankshaft key are located as shown in the figure. (No. 1 cylinder at compression TDC) NOTE: Though camshaft does not stop at the position as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure. Camshaft dowel pin hole (intake side) At cylinder head upper face side in each bank Camshaft dowel pin (exhaust side) At cylinder head upper face side in each bank Crankshaft key At cylinder head side of right bank CAUTION: Hole on small dia. side must be used for intake side dowel pin hole. Do not misidentify (ignore big dia. side). Install timing chain (secondary) and camshaft sprockets (INT and EXH) as follows: CAUTION: Mating marks between timing chain and sprockets slip easily. Confirm all mating mark positions repeatedly during the installation process. Push plunger of timing chain tensioner (secondary) and keep it pressed in with stopper pin. Install timing chain (secondary) and camshaft sprockets (INT and EXH). Align the mating marks on timing chain (secondary) (gold link) with the ones on camshaft sprockets (INT and EXH) (punched), and install them. NOTE: Mating marks for camshaft sprocket (INT) are on the back side of camshaft sprocket (secondary). There are two types of mating mark, circle and oval types. They should be used for the right and left banks, respectively. Right bank: Use circle type. Left bank: Use oval type. Align dowel pin and pin hole on camshafts with the groove and dowel pin on sprockets, and install them. On the intake side, align pin hole on the small diameter side of the camshaft front end with dowel pin on the back side of camshaft sprocket, and install them. On the exhaust side, align dowel pin on camshaft front end with pin groove on camshaft sprocket, and install them. In case that positions of each mating mark and each dowel pin are not fit on mating parts, make fine adjustment to the position holding the hexagonal portion on camshaft with wrench or equivalent. Mounting bolts for camshaft sprockets must be tightened in the next step. Tightening them by hand is enough to prevent the dislocation of dowel pins. It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the top of sprocket teeth and its extended line in advance with paint. After confirming the mating marks are aligned, tighten camshaft sprocket mounting bolts. Secure camshaft using wrench at the hexagonal portion to tighten mounting bolts. Pull stopper pins out from timing chain tensioners (secondary). Install tension guide. Install timing chain (primary) as follows: Install crankshaft sprocket. Make sure the mating marks on crankshaft sprocket face the front of the engine. Install timing chain (primary). Install timing chain (primary) so the mating mark (punched) on camshaft sprocket (INT) is aligned with the yellow link on timing chain, while the mating mark (notched) on crankshaft sprocket is aligned with the orange one on timing chain, as shown in the figure. When it is difficult to align mating marks of timing chain (primary) with each sprocket, gradually turn camshaft using wrench on the hexagonal portion to align it with the mating marks. During alignment, be careful to prevent dislocation of mating mark alignments of timing chains (secondary). Install internal chain guide, slack guide and timing chain tensioner (primary). CAUTION: Do not overtighten slack guide mounting bolt. It is normal for a gap to exist under the bolt seat when mounting bolt is tightened to specification. When installing timing chain tensioner (primary), push in plunger and keep it pressed in with stopper pin. Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary). After installation, pull out a stopper pin by pressing slack guide. Make sure again that the mating marks on each sprocket and each timing chain have not slipped out of alignment. Install new O-rings on rear timing chain case. Install new front oil seal on front timing chain case. Apply new engine oil to both oil seal lip and dust seal lip. Install it so that each seal lip is oriented as shown in the figure. Using a suitable drift [outer diameter: 60 mm (2.36 in)], press-fit oil seal until it becomes flush with front timing chain case end face. Make sure the garter spring is in position and seal lip is not inverted. Install water pump cover and chain tensioner cover to front timing chain case. Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to front timing chain case as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . Install front timing chain case as follows: Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to front timing chain case back side as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . Install front timing chain case as to fit its dowel pin hole together dowel pin on rear timing chain case. Tighten mounting bolts to the specified torque in numerical order as shown in the figure. There are two types of mounting bolt. Refer to the following for locating bolts. M8 bolts: 1, 2 28.4 N.m (2.9 kg-m, 21 ft-lb) M6 bolts: Except the above 12.7 N.m (1.3 kg-m, 9 ft-lb) After all bolts tightening, retighten them to the specified torque in numerical order as shown in the figure. CAUTION: Be sure to wipe off any excessive liquid gasket leaking on surface mating with oil pan (upper). After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface. Standard Front timing chain case to rear timing chain case: -0.14 to 0.14 mm (-0.006 to 0.006 in) If not within the standard, repeat the installation procedure. Install intake valve timing control covers as follows: Install new seal rings in shaft grooves. Apply a continuous bead of liquid gasket with the tube presser [SST: WS39930000 ( - )] to intake valve timing control covers as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent. Refer to «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-233992-S15687029032006052800000) . Install new collared O-rings in front timing chain case oil hole (left and right sides). Being careful not to move seal rings from the installation grooves, align dowel pins on front timing chain case with the holes to install intake valve timing control covers. Tighten mounting bolts in numerical order as shown in the figure. Install crankshaft pulley as follows: Install crankshaft pulley, taking care not to damage front oil seal. When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). Fix crankshaft with the pulley holder [SST: KV10109300 ( - )]. Tighten crankshaft pulley bolt. 44.1 N.m (4.5 kg-m, 33 ft-lb) Put a paint mark on crankshaft pulley aligning with angle mark on crankshaft pulley bolt. Then, further retighten bolt by 60 degrees. (Angle tightening) Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly. Install in the reverse order of removal after this step.

1. Remove the following parts: Right side front road wheel and tire Splash guard (RH) Drive belts; Refer to «DRIVE BELTS»(ref-233993-S14607392772006052800000) . Crankshaft pulley; Refer to «TIMING CHAIN»(ref-233993-S27825796252006052800000) .
2. Remove front oil seal using a suitable tool.

Scheme 205

Scheme 206

Scheme 207

1. Apply new engine oil to both oil seal lip and dust seal lip of new front oil seal.
2. Install front oil seal. Install front oil seal so that each seal lip is oriented as shown in the figure. Using a suitable drift, press-fit until the height of front oil seal is level with the mounting surface. Suitable drift: outer diameter 60 mm (2.36 in), inner diameter 50 mm (1.97 in). CAUTION: Be careful not to damage front timing chain case and crankshaft. Press-fit straight and avoid causing burrs or tilting oil seal.
3. Install in the reverse order of removal after this step.

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 drive plate. Refer to «CYLINDER BLOCK»(ref-233993-S21665934002006052800000) .
4. Remove oil pan (upper). Refer to «OIL PAN AND OIL STRAINER»(ref-233993-S25354294872006052800000) .
5. Use a seal cutter [SST] to cut away liquid gasket and remove rear oil seal retainer.

Note. Regard both rear oil seal and retainer a an assembly.

Scheme 208

Scheme 209

1. Remove old liquid gasket on mating surfaces of cylinder block and oil pan (upper) using a scraper.
2. Apply new engine oil to both oil seal lip and dust seal lip of new rear oil seal retainer.
3. 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: Attaching should be done within 5 minutes after coating.
4. Install rear oil seal retainer to cylinder block. Refer to «CYLINDER BLOCK»(ref-233993-S21665934002006052800000) . Make sure the garter spring is in position and seal lips not inverted.
5. Install in the reverse order of removal after this step.

Scheme 210

Scheme 211

Scheme 212

1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to «FUEL PRESSURE RELEASE»(ref-233996-S05768987042006052700000) .
3. Disconnect fuel pump fuse to avoid fuel injection during measurement.
4. Remove engine cover. Refer to «INTAKE MANIFOLD COLLECTOR»(ref-233993-S36113184132006052800000) .
5. Remove ignition coil and spark plug from each cylinder. Refer to «IGNITION COIL»(ref-233993-S03131100382006052800000) and «SPARK PLUG (PLATINUM-TIPPED TYPE)»(ref-233993-S01373001272006052800000) .
6. Connect engine tachometer (not required in use of CONSULT-II).
7. Install compression tester with adapter onto spark plug hole. Use compression gauge whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal.
8. With accelerator pedal fully depressed, turn ignition switch to "START" for cranking. When the gauge pointer stabilizes, read the compression pressure and engine RPM. Perform these steps to check each cylinder. COMPRESSION PRESSURE Standard Minimum Deference limit between cylinders 1,275 (13.0, 185)/300 981 (10.0, 142)/300 98 (1.0, 14)/300 CAUTION: Always use a fully changed battery to obtain specified engine speed. If the engine speed is out of the specified range, check battery liquid for proper gravity. Check the engine speed again with normal battery gravity. If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure compression pressure again. If some cylinders have low compression pressure, pour small amount of engine oil into spark plug hole of cylinder to re-check it for compression. If the added engine oil improves the compression, piston rings may be worn out or damaged. Check piston rings and replace if necessary. If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly. If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cylinder head gaskets.
9. After inspection is completed, install removed parts.
10. Start the engine, and make sure that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to «TROUBLE DIAGNOSIS»(ref-233996-S20134012652006052700000) .

Scheme 213

Scheme 214

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. Remove camshaft. Refer to «CAMSHAFT»(ref-233993-S24061581132006052800000) .
4. Remove engine slingers.
5. Remove the following parts: Fuel tube and fuel injector assembly; Refer to «FUEL INJECTOR AND FUEL TUBE»(ref-233993-S41105589972006052800000) . Intake manifold; Refer to «INTAKE MANIFOLD»(ref-233993-S12366549612006052800000) . Exhaust manifold; Refer to «EXHAUST MANIFOLD AND THREE WAY CATALYST»(ref-233993-S37636481532006052800000) . Water inlet and thermostat assembly; Refer to «WATER INLET AND THERMOSTAT ASSEMBLY»(ref-233995-S41877319852006052700000) . Water outlet, water bypass pipe, heater pipe and water connector; Refer to «WATER OUTLET AND WATER PIPING»(ref-233995-S09088542642006052700000) .
6. Remove cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool) to remove cylinder heads (right and left banks).
7. Remove cylinder head gaskets.

Scheme 215

1. Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between "d1" and "d2" exceeds the limit, replace them with new one. Limit ("d1" - "d2"): 0.11 mm (0.0043 in)
2. If reduction of outer diameter appears in a position other than "d2", use it as "d2" point.

VALVE GUIDE REPLACEMENT

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

Scheme 216

Scheme 217

Scheme 218

Scheme 219

Scheme 220

Scheme 221

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 valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 Imp ton) pressure] or hammer and valve guide drift (commercial service tool). CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
3. Using the valve guide reamer (commercial service tool), 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.
5. Using the valve guide drift (commercial service tool), press valve guide from camshaft side to the dimensions as in the figure. Projection "L" Intake and exhaust 12.6 - 12.8 mm (0.496 - 0.504 in) CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
6. Using the valve guide reamer (commercial service tool), apply reamer finish to valve guide. Standard: Intake and exhaust 6.000 - 6.018 mm (0.2362 - 0.2369 in)

Scheme 222

1. After confirming that the dimensions of valve guides and valves are within the specifications, perform this procedure.
2. Apply Prussian blue (or white lead) 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 "NG" conditions even after the re-check, replace valve seat. Refer to «VALVE SEAT REPLACEMENT»(ref-233993-S22800445722006052800000) .

VALVE SEAT REPLACEMENT

When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat.

Scheme 223

Scheme 224

Scheme 225

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. Refer to «VALVE SEAT»(ref-233993-S09439975532006052800000) . CAUTION: Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)] Intake: 38.500 - 38.516 mm (1.5157 -1.5164 in) Exhaust: 32.700 - 32.716 mm (1.2874 - 1.2880 in) Be sure to ream in circles concentric to valve guide center. This will enable valve to fit correctly.
3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head. CAUTION: Avoid directly touching cold valve seats. Cylinder head contains heat. When working, wear protective equipment to avoid getting burned.
5. Using the valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. Refer to «VALVE SEAT»(ref-233993-S09439975532006052800000) . CAUTION: When using the valve seat cutter, firmly grip cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on with cutter or cutting many different times may result in stage valve seat.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to «VALVE SEAT CONTACT»(ref-233993-S19889113702006052800000) .

Scheme 226

1. Set a try square along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and try square. Limit: 2.1 mm (0.083 in)
2. If it exceeds the limit, replace valve spring.

Scheme 227

1. Check valve spring pressure at the specified spring height. Standard: Intake and exhaust Free height 47.07 mm (1.8531 in) Installation height 37.00 mm (1.457 in) Installation load 166 - 188 N (16.9 - 19.2 kg, 37 - 42 lb) Height during valve open 27.2 mm (1.0709 in) Load with valve open 373 - 421 N (38.0 - 42.9 kg, 84 - 95 lb)
2. If the installation load or load with valve open is out of the standard, replace valve spring.

Scheme 228

Scheme 229

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

1. Do not allow engine mounting insulator to be damage and careful no oil gets on it.
2. For a path with a specified installation orientation, refer to component figure in «REMOVAL AND INSTALLATION»(ref-233993-S11339537582006052800000) .
3. Make sure all mounting insulators are seated properly, then tighten mounting nuts and bolts.