Engine Mechanical: Removal & Installation Nissan Rogue I

FOR USA AND CANADA : 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. Cover openings of engine system with a tape or 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.

FOR USA AND CANADA : 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.

FOR MEXICO : 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. Cover openings of engine system with a tape or 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.

FOR MEXICO : 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 OF LIQUID GASKET SEALING

1. After removing mounting nuts and bolts, separate the mating surface using the seal cutter (SST) and remove old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces.
2. Tap the seal cutter to insert it (1), and then slide it (2) by tapping on the side as shown in the figure.
3. In areas where the seal cutter (SST) is difficult to use, use a plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason tool such as a screwdriver is used, be careful not to damage the mating surfaces.

INSTALLATION

Installation is the reverse order of removal.

Scheme 92

Refer to REMOVAL AND INSTALLATION .

Scheme 93

1. Remove ignition coil. Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S26597207762008081400000) ".
2. Remove spark plug with spark plug wrench (commercial service tool). CAUTION: Never drop or shock spark plug.

Removal

Scheme 94

1. Remove front wheel and tire (RH).
2. Remove front fender protector (RH).
3. Remove drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S15202389272008081400000) ".
4. Support the bottom surface of engine using a transmission jack, and loosen engine mounting insulator bolts (RH). Refer to " «EXPLODED VIEW»(ref-295108-S31450719252008081400000) ". CAUTION: Never remove the bolts (No. 4, 5) as shown in the figure.
5. Remove idler pulley.
6. Release the fixed drive belt auto-tensioner pulley.
7. Remove drive belt auto-tensioner. CAUTION: Never loosen the hexagonal part in center of drive belt auto-tensioner pulley (Never turn it counterclockwise). If turned counterclockwise, the complete drive belt auto-tensioner must be replaced as a unit, including the pulley.

Installation

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

Scheme 95

Scheme 96

1. Remove air duct (inlet).
2. Remove battery. Refer to " «EXPLODED VIEW»(ref-295086-S39554998382008081400000) ".
3. Disconnect harness connectors (A) and then remove bracket (1).
4. Disconnect mass air flow sensor harness connector.
5. Disconnect fresh air hose.
6. Remove air cleaner case and mass air flow sensor assembly, air duct and resonator assembly and air duct disconnecting their joints. Add marks as necessary for easier installation.
7. Remove mass air flow sensor from air cleaner case, if necessary. CAUTION: Handle mass air flow sensor with the following cares. Never shock mass air flow sensor. Never disassemble mass air flow sensor. Never touch its sensor.

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

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

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

Intake Manifold

1. If stud bolts were removed, install them and tighten to the specified torque below. : 9.4 N.m (0.96 kg-m, 83 in-lb)
2. Tighten in numerical order as shown in the figure. NOTE: No. 6 means double tightening of bolt No. 1.

Electric Throttle Control Actuator

1. Tighten mounting bolts equally and diagonally in several steps and in numerical order as shown in the figure.
2. Perform the "Throttle Valve Closed Position Learning" when harness connector of electric throttle control actuator is disconnected. Refer to " «THROTTLE VALVE CLOSED POSITION LEARNING : DESCRIPTION»(ref-295106-S40302339052008081400000) ".
3. Perform the "Idle Air Volume Learning" and "Throttle Valve Closed Position Learning" when electric throttle control actuator is replaced. Refer to " «IDLE AIR VOLUME LEARNING : DESCRIPTION»(ref-295106-S10113910242008081400000) " and " «THROTTLE VALVE CLOSED POSITION LEARNING : DESCRIPTION»(ref-295106-S40302339052008081400000) ".

Scheme 97

Scheme 98

1. Drain engine oil. Refer to " «DRAINING»(ref-295124-S40915947592008081400000) ".
2. Remove oil pan (lower) with the following procedure: Loosen mounting bolts in reverse order as shown in the figure. Insert seal cutter (SST) between oil pan (upper) and oil pan (lower). CAUTION: Be careful not to damage the mating surface.

Scheme 99

Scheme 100

1. Install oil pan (lower) with the following procedure: Use a scraper to remove old liquid gasket from mating surfaces. Also remove old liquid gasket from mating surface of oil pan (upper). Remove old liquid gasket from the bolt holes and threads. CAUTION: Never scratch or damage the mating surface when cleaning off liquid gasket. Apply a continuous bead of liquid gasket with a tube presser (commercial service tool) as shown in the see scheme 4.0 - 5.0 mm (0.157 - 0.197 in) Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: Attaching should be done within 5 minutes after liquid gasket application. Tighten bolts in numerical order as shown in the figure.
2. Install oil pan drain plug. Refer to the figure of components of former page for installation direction of washer. Refer to " «EXPLODED VIEW»(ref-295108-S28845643232008081400000) ".
3. Install in the reverse order of removal after this step. NOTE: Pour engine oil at least 30 minutes after oil pan is installed.

Scheme 101

1. Remove undercover.
2. Drain engine oil. Refer to " «DRAINING»(ref-295124-S40915947592008081400000) ".
3. Remove oil pan (lower). Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S37346946262008081400000) ".
4. Remove oil level gauge and guide.
5. Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to " «EXPLODED VIEW»(ref-295099-S26986491412008081400000) ".
6. Disconnect steering outer sockets from steering knuckle. Refer to " «EXPLODED VIEW»(ref-295099-S26986491412008081400000) ".
7. Remove rear torque rod. Refer to " «EXPLODED VIEW»(ref-295108-S31450719252008081400000) ".
8. Remove stabilizer connecting rod. Refer to " «EXPLODED VIEW»(ref-295125-S34345650292008081400000) ".
9. Remove front suspension member. Refer to " «EXPLODED VIEW»(ref-295125-S20780960282008081400000) ".
10. Remove A/C compressor without disconnecting A/C piping, and temporarily fasten it on vehicle with a rope. Refer to " «EXPLODED VIEW»(ref-295091-S27345162032008081400000) ".
11. Remove oil strainer.
12. Remove oil pan (upper) with the following procedure: Loosen bolts in reverse order as shown in the figure. Insert seal cutter (SST) between oil pan (upper) and lower cylinder block, and slide it by tapping on the side of the tool with a hammer. CAUTION: Be careful not to damage the mating surface.
13. Remove O-rings at front cover side.

Scheme 102

Scheme 103

1. Install oil pan (upper) with the following procedure: Use a scraper to remove old liquid gasket from mating surfaces. Also remove the old liquid gasket from mating surface of cylinder block. Remove old liquid gasket from the bolt holes and threads. CAUTION: Never scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket with a tube presser (commercial service tool) as shown in the see scheme 4.0 - 5.0 mm (0.157 - 0.197 in) Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: For bolt holes with marks (3 locations), apply liquid gasket out side the holes. Attaching should be done within 5 minutes after liquid gasket application. Install new O-rings at front cover side. CAUTION: Install avoiding misalignment of O-rings. Tighten bolts in numerical order as shown in the figure. NOTE: Refer to the following for locating bolts. M6 x 20 mm (0.79 in): No. 16, 17 M8 x 25 mm (0.98 in): No. 4, 6, 11, 13, 14, 15 M8 x 60 mm (2.36 in): No. 7, 8, 9, 10 M8 x 100 mm (3.94 in): No. 1, 2, 3, 5, 12 Tightening torque: Refer to " «EXPLODED VIEW»(ref-295108-S33070393622008081400000) ".
2. Install oil strainer.
3. Install front suspension member. Refer to " «EXPLODED VIEW»(ref-295125-S20780960282008081400000) ".
4. Install oil pan (lower). Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S37346946262008081400000) ".
5. Install oil pan drain plug. Refer to the figure of components of former page for installation direction of washer. Refer to " «EXPLODED VIEW»(ref-295108-S33070393622008081400000) ".
6. Install in the reverse order of removal after this step. NOTE: Pour engine oil at least 30 minutes after oil pan is installed.

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

1. Release fuel pressure. Refer to " «INSPECTION»(ref-295105-S04323263622008081400000) ".
2. Remove air cleaner case, mass air flow sensor and air duct assembly. Refer to " «EXPLODED VIEW»(ref-295108-S07007942622008081400000) ".
3. Disconnect quick connector (A) with the following procedure: CAUTION: Disconnect quick connector by using quick connector release, not by picking out retainer tabs. Remove quick connector cap. With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube. Insert 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 fuel tube. CAUTION: Pull quick connector holding "A" position in the figure. Never pull with lateral force applied. O-ring inside quick connector may be damaged. Prepare container and cloth beforehand as fuel will leak 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 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.
4. Remove intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S11821435882008081400000) ".
5. Disconnect sub-harness for fuel injector.
6. Remove fuel tube and fuel injector assembly. Loosen mounting bolts in reverse order as shown in the figure. CAUTION: When removing, be careful to avoid any interference with fuel injector. Use a shop cloth to absorb any fuel leaks from fuel tube.
7. Remove fuel injector from fuel tube with the following procedure: Open and remove clip (1). Remove fuel injector (2) from fuel tube (3) by pulling straight. CAUTION: Be careful with remaining fuel that may go out from fuel tube. Be careful not to damage fuel injector nozzle during removal. Never bump or drop fuel injector. Never disassemble fuel injector.

Scheme 110

Scheme 111

1. Note the following, and install O-rings to fuel injector. CAUTION: Upper and lower O-rings are different. Be careful not to confuse them. Except for California: Fuel tube side : Blue Nozzle side : Brown For California: 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 tube. Never decenter or twist it.
2. Install fuel injector to fuel tube with the following procedure: Except for California: 2 : O-ring (Blue) 4 : O-ring (Brown) For California: 2 : O-ring (Black) 4 : O-ring (Green) 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 a 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 (A) of fuel tube (1) 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 making sure that fuel injector does not rotate or come off.
3. Install fuel tube and fuel injector assembly with the following procedure: Insert the tip of each fuel injector into intake manifold adapter. Tighten mounting bolts in numerical order as shown in the figure.
4. Connect sub-harness for fuel injector.
5. Install intake manifold. Refer to " «EXPLODED VIEW»(ref-295108-S01708762182008081400000) ".
6. Note the following, and connect quick connector to install fuel feed hose. Check the connection for foreign material and damage. Align center to insert quick connector straightly into fuel tube. NOTE: The figure shows engine side as an example. Insert fuel tube into quick connector until the top spool on fuel tube is inserted completely and the second level spool is positioned slightly below quick connector bottom end. CAUTION: Hold "A" position in the figure when inserting fuel tube into quick connector. Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector. Insert until you hear a "click" sound and actually feel the engagement. To avoid misidentification of engagement with a similar sound, be sure to perform the next step. Before clamping fuel feed hose with hose clamps, pull quick connector hard by hand holding "A" position. Check it is completely engaged (connected) so that it does not come out from fuel feed tube. Install quick connector cap to quick connector connection. Install so that the arrow mark on the side faces up. CAUTION: Check that quick connector and fuel tube are securely fit into quick connector cap installation groove. If quick connector cap cannot be installed smoothly, quick connector may have not been installed correctly. Check connection again.
7. Install fuel feed hose to hose clamp.
8. Install in the reverse order of removal after this step.

Note. This section describes removal/installation procedure of camshaft without removing front cover. If front cover is removed or installed, removal of camshaft bracket (No. 1) is easier before step 9 and installation is easier after step 4 . Regarding removal and installation of front cover, refer to " EXPLODED VIEW ".

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

1. Release fuel pressure. Refer to " «INSPECTION»(ref-295105-S04323263622008081400000) ".
2. Remove the following parts. Intake manifold: Refer to " «EXPLODED VIEW»(ref-295108-S01708762182008081400000) ". Rocker cover: Refer to " «REMOVAL AND INSTALLATION»(ref-295108-S26597207762008081400000) ".
3. Remove camshaft position sensor (PHASE). CAUTION: Handle carefully to avoid dropping and shocks. Never disassemble. Never allow metal powder to adhere to magnetic part at sensor tip. Never place sensor in a location where it is exposed to magnetism.
4. Remove camshaft position sensor bracket. Loosen mounting bolts in reverse order as shown in the figure.
5. Remove intake valve timing control cover with the following procedure: Disconnect intake valve timing control solenoid valve harness connector. Remove intake valve timing control solenoid valve, if necessary. Loosen bolts in reverse order as shown in the figure. Use a seal cutter [SST: KV10111100 (J37228)] or equivalent tool to cut liquid gasket for removal.
6. Pull chain guide between camshaft sprockets out through front cover.
7. Set No. 1 cylinder at TDC on its compression stroke with the following procedure: Open splash guard on RH undercover. Rotate crankshaft pulley clockwise and align TDC mark to timing indicator on front cover. At the same time, check that the mating marks on camshaft sprockets are located as shown in the figure. If not, rotate crankshaft pulley one more turn to align mating marks to the positions in the figure.
8. Remove camshaft sprockets with the following procedure: Line up the mating marks on camshaft sprockets, and paint indelible mating marks on timing chain link plate. Push in chain tensioner plunger. Insert a stopper pin into hole on chain tensioner body to secure chain tensioner plunger and remove chain tensioner. NOTE: Use approximately 0.5 mm (0.02 in) dia. hard metal pin as a stopper pin. Secure hexagonal part of camshaft with a wrench. Loosen camshaft sprocket mounting bolts and remove camshaft sprockets. CAUTION: Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. NOTE: Chain tension holding work is not necessary. Crankshaft sprocket and timing chain do not disconnect structurally while front cover is attached.
9. Loosen mounting bolts in reverse order as shown in the figure, and remove camshaft brackets and camshafts. Remove camshaft bracket (No. 1) by slightly tapping it with a plastic hammer.
10. Remove valve lifters. Identify installation positions, and store them without mixing them up.

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

1. Install valve lifters. Install them in the original positions.
2. Install camshafts. Distinction between intake and exhaust camshafts is performed with the different shapes of rear end. Camshaft (EXH) Camshaft (INT) Install camshafts so that camshaft dowel pins on the front side are positioned as shown in the figure.
3. Install camshaft brackets with the following procedure: Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown in the figure. NOTE: Install so that identification mark can be correctly read when viewed from the exhaust side. Install camshaft bracket (No. 1) with the following procedure: Apply liquid gasket to camshaft bracket (No. 1) as shown in the figure. Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part "A". Apply liquid gasket to camshaft bracket (No. 1) contact surface on the front cover backside. 1: Front cover a: 3.4 - 4.4 mm (0.134 - 0.173 in) Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". Apply liquid gasket to the outside of bolt hole on front cover. For camshaft bracket (No. 1) near installation position, and install it without disturbing the liquid gasket applied to the surfaces.
4. Tighten mounting bolts of camshaft brackets in the following steps, in numerical order as shown in the figure. Tighten No. 9 to 11 in numerical order.: 2.0 N.m (0.2 kg-m, 1 ft-lb) Tighten No. 1 to 8 in numerical order.: 2.0 N.m (0.2 kg-m, 1 ft-lb) Tighten all bolts in numerical order.: 5.9 N.m (0.6 kg-m, 4 ft-lb) Tighten all bolts in numerical order.: 10.4 N.m (1.1 kg-m, 8 ft-lb) CAUTION: After tightening mounting bolts of camshaft brackets, be sure to wipe off excessive liquid gasket from the parts listed below. Mating surface of rocker cover. Mating surface of front cover. (When installed without front cover)
5. Install camshaft sprockets. Install them by aligning the mating marks on each camshaft sprocket with the ones painted on timing chain link plate during removal. CAUTION: Aligned mating marks could slip. Therefore, after matching them, hold the timing chain in place by hand. Before and after installing chain tensioner, check again that mating marks have not slipped. NOTE: Before installation of chain tensioner, it is possible to re-match the marks on timing chain with the ones on each sprocket.
6. Install chain tensioner. CAUTION: After installation, pull the stopper pin off completely, and check that chain tensioner plunger is released.
7. Install chain guide.
8. Install intake valve timing control cover with the following procedure: Install intake valve timing control solenoid valve to intake valve timing control cover if removed. Install oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control cover. Install new O-ring to front cover. Apply liquid gasket with a tube presser (commercial service tool) to intake valve timing control cover as shown in the see scheme 3.4 - 4.4 mm (0.134 - 0.173 in) Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: Attaching should be done within 5 minutes after liquid gasket application. Tighten mounting bolts in numerical order as shown in the figure.
9. Install camshaft position sensor bracket. Apply liquid gasket with a tube presser (commercial service tool) to camshaft position sensor bracket as shown in the see scheme 2.0 - 3.0 mm (0.079 - 0.118 in) 10.5 mm (0.413 in) Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: After installation, be sure to wipe off any excessive liquid gasket leaking from part "b". Attaching should be done within 5 minutes after liquid gasket application. Tighten mounting bolts in numerical order as shown in the figure.
10. Install camshaft position sensor (PHASE).
11. Inspect and adjust valve clearance. Refer to " «INSPECTION AND ADJUSTMENT»(ref-295108-S14194040302008081400000) ".
12. Install in the reverse order of removal after this step.

1. Remove transaxle assembly. Refer to " «2WD : EXPLODED VIEW»(ref-295118-S21358052582008081400000) " (2WD models) or " «AWD : EXPLODED VIEW»(ref-295118-S16673714632008081400000) " (AWD models).
2. Remove drive plate. Refer to " «EXPLODED VIEW»(ref-295108-S07286710592008081400000) ".
3. Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block.

Scheme 126

Scheme 127

1. Apply new engine oil to new rear oil seal joint surface and seal lip.
2. Install rear oil seal so that each seal lip is oriented as shown in the figure. Dust seal lip Oil seal lip Press in rear oil seal (1) to the position as shown in the figure. Rear end surface of cylinder block Press-fit rear oil seal with a suitable drift [outer diameter 102 mm (4.02 in), inner diameter 86 mm (3.39 in)]. CAUTION: Be careful not to damage crankshaft and cylinder block. Press-fit oil seal straight to avoid causing burrs or tilting. Never touch grease applied onto oil seal lip.
3. Install in the reverse order of removal after this step.

Scheme 128

Removal and Installation

Outline

Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle.

Preparation

1. Release fuel pressure. Refer to " «INSPECTION»(ref-295106-S38449173432008081400000) ".
2. Drain engine coolant from radiator. Refer to " «DRAINING»(ref-295111-S26518184832008081400000) ". CAUTION: Perform this step when the engine is cold. Never spill engine coolant on drive belt.
3. Remove the following parts. Air duct and air cleaner case assembly: Refer to " «EXPLODED VIEW»(ref-295108-S07007942622008081400000) ". Battery and battery tray: Refer to " «EXPLODED VIEW»(ref-295086-S39554998382008081400000) ". Engine undercover Radiator hose (upper and lower) and cooling fan assembly: Refer to " «EXPLODED VIEW»(ref-295111-S03513801902008081400000) ". Front road wheels and tires: Refer to " «ADJUSTMENT»(ref-295121-S04759428322008081400000) ". Front fender protector (RH and LH): Refer to " «EXPLODED VIEW»(ref-295102-S41180941832008081400000) ". Exhaust front tube: Refer to " «EXPLODED VIEW»(ref-295123-S20064475632008081400000) ".

Engine Room LH

1. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors using a resin bag against foreign materials during the operation.
2. Disconnect fuel feed hose at engine side. Refer to " «2WD : EXPLODED VIEW»(ref-295126-S06813066812008081400000) " [TYPE 1 (2WD models)], " «AWD : EXPLODED VIEW»(ref-295126-S01206926242008081400000) " [TYPE 1 (AWD models)] or " «EXPLODED VIEW»(ref-295126-S19102324542008081400000) " (TYPE 2).
3. Disconnect heater hoses. Refer to " «EXPLODED VIEW»(ref-295111-S04326926112008081400000) ".
4. Disconnect control cable from transaxle. Refer to " «EXPLODED VIEW»(ref-295118-S26156265452008081400000) ".
5. Remove ground cable at transaxle side.
6. Disconnect CVT fluid cooler hose. Refer to " «FLUID COOLER : EXPLODED VIEW»(ref-295118-S09179841802008081400000) ".

Engine Room RH

1. Remove alternator. Refer to " «EXPLODED VIEW»(ref-295109-S22590187712008081400000) ".
2. Disconnect vacuum hose from intake manifold. Refer to " «EXPLODED VIEW»(ref-295108-S01708762182008081400000) ".
3. Remove A/C compressor without disconnecting A/C piping, and temporarily fasten it on vehicle with a rope (with A/C models). Refer to " «EXPLODED VIEW»(ref-295091-S27345162032008081400000) ".

Vehicle inside

Disconnect steering lower joint at steering gear assembly side, and release steering lower shaft. Refer to " EXPLODED VIEW ".

Vehicle Underbody

1. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to " «REMOVAL AND INSTALLATION»(ref-295099-S07035929032008081400000) ".
2. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the vehicle side with a rope to avoid load on it. Refer to " «BRAKE CALIPER ASSEMBLY : EXPLODED VIEW»(ref-295127-S35270806472008081400000) ".
3. Disconnect steering outer sockets from steering knuckle. Refer to " «EXPLODED VIEW»(ref-295099-S26986491412008081400000) ".
4. Remove transverse link from steering knuckle. Refer to " «EXPLODED VIEW»(ref-295125-S21111396202008081400000) ".
5. Remove drive shafts (LH and RH). Refer to " «EXPLODED VIEW»(ref-295128-S04618667002008081400000) " (2WD models) or " «EXPLODED VIEW»(ref-295128-S00326362762008081400000) " (AWD models).
6. Remove propeller shaft. Refer to " «EXPLODED VIEW»(ref-295114-S06929156152008081400000) " (AWD models).
7. Remove stabilizer connecting rod. Refer to " «EXPLODED VIEW»(ref-295125-S34345650292008081400000) ".
8. Remove rear torque rod.
9. Remove front suspension member. Refer to " «EXPLODED VIEW»(ref-295125-S02850402912008081400000) ".
10. Preparation for the separation work of transaxle is as follows: Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to " «EXPLODED VIEW»(ref-295108-S33070393622008081400000) ".

Removal

Scheme 129

Scheme 130

1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle assembly. CAUTION: Put a piece of wood or an equivalent as the supporting surface, secure a completely stable condition.
2. Remove upper torque rod.
3. Remove engine mounting insulator bolts (RH). Loosen the mounting bolts in the reverse order as shown in the figure.
4. Remove engine mounting insulator bolts (LH). Loosen the mounting bolts in the reverse order as shown in the figure.
5. Carefully lower jack, or raise lift to remove the engine and the transaxle assembly. When performing work, observe the following caution. CAUTION: Check that no part interferes with the vehicle side. Before and during this lifting, always check if any harnesses are left connected. During the removal, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. If necessary, support the vehicle by setting jack or suitable tool at the rear.

Separation

Scheme 131

1. Install engine slingers into front left of cylinder head and rear right of cylinder head. Use alternator bracket mounting bolt holes for the front side. Slinger bolts Cylinder head side (A): : 28.0 N.m (2.9 kg-m, 21 ft-lb) Front cover side (B): : 45.0 N.m (4.6 kg-m, 33 ft-lb)
2. Remove starter motor. Refer to " «2WD : EXPLODED VIEW»(ref-295129-S41044118552008081400000) " (2WD models) or " «AWD : EXPLODED VIEW»(ref-295129-S14470626522008081400000) " (AWD models).
3. Lift with a hoist and separate the engine from the transaxle assembly. Refer to " «2WD : EXPLODED VIEW»(ref-295118-S21358052582008081400000) " (2WD models) or " «AWD : EXPLODED VIEW»(ref-295118-S16673714632008081400000) " (AWD models).

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

Preparation

Scheme 132

1. Install the engine mounting insulator (RH) to the body temporarily.
2. Install the upper torque rod to the body side bracket temporarily.
3. Install the engine mounting stay (LH) to the body and tighten. (specified torque)
4. Install the engine mounting insulator (LH) to the body as follows: Tighten the bolt No. 1 as shown in the figure. (temporarily) Tighten the bolts No. 2, 3, 4 in numerical order as shown in the figure. (specified torque) Tighten the bolts No. 5, 6, 7 in numerical order as shown in the figure. (specified torque) Tighten the bolt No. 1 as shown in the figure. (specified torque) Tighten the nut No. 8 as shown in the figure. (specified torque)
5. Install the rear bracket to the transaxle and tighten. (specified torque)

Installation

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

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

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

1. Check that crankshaft key points straight up.
2. Tighten mounting bolts in numerical order as shown in figure with the following procedure, and install balancer unit. CAUTION: If mounting bolts are re-used, check their outer diameter before installation. Refer to " «INSPECTION»(ref-295108-S35949980402008081400000) ". Apply new engine oil to threads and seat surfaces of mounting bolts. Tighten No. 1 to 5 bolts.: 42.0 N.m (4.3 kg-m, 31 ft-lb) Tighten No. 6 bolt.: 36.0 N.m (3.7 kg-m, 27 ft-lb) Turn No. 1 to 5 bolts 120 degrees clockwise (angle tightening). CAUTION: Use the angle wrench [SST: KV10112100 (BT8653-A)] (A) to check tightening angle. Never make judgment by visual inspection. Turn No. 6 bolt 90 degrees clockwise (angle tightening). Completely loosen all bolts.: 0 N.m (0 kg-m, 0 ft-lb) CAUTION: In this step, loosen bolts in reverse order as shown in the figure. Repeat step b to e.
3. Install crankshaft sprocket and balancer unit timing chain. Check that crankshaft sprocket is positioned with mating marks on cylinder block and crankshaft sprocket meeting at the top. Install it by aligning mating marks on each sprocket and balancer unit timing chain.
4. Install balancer unit timing chain tensioner. Be careful not to let mating marks of each sprocket and timing chain slip. After installation, check the mating marks have not slipped, then remove stopper pin and release tensioner sleeve.
5. Install timing chain and related parts. Install by aligning mating marks on each sprocket and timing chain. Before and after installing chain tensioner, check again to check that mating marks have not slipped. After installing chain tensioner, remove stopper pin, and check that tensioner moves freely. CAUTION: For the following note, after the mating marks are aligned, keep them aligned by holding them with a hand. To avoid skipped teeth, never rotate crankshaft and camshaft until front cover is installed. NOTE: Before installing chain tensioner, it is possible to change the position of mating mark on timing chain for that on each sprocket for alignment.
6. Install front oil seal to front cover. Refer to " «FRONT OIL SEAL: Removal and Installation»(ref-295108-S10183517872008081400000) ".
7. Install front cover with the following procedure: Install O-rings to cylinder head and cylinder block. Apply a continuous bead of liquid gasket with a tube presser (commercial service tool) to front cover as shown in the figure. G: Dowel pin hole 35.7 mm (1.406 in) 4.8 - 5.8 mm (0.189 - 0.228 in) 3.4 - 4.4 mm (0.134 - 0.173 in) 179.6 mm (7.07 in) 35.5 mm (1.398 in) 31.3 mm (1.232 in) Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: For bolt holes with marks (5 locations), apply liquid gasket out side the holes. Attaching should be done within 5 minutes after coating. NOTE: Application instruction differs depending on the position. Check that mating marks of timing chain and each sprocket are still aligned. Then install front cover. CAUTION: Be careful not to damage front oil seal by interference with front end of crankshaft. Tighten mounting bolts in numerical order as shown in the figure. After all bolts are tightened, retighten them to specified torque in numerical order as shown in the figure. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface for fitting oil pan. Tightening torque M10 bolt: 49.0 N.m (5.0 kg-m, 36 ft-lb) M6 bolt: 12.8 N.m (1.3 kg-m, 9 ft-lb)
8. Install chain guide between camshaft sprockets.
9. Install intake valve timing control cover with the following procedure: Install intake valve timing control solenoid valves to intake valve timing control cover if removed. Install new oil rings to the camshaft sprocket (INT) insertion points on backside of intake valve timing control cover. Install new O-ring to front cover. Apply a continuous bead of liquid gasket with a tube presser (commercial service tool) to intake valve timing control cover as shown in the see scheme 3.4 - 4.4 mm (0.134 - 0.173 in) Use Genuine RTV Silicone Sealant or equivalent Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-295085-S25948978912008081400000) ". CAUTION: Attaching should be done within 5 minutes after liquid gasket application. Tighten mounting bolts in numerical order as shown in the figure.
10. Insert crankshaft pulley by aligning with crankshaft key. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). CAUTION: Install protecting front oil seal lip section from any damage.
11. Tighten crankshaft pulley bolt. Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley bolt. Perform angle tightening with the following procedure: Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. Tighten crankshaft pulley bolt.: 42.1 N.m (4.3 kg-m, 31 ft-lb) Put a paint mark on crankshaft pulley, mating with any one of six easy to recognize angle marks on bolt flange. Turn another 60 degrees clockwise (angle tightening). Check the tightening angle with movement of one angle mark.
12. Install all removed parts in the reverse order of removal.