Engine Mechanical: Removal & Installation Nissan Quest IV

REMOVAL AND DISASSEMBLY

1. When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
2. Exercise maximum care to avoid damage to mating or sliding surfaces.
3. Dowel pins are used for several parts alignment. When replacing and reassembling parts with dowel pins, check that dowel pins are installed in the original position.
4. Must cover openings of engine system with a tape or equivalent, to seal out foreign materials.
5. Mark and arrange disassembly parts in an organized way for easy troubleshooting and reassembly.
6. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Power tools may be used in the step.

ASSEMBLY AND INSTALLATION

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

REMOVAL

1. Remove front wheel and tire (RH).
2. Remove splash guard (RH). Refer to " «EXPLODED VIEW»(ref-672623-S22478781722014112400000) ".
3. While securely holding the square part (A) in pulley center of drive belt auto-tensioner (1), move in the direction of arrow (loosening direction of drive belt auto-tensioner) using suitable tool. CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off.
4. Insert a rod approximately 6 mm (0.24 in) in diameter such as short-length screwdriver into the hole (B) of the retaining boss to fix drive belt auto-tensioner pulley.
5. Loosen drive belt in sequence, and remove it.

Scheme 69

Scheme 70

1. While securely holding the square part (A) in pulley center of drive belt auto-tensioner (1), move in the direction of arrow (loosening direction of drive belt auto-tensioner) using suitable tool. CAUTION: Avoid placing hand in a location where pinching may occur if the holding tool accidentally comes off.
2. Insert a rod approximately 6 mm (0.24 in) in diameter such as short-length screwdriver into the hole (A) of retaining boss to fix drive belt auto-tensioner pulley.
3. Hook drive belt onto all pulleys except for drive belt auto-tensioner pulley, and then onto drive belt auto-tensioner pulley finally. CAUTION: Confirm drive belt is completely set to pulleys. Check for engine oil, working fluid and engine coolant on drive belt and each pulley groove.
4. Release drive belt auto-tensioner, and apply tension to drive belt.
5. Turn crankshaft pulley clockwise several times to equalize tension between each pulley.
6. Confirm tension of drive belt at indicator is within the possible use range. Refer to " «EXPLODED VIEW»(ref-672620-S16874419572014112400000) ".

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

INSTALLATION

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

Scheme 71

1. Insert pawls (B) of air cleaner case (upper) (1) into 3 notches (A) of air cleaner case (lower) (2) and fix with clips.
2. Check that the air cleaner case (upper) is securely installed with no backlash.

Install in the reverse order of removal.

Install in the reverse order of removal.

Scheme 72

1. Remove drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S02403723332014112400000) ".
2. Remove auto-tensioner.

Install in the reverse order of removal.

Scheme 73

Note. Mass air flow sensor is removable under the car-mounted condition. Remove air duct (inlet). Disconnect harness connector from mass air flow sensor. Remove PCV hose at air duct assembly side. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly disconnecting their joints. Add mating marks if necessary for easier installation. Remove mass air flow sensor from air cleaner case (upper), if necessary.

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

Scheme 74

1. Install each part, according to the marks put at the removal procedure and tighten clamp.
2. Insert pawls (B) of air cleaner case (upper) (1) into 3 notches (A) of air cleaner case (lower) (2) and fix with clips.
3. Check that the air cleaner case (upper) is securely installed with no backlash.

Scheme 75

Scheme 76

1. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-672620-S40358377172014112400000) ". CAUTION: Be careful not to damage or scratch engine cover.
2. Remove air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly. Refer to " «EXPLODED VIEW»(ref-672620-S30704453622014112400000) ".
3. Prevent engine coolant leakage by draining engine coolant or attaching plug after disconnecting water hoses. Refer to " «DRAINING»(ref-672622-S03082931862014112400000) ". CAUTION: Perform this step when the engine is cold. NOTE: The above step is not required when removing only intake manifold collector.
4. Remove electric throttle control actuator as follows: NOTE: Water hose is not required to be disconnected when removing only intake manifold collector. Loosen mounting bolts in reverse of the order shown in the figure below to remove. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Never disassemble.
5. Remove the following parts: Vacuum hose PCV hose Electronic controlled engine mount control solenoid valve
6. Remove power steering hose located on the high pressure side from the rear of intake manifold collector. " «EXPLODED VIEW»(ref-672626-S11815896182014112400000) "
7. Disconnect EVAP hoses and harness connector from EVAP canister purge volume control solenoid valve.
8. Loosen mounting nuts and bolts in the reverse order as shown in the figure below, and remove intake manifold collector and gasket. CAUTION: Cover engine openings to avoid entry of foreign materials.

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

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

Scheme 77

1. If stud bolts were removed, install them and tighten to the specified torque below. Torque: 10.8 N.m (1.1 kg-m, 8 ft-lb)
2. Tighten all mounting nuts and bolts to the specified torque in two or more steps in numerical order shown in the figure below. Torque 1st step: 7.4 N.m (0.75 kg-m, 5 ft-lb) Torque 2nd step and after: 25.5 N.m (2.6 kg-m, 19 ft-lb) CAUTION: Install manifold, according to the marks put on the intake manifold and cylinder head.

Scheme 78

1. Check the surface distortion of the intake manifold mating surface with a straightedge (A) and a feeler gauge (B). Limit: Refer to " «INTAKE MANIFOLD»(ref-672620-S19874267812014112400000) ".
2. If it exceeds the limit, replace intake manifold.

Scheme 79

Scheme 80

Scheme 81

Scheme 82

1. Bank 1 side Air cleaner case (upper) with mass air flow sensor and air duct assembly: Refer to " «EXPLODED VIEW»(ref-672620-S30704453622014112400000) ". Engine cover: Refer to " «EXPLODED VIEW»(ref-672620-S40358377172014112400000) ". Front wiper arm: Refer to " «WIPER ARM: REMOVAL AND INSTALLATION»(ref-672627-S22259871952014112400000) ". Extension cowl top: Refer to " «EXPLODED VIEW»(ref-672623-S24692554682014112400000) ". Heat insulator: Refer to " «EXPLODED VIEW»(ref-672626-S05287429072014112400000) ".
2. Bank 2 side Engine under cover.
3. Remove exhaust front tube. Refer to " «EXPLODED VIEW»(ref-672628-S26761624652014112400000) ".
4. Disconnect harness connector and remove air fuel ratio sensor 1 on both banks with the heated oxygen sensor wrench [SST: KV10117100 (J-3647-A)] (B). Put marks to identify installation positions of each air fuel ratio sensor 1. CAUTION: If air fuel ratio sensor is dropped on to a hard surface-like a concrete floor from a height of 0.5 m (19.69 in) or more, discard the sensor and use a new one. Clean the mounting area of air fuel ratio sensor before installing a new air fuel ratio sensor. NOTE: Figure is shown as an example of bank 2 (A).
5. Disconnect harness connector and remove heated oxygen sensor 2 on both banks with the heated oxygen sensor wrench [SST: KV10114400 (J-38365)] (B). Put marks to identify installation positions of each heated oxygen sensor 2. CAUTION: If air fuel ratio sensor is dropped on to a hard surface-like a concrete floor from a height of 0.5 m (19.69 in) or more, discard the sensor and use a new one. Clean the mounting area of air fuel ratio sensor before installing a new air fuel ratio sensor.
6. Remove exhaust manifold covers (bank 1 and bank 2).
7. Remove three way catalyst support mounting bolts (bank 1 and bank 2).
8. Remove three way catalysts by loosening bolts first and then removing nuts. (Stud bolt and flange bolt type) CAUTION: Handle carefully to avoid any shock to three way catalyst.
9. Loosen mounting nuts in the reverse order as shown in the figure below to remove exhaust manifolds (bank 1 and bank 2). NOTE: Disregard No. 7 and 8 when loosing.
10. Remove gaskets. CAUTION: Cover engine openings to avoid entry of foreign materials.

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

Note. When removing oil pan (lower) or oil strainer only, take step 1 then step 32 and 33 .

Scheme 83

Scheme 84

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Scheme 86

Scheme 87

1. Drain engine oil. Refer to " «DRAINING»(ref-672629-S13228114362014112400000) ". CAUTION: Never spill engine oil on drive belt.
2. Drain engine coolant. Refer to " «DRAINING»(ref-672622-S03082931862014112400000) ". CAUTION: Never spill engine coolant on drive belt.
3. Remove following parts: Front road wheel and tires (RH and LH). Splash guard (RH and LH): Refer to " «EXPLODED VIEW»(ref-672623-S22478781722014112400000) ". Exhaust front tube: Refer to " «EXPLODED VIEW»(ref-672628-S26761624652014112400000) ". Drive belt: Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S02403723332014112400000) ". Engine under cover. Crankshaft position sensor.
4. Remove A/C compressor with piping connected, and temporarily secure it to aside. Refer to " «COMPRESSOR: REMOVAL AND INSTALLATION»(ref-672613-S13536270442014112400000) ".
5. Remove oil level gauge. Refer to " «EXPLODED VIEW»(ref-672620-S02052188792014112400000) ".
6. Remove air duct (inlet). Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S13912561332014112400000) ".
7. Remove extension cowl top. Refer to " «REMOVAL AND INSTALLATION»(ref-672623-S22273486832014112400000) ".
8. Remove high pressure side piping from intake manifold collector. Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ".
9. Remove heater tube bracket (front). Refer to " «EXPLODED VIEW»(ref-672613-S21453871532014112400000) ".
10. Remove vacuum hose from engine mounting (front and rear). Refer to " «EXPLODED VIEW»(ref-672620-S33173820222014112400000) ".
11. Remove front drive shaft (RH). Refer to " «RIGHT SIDE: REMOVAL AND INSTALLATION»(ref-672630-S29472552812014112400000) ".
12. Remove heat insulator. Refer to " «EXPLODED VIEW»(ref-672626-S05287429072014112400000) ".
13. Remove steering lower joint. Refer to " «EXPLODED VIEW»(ref-672626-S26430632562014112400000) ".
14. Remove three way catalyst (bank 1 and bank 2). Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S06534965302014112400000) "
15. Remove oil pressure switch.
16. Remove oil filter. Refer to " «REMOVAL AND INSTALLATION»(ref-672629-S01674900242014112400000) ".
17. Remove engine mounting insulator (front and rear) fixing nuts. Refer to " «EXPLODED VIEW»(ref-672620-S33173820222014112400000) ".
18. Remove front drive shaft (LH) from transaxle. Refer to " «LEFT SIDE: REMOVAL AND INSTALLATION»(ref-672630-S18837170522014112400000) ".
19. Remove CVT fluid cooler hose from front suspension member.
20. Remove the connector of auto levelizer control unit and clip.
21. Remove the mounting nuts of stabilizer connecting rod upper side. Refer to " «EXPLODED VIEW»(ref-672631-S31664588562014112400000) ".
22. Remove power steering return hose and power steering return tube from front suspension member. Refer to " «EXPLODED VIEW»(ref-672626-S11815896182014112400000) ".
23. Support transaxle assembly with a suitable jack. CAUTION: When setting the transmission jack, be careful not to allow it to collide against the drain plug.
24. Remove engine mounting insulator (LH) mounting bolts from front suspension member. Refer to " «EXPLODED VIEW»(ref-672620-S33173820222014112400000) ".
25. Remove rear torque rod and rear torque rod bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S00497577782014112400000) ".
26. Support front suspension member assembly with a suitable jack.
27. Remove member stay, front suspension member fixing bolts and bolts. Refer to " «EXPLODED VIEW»(ref-672631-S06650575382014112400000) ".
28. Lower the jack on the front suspension side to the height where the hose of power steering is not stretched taut.
29. Remove support bearing bracket. Refer to " «EXPLODED VIEW»(ref-672630-S39377233802014112400000) "
30. Remove oil cooler and water pipe. Refer to " «EXPLODED VIEW»(ref-672629-S00880873952014112400000) ".
31. Remove oil pan (lower) as follows: Loosen mounting bolts in the reverse order as shown in the figure below to remove. Insert the seal cutter [SST: KV10111100 (J-37228)] (A) between oil pan (upper) and oil pan (lower). CAUTION: Be careful not to damage the mating surfaces. Never insert a screwdriver, this will damage the mating surfaces. Slide the seal cutter by tapping on the side of tool with a hammer. Remove oil pan (lower).
32. Remove oil strainer.
33. Loosen mounting bolts in the reverse order as shown in the figure below to remove. Insert the seal cutter [SST: KV10111100 (J-37228)] between oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of tool with a hammer. Remove oil pan (upper). CAUTION: Be careful not to damage the mating surfaces. Never insert a screwdriver, this will damage the mating surfaces.
34. Remove O-rings (2) from bottom of cylinder block (1) and oil pump (3).
35. Remove oil pan gaskets (1).

Scheme 88

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Scheme 91

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Scheme 96

1. Install oil pan (upper) as follows: Use a scraper to remove old liquid gasket from mating surfaces. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Also remove old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt holes and threads. Install new O-rings (2) on the bottom of cylinder block (1) and oil pump (3). CAUTION: Do not reuse O-rings. Install new oil pan gaskets. Apply liquid gasket to new oil pan gaskets as shown in the figure below. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". To install, align protrusion (B) of oil pan gasket with notches (A) of front timing chain case and rear oil seal retainer. Install oil pan gasket (1) with smaller arc to front timing chain case side. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to the cylinder block mating surface of oil pan (upper) to a limited portion as shown in the figure below. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". CAUTION: For bolt holes with "triangle" 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 O-rings. Tighten mounting bolts in numerical order as shown in the figure below. There are three types of mounting bolts. Refer to the following for locating bolts. M8 x 135 mm (5.31 in): 11 M8 x 92 mm (3.62 in): 5, 7, 8 M8 x 25 mm (0.98 in): Except the above
2. Install oil strainer to oil pump.
3. Install oil pan (lower) as follows: Use scraper (A) to remove old liquid gasket from mating surfaces. Remove old liquid gasket from the bolt holes and thread. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) (A) to the oil pan (lower) as shown in the figure below. b: ø4.0 - 5.0 mm (0.157 - 0.197 in) Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". 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 below.
4. Install oil pan drain plug. Refer to the figure of components above for installation direction of drain plug washer. Refer to " «EXPLODED VIEW»(ref-672620-S21429898042014112400000) ". CAUTION: Do not reuse drain plug washer.
5. Install in the reverse order of removal after this step. NOTE: At least 30 minutes after oil pan is installed, pour engine oil.

Scheme 97

Scheme 98

Scheme 99

Scheme 100

1. Remove air duct (inlet), air cleaner cases (upper and lower) with mass air flow sensor and air duct assembly. Refer to " «EXPLODED VIEW»(ref-672620-S30704453622014112400000) ".
2. Remove engine cover. Refer to " «EXPLODED VIEW»(ref-672620-S40358377172014112400000) ".
3. Release the fuel pressure. Refer to " «WORK PROCEDURE»(ref-672625-S22980190582014112400000) ".
4. Drain engine coolant, or when water hoses are disconnected, attach plug to prevent engine coolant leakage. Refer to " «DRAINING»(ref-672622-S03082931862014112400000) ". CAUTION: Perform this step when the engine is cold.
5. Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ".
6. When separating fuel feed hose and fuel tube connection, disconnect quick connector as follows: Remove quick connector cap from quick connector. Disconnect quick connector from fuel tube as follows: CAUTION: Disconnect quick connector by using the quick connector release (commercial service tool: 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 (A) into quick connector (2) until sleeve (B) 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 fuel tube (1). CAUTION: Pull quick connector (E) holding position (D) as shown in the figure below. Never pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leakage out. Avoid fire and sparks. Keep parts away from heat source. Especially, be careful when welding is performed around them. Never expose parts to battery electrolyte or other acids. Never bend or twist connection between quick connector and fuel feed hose (with damper) during installation/removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags, etc. (A) or something similar.
7. Disconnect harness connector from fuel injector.
8. Loosen mounting bolts in the reverse order as shown in the figure below, and remove fuel tube and fuel injector assembly. CAUTION: Never tilt fuel tube, or remaining fuel in pipes may flow out from pipes.
9. Remove fuel injector from fuel tube as follows: Open and remove clip (1). Remove fuel injector (2) from fuel tube (5) by pulling straight. CAUTION: Be careful with remaining fuel that may go out from fuel tube. Be careful not to damage injector nozzle during removal. Never bump or drop fuel injector. Never disassemble fuel injector.
10. Remove fuel damper from fuel tube.

Scheme 101

Scheme 102

Scheme 103

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Scheme 105

1. Install fuel damper as follows: Install new O-ring (2) to fuel tube (1) as shown below. When handling new O-ring, be careful of the following caution: CAUTION: Do not reuse O-rings. Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. Insert new O-ring straight into fuel tube. Never twist it. Install spacer (3) to fuel damper (4). Insert fuel damper straight into fuel tube. CAUTION: Insert straight, checking that the axis is lined up. Never pressure-fit with excessive force. Reference value: 130 N (13.3 kg, 29.2 lb) Insert fuel damper until (B) is touching (A) of fuel tube. Tighten bolts evenly in turn. After tightening bolts, check that there is no gap between fuel damper cap (5) and fuel tube.
2. Install new O-rings to fuel injector paying attention to the following. CAUTION: Do not reuse O-rings. Upper and lower O-ring are different. Be careful not to confuse them. Fuel tube side: Black Nozzle side: Green Handle O-ring with bare hands. Never wear gloves. Lubricate O-ring with new engine oil. Never clean O-ring with solvent. Check that O-ring and its mating part are free of foreign material. When installing O-ring, be careful not to scratch it with tool or fingernails. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, never insert it quickly into fuel tube. Insert O-ring straight into fuel injector. Never decenter or twist it.
3. Install fuel injector to fuel tube as follows: Insert clip (3) into clip mounting groove (F) on fuel injector (5). Insert clip so that protrusion (E) of fuel injector matches cutout (C) of clip. CAUTION: Never reuse clip. Replace it with new one. Be careful to keep clip from interfering with O-ring. If interference occurs, replace O-ring. Insert fuel injector into fuel tube (1) with clip attached. Insert it while matching it to the axial center. Insert fuel injector so that protrusion (A) of fuel tube matches cutout (B) of clip. Check that fuel tube flange (G) is securely fixed in flange fixing groove (D) on clip. Check that installation is complete by checking that fuel injector does not rotate or come off. Check that protrusions of fuel injectors and fuel tubes are aligned with cutouts of clips after installation.
4. Install fuel tube and fuel injector assembly to intake manifold. CAUTION: Be careful not to let tip of injector nozzle come in contact with other parts. Tighten mounting bolts in two steps in numerical order as shown in the figure below. 1st step: 10.1 N.m (1.0 kg-m, 7 ft-lb) 2nd step: 22.0 N.m (2.2 kg-m, 16 ft-lb)
5. Connect fuel injector harness.
6. Install intake manifold collector. Refer to " «EXPLODED VIEW»(ref-672620-S20207820862014112400000) ".
7. Connect quick connector between fuel feed hose and fuel tube connection with the following procedure: Check no foreign substances are deposited in and around fuel tube and quick connector, and no damage on them. Thinly apply new engine oil around fuel tube from tip end to spool end. Align center to insert quick connector straightly into fuel tube. Insert quick connector (1) to fuel tube until top spool (2) is completely inside quick connector, and 2nd level spool (3) exposes right below quick connector. CAUTION: Hold (A) position as shown in the figure below when inserting fuel tube into quick connector. Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Pull quick connector by hand holding position. Check it is completely engaged (connected) so that it does not come out from fuel tube. Install quick connector cap (3) to quick connector. Install quick connector cap with arrow (A) on surface facing in direction of quick connector (fuel feed hose side). CAUTION: If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again. Secure fuel feed hose to clamp of quick connector cap.
8. Install in the reverse order of removal after this step.

Scheme 106

Scheme 107

1. Apply liquid gasket to the position shown in the figure below with the following procedure: Use Genuine RTV silicone sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". Refer to figure (E) to apply liquid gasket to joint part of camshaft bracket (No. 1) (1) and cylinder head. Refer to figure (H) to apply liquid gasket in 90 degrees to figure.
2. Install rocker cover gasket to rocker cover.
3. Install rocker cover. Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
4. Tighten bolts in two steps separately in numerical order as shown in the figure below. 1st step: 1.96 N.m (0.20 kg-m, 17 in-lb) 2nd step: 8.33 N.m (0.85 kg-m, 74 in-lb)
5. Install in the reverse order of removal after this step.

Scheme 108

Removal and Installation

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

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

Scheme 109

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Scheme 119

1. Install the engine mounting bracket (RH) to the engine as follows: Tighten the bolt No. 7 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
2. Install the engine mounting bracket (front) to the engine as follows: Tighten the bolt No. 4 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
3. Install the engine mounting bracket (rear) and gusset to the engine as follows: Tighten the bolt No. 4 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
4. Install the rear torque rod bracket to the engine as follows: Tighten the bolt No. 3 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
5. Install the engine mounting insulator (LH) to the transaxle as follows: Tighten the bolt No. 3 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
6. Install the engine mounting insulator (front) to the front suspension member as follows: Tighten the bolt No. 3 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
7. Install the engine mounting insulator (rear) to the front suspension member as follows: Tighten the bolt No. 3 as shown in the figure below. (temporarily) Tighten the bolts No. 1, 2, 3 in numerical order as shown in the figure below. (specified torque) Tighten the bolt No. 6 as shown in the figure below. (temporarily) Tighten the bolts No. 4, 5, 6 in numerical order as shown in the figure below. (specified torque)
8. Install the rear torque rod to the front suspension member as follows: Tighten the bolt No. 3 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
9. Install the engine mounting brackets (front) to the engine mounting insulators (front).
10. Install engine mounting bracket (rear) to engine mounting insulator (rear).
11. Install the engine mounting insulator (LH) to the front suspension member. Tighten the bolts in numerical order as shown in the figure below.
12. Install the rear torque rod to the rear torque rod bracket.
13. Install the vacuum tube (front) as follows: Tighten the bolt No. 3 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)
14. Install the vacuum tube (rear) as follows: Tighten the bolt No. 3 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)

Scheme 120

Scheme 121

1. Install the engine mounting insulator (RH) as follows: Tighten the bolt No. 1 as shown in the figure below. (temporarily) Tighten the bolts No. 2, 3 in numerical order as shown in the figure below. (specified torque) Tighten the bolt No. 1 as shown in the figure below. (specified torque) Tighten the bolts No. 4, 5, 6 in numerical order as shown in the figure below. (specified torque)
2. Install the upper torque rod as follows: Tighten the bolt No. 2 as shown in the figure below. (temporarily) Tighten the bolts in numerical order as shown in the figure below. (specified torque)

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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1. Install timing chain tensioners (secondary) to cylinder head as follows if removed. Install timing chain tensioners (secondary) with a stopper pin attached and new O-ring.
2. Install No. 1 camshaft bracket. Refer to " «REMOVAL AND INSTALLATION»(ref-672620-S04251826952014112400000) ".
3. Measure difference in levels between front end faces of camshaft bracket (No. 1) and cylinder head. Standard: -0.14 to 0.14 mm (-0.0055 to 0.0055 in) Measure two positions (both intake and exhaust side) for a single bank. If the measured value is out of the standard, reinstall camshaft bracket (No. 1).
4. Install rear timing chain case as follows: Install new O-rings (1) onto cylinder block. CAUTION: Do not reuse O-rings. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as shown in the figure below. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". 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 with dowel pins (bank 1 and bank 2) on cylinder block and install rear timing chain case. Check O-rings stay in place during installation to cylinder block and cylinder head. Tighten mounting bolts in numerical order as shown in the figure below. There are two types of mounting bolts. 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 Torque: 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 below. If liquid gasket protrudes, wipe it off immediately. After installing rear timing chain case (1), 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.
5. Install water pump. Refer to " «REMOVAL AND INSTALLATION»(ref-672622-S36362390632014112400000) ".
6. Install oil pump. Refer to " «REMOVAL AND INSTALLATION»(ref-672629-S31989881232014112400000) ".
7. Check that dowel pin (A) and crankshaft key (1) are located as shown in the figure below. (No. 1 cylinder at compression TDC) NOTE: Though camshaft does not stop at the position as shown in the figure below, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure. Camshaft dowel pin: At cylinder head upper face side in each bank Crankshaft key: At cylinder head side of bank 1 CAUTION: Hole on small dia. side must be used for intake side dowel pin hole. Never misidentify (ignore big dia. side).
8. 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 (A). Install timing chain (secondary) (1) and camshaft sprockets (INT and EXH). NOTE: Figure shows bank 1 (rear view). Align the mating marks on timing chain (secondary) (orange 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 bank 1 and bank 2, respectively. Bank 1: Use circle type. Bank 2: Use oval type. Align dowel pin on camshafts with the groove or hole on sprockets, and install them. On the intake side, align dowel pin on the camshaft front end with dowel pin hole on the back side of camshaft sprocket, and install them. On the exhaust side, align dowel pin on camshaft front end with dowel 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 (A) 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 (B) out from timing chain tensioners (secondary) (1).
9. Install tension guide.
10. Install timing chain (primary) as follows: Install crankshaft sprocket (1). Check 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) (B) on camshaft sprocket (INT) (1) is aligned with the pink link (A) on timing chain, while the mating mark (notched) (C) on crankshaft sprocket (2) is aligned with the orange link (D) on timing chain, as shown in the figure below. 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).
11. Install internal chain guide (1) and slack guide (2). CAUTION: Never over tighten slack guide mounting bolt (2). It is normal for a gap (A) to exist under the bolt seat when mounting bolt is tightened to specification.
12. Install the timing chain tensioner (primary) with the following procedure: Pull plunger stopper tab (A) up (or turn lever downward) so as to remove plunger stopper tab from the ratchet of plunger (D). NOTE: Plunger stopper tab and lever (C) are synchronized. Push plunger into the inside of tensioner body. Hold plunger in the fully compressed position by engaging plunger stopper tab with the tip of ratchet. To secure lever, insert stopper pin (E) through hole of lever into tensioner body hole (B). The lever parts and the tab are synchronized. Therefore, the plunger will be secured under this condition. NOTE: Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin. Install timing chain tensioner (primary) (1). Remove any dirt and foreign materials completely from the back and the mounting surfaces of timing chain tensioner (primary). Pull out stopper pin (A) after installing, and then release plunger.
13. Check again that the mating marks on each sprocket and each timing chain have not slipped out of alignment.
14. Install new O-rings (1) on rear timing chain case. CAUTION: Do not reuse O-rings.
15. 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 below. 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. Check the garter spring is in position and seal lip is not inverted.
16. Install front timing chain case as follows: Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to front timing chain case back side as shown in the figure below. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ". 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 below. There are two types of mounting bolt. Refer to the following for locating bolts. M8 bolts: 1, 2 Torque: 28.4 N.m (2.9 kg-m, 21 ft-lb) M6 bolts: Except the above Torque: 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 below. 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.
17. Install water pump cover to front timing chain case. Apply a continuous bead of liquid gasket with the tube presser (commercial service tool) to water pump cover (1) as shown in the figure below. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ".
18. Install intake camshaft sprocket covers as follows: Install new seal rings in shaft grooves. Install camshaft sprocket cover to timing chain case (front). CAUTION: To insert, align shaft and the shaft hole center of cam sprocket on the intake side. Securely install seal ring to each shaft groove. Being careful not to move seal rings from the installation grooves, align dowel pins on front timing chain case with the holes to install camshaft sprocket covers. Tighten mounting bolts in numerical order as shown in the figure below.
19. Install oil pan (upper and lower) Refer to " «EXPLODED VIEW»(ref-672620-S21429898042014112400000) "
20. Install crankshaft pulley as follows: Install crankshaft pulley, taking care not to damage front oil seal. CAUTION: When press-fitting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). Fix crankshaft with the pulley holder (commercial service tool). Tighten crankshaft pulley bolt. Torque: 44.1 N.m (4.5 kg-m, 33 ft-lb) Place a paint mark (A) on crankshaft pulley (1) aligning with the angle mark (B) on crankshaft pulley bolt (2). Tighten the bolt 90 degrees (angle tightening).
21. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
22. Install in the reverse order of removal after this step.

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Scheme 156

1. Install timing chain tensioners (secondary) (1) on both sides of cylinder head. Install timing chain tensioner (secondary) with its stopper pin (C) attached. Install timing chain tensioner (secondary) with sliding part facing downward on cylinder head (bank 1), and with sliding part facing upward on cylinder head (bank 2).
2. Install valve lifters. Install it in the original position.
3. Install camshafts. Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction. Bank INT/EXH Dowel pin (1) Paint marks M1 (D) M2 (E) M3 (C) 1 EXH (B) Yes No Light blue Light blue INT (A) Yes Pink No Light blue 2 INT (A) Yes Pink No Light blue EXH (B) Yes No Light blue Light blue Install camshaft so dowel pin (A) on front end face are positioned as shown in the figure below. (No. 1 cylinder TDC on its compression stroke) NOTE: Though camshaft does not stop at the portion as shown in the figure below, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
4. Install camshaft brackets. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft bracket in original position and direction as shown in the figure below. Install camshaft brackets (No. 2 to 4) aligning the stamp marks (A) as shown in the figure below. NOTE: There are no identification marks indicating left and right for camshaft bracket (No. 1). Apply liquid gasket to mating surface of camshaft bracket (No. 1) as shown on bank 1 and bank 2 in the figure below. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-672611-S40047121162014112400000) ".
5. Tighten camshaft bracket bolts in the following steps, in numerical order as shown in the figure below. CAUTION: Do not reuse washers. Tighten No. 7 to 10 in order as shown below. Torque: 1.96 N.m (0.20 kg-m, 1 ft-lb) Tighten No. 1 to 6 in order as shown below. Torque: 1.96 N.m (0.20 kg-m, 1 ft-lb) Tighten No. 1 to 10 in numerical order as shown below. Torque: 5.88 N.m (0.60 kg-m, 4 ft-lb) Tighten No. 1 to 10 in numerical order as shown below. Torque: 10.4 N.m (1.1 kg-m, 8 ft-lb) CAUTION: After tightening mounting bolts of camshaft brackets (No. 1), be sure to wipe off excessive liquid gasket from the parts list below. Mating surface of rocker cover Mating surface of rear timing chain case
6. Tighten camshaft sensor bracket bolts in numerical order as shown in the figure below. NOTE: The order of tightening bolts in the same for bank 1 and bank 2.
7. Inspect and adjust the valve clearance. Refer to " «INSPECTION AND ADJUSTMENT»(ref-672620-S29410035842014112400000) ".
8. Install in the reverse order of removal after this step.

Scheme 157

1. Put V-block on precise flat table, and support No. 2 and 4 journals of camshaft. CAUTION: Never support No. 1 journal (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 a dial indicator. (Total indicator reading) Standard and limit: Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ". If it exceeds the limit, replace camshaft.

Scheme 158

1. Measure the camshaft cam height with a micrometer. Standard cam height (Intake and exhaust): Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) " Cam wear limit: Refer to " «CAMSHAFT»(ref-672620-S10622127142014112400000) ".
2. If wear exceeds the limit, replace camshaft.