Engine Mechanical: Removal & Installation Nissan Versa I

Precautions for Removal and Disassembly

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

Precautions for Assembly and Installation

1. Use torque wrench to tighten bolts or nuts to Specifications.
2. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified.
3. Replace with new gasket, packing, oil seal or O-ring.
4. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage.
5. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well.
6. Release air within route after draining coolant.
7. Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections.
8. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage.

INSTALLATION

1. Hold the hexagonal part (A) of drive belt auto-tensioner (1) with a box wrench securely. Then move the wrench handle in the direction of arrow (loosening direction of tensioner). CAUTION: Never place hand in a location where pinching may occur if the holding tool accidentally comes off.
2. Insert a rod such as short-length screwdriver approximately 6 mm (0.24 in) in diameter into the hole (B) of retaining boss to fix drive belt auto-tensioner.
3. Install drive belt. CAUTION: Confirm drive belt is completely set to pulleys. Check for engine oil, working fluid and engine coolant are not adhered to 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 (notch on fixed side) is within the possible use range. Refer to " «CHECKING DRIVE BELTS»(ref-337614-S30978727972009080600000) ".

Scheme 52

REMOVAL

1. Remove drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-337614-S23052367982009080600000) ".
2. Release the fixed drive belt auto-tensioner pulley.
3. Loosen bolt and remove drive belt auto-tensioner. NOTE: Use TORX socket (size T50).
4. Remove idler pulley and bracket (models without A/C).

Installation is the reverse order of removal.

Scheme 53

1. Remove the air duct (inlet).
2. Remove the air cleaner filter from the air cleaner case. Refer to " «CHANGING AIR CLEANER FILTER»(ref-337614-S17587232192009080600000) ".
3. Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case.
4. Remove the PCV hose.
5. Remove the air duct (between air cleaner case and electronic throttle control actuator). Add marks as necessary for easier installation.
6. Remove air cleaner case with the following procedure. Remove battery. Refer to " «BATTERY»(ref-319467-S12713775672009062600000) ". Disconnect harness connector from mass air flow sensor. Remove the air cleaner case.
7. Remove the mass air flow sensor from the air cleaner case, if necessary. CAUTION: Handle it carefully and avoid impacts. Do not touch sensor part.

Installation is in the reverse order of removal.

1. Align marks.
2. Attach each joint securely.
3. Screw clamps firmly.

Scheme 54

Scheme 55

1. Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B).
2. Pull up the air cleaner cover forward (C) and remove it.
3. Remove the air cleaner filter (1) and holder (2) assembly from the air cleaner case.
4. Remove the air cleaner filter from the holder.

Installation is in the reverse order of removal.

Scheme 56

1. Install the air cleaner cover (1) in the direction shown.
2. Air cleaner filter (2)
3. Holder (3)

Scheme 57

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Scheme 60

1. Remove engine cover (1).
2. Drain engine coolant. Refer to " «DRAINING ENGINE COOLANT»(ref-337624-S40553162252009080600000) ". CAUTION: Perform this step when engine is cold. NOTE: This step is unnecessary when putting plugs to water hoses (to electronic throttle control actuator) Disconnect water hoses from electronic throttle control actuator. Remove electronic throttle control actuator. CAUTION: Handle carefully to avoid any shock to electronic throttle control actuator. Never disassemble.
3. Remove oil level gauge. CAUTION: Cover the oil level gauge guide openings to avoid entry of foreign materials.
4. Loosen and remove intake manifold (1) bolts (A) (B). <-- : Engine front
5. Loosen bolts in reverse order as shown. <-- : Engine front CAUTION: Cover engine openings to avoid entry of foreign materials.
6. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary. CAUTION: Handle it carefully and avoid impacts.
7. Remove intake manifold.

Scheme 61

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Scheme 63

1. Install intake manifold. NOTE: Be sure the intake manifold gasket is seated correctly in groove of intake manifold.
2. Tighten bolts in numerical order as shown. <-- : Engine front
3. Tighten intake manifold bolt (A). Then tighten intake manifold bolt (B).
4. Install electronic throttle control actuator
5. Install water hoses (3), (5) to electronic throttle control actuator as shown.
6. Installation of the remaining components is in the reverse order of removal.

Scheme 64

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Scheme 67

1. Drain engine oil. Refer to " «ENGINE OIL»(ref-337626-S07834940802009080600000) ".
2. Remove engine and transaxle assembly. Refer to «ENGINE ASSEMBLY»(ref-337614-S05448959292009080600000) .
3. Remove oil filter using Tool. Tool number: KV10115801 ( - ) CAUTION: When removing, prepare a shop cloth to absorb any engine oil leakage or spillage.
4. Remove oil pan (lower) bolts in reverse order as shown.
5. After removing the bolts and nuts, separate the mating surface and remove the sealant using Tool. Tool number: KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surfaces.
6. Remove the following parts: Flywheel (M/T models) or drive plate (A/T or CVT models); Refer to " «CYLINDER BLOCK»(ref-337614-S10976037552009080600000) ". Front cover, timing chain, oil pump drive chain; Refer to " «TIMING CHAIN»(ref-337614-S34589023372009080600000) ".
7. Remove oil pump. Loosen bolts in reverse order as shown.
8. Remove oil pan (lower) bolts in reverse order as shown.
9. Insert a screwdriver shown by the arrow ( <-- ) and open up a crack between oil pan (upper) and cylinder block. CAUTION: A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
10. After removing the bolts, separate the mating surface and remove the sealant using Tool. Tool number: KV10111100 (J-37228) Slide (1) the Tool by tapping (2) its side with a hammer to remove the lower oil pan from the upper oil pan. CAUTION: Be careful not to damage the mating surfaces.
11. Remove O-ring between cylinder block and oil pan (upper).

1. Install rocker cover gasket to rocker cover.
2. Install rocker cover. Tighten bolts in two steps separately in numerical order as shown. 1st step: 1.96 N.m (0.20 kg-m, 17 in-lb) 2nd step: 8.33 N.m (0.85 kg-m, 73 in-lb) <= Engine front CAUTION: Check if rocker cover gasket is not dropped from the installation groove of rocker cover.
3. Install spark plug using suitable tool. Plug type: Iridium tipped Make: DENSO Part number: FXE20HR11 Gap (nominal): 1.1 mm (0.043 in) CAUTION: Never drop or shock it.
4. Install ignition coil. CAUTION: Handle it carefully and avoid impacts. Never disassemble.
5. Install intake manifold. Refer to " «INTAKE MANIFOLD»(ref-337614-S01782696042009080600000) ".

Scheme 68

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Scheme 73

1. Release the fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-319464-S13067058452009062600000) ".
2. Remove quick connector cap (1) from quick connector connection.
3. Disconnect fuel feed hose from hose clamp. NOTE: There is no fuel return path.
4. With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube.
5. 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.
6. Draw and pull out quick connector straight from fuel tube. CAUTION: Pull quick connector holding "A" position. 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 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.
7. Remove intake manifold. Refer to " «INTAKE MANIFOLD»(ref-337614-S01782696042009080600000) ".
8. Remove fuel tube. Loosen bolts in reverse order as shown.
9. Remove the fuel tube and fuel injector assembly. CAUTION: When removing, be careful to avoid any interference with fuel injector. Use a shop cloth to absorb any fuel leaks from fuel tube.
10. Remove fuel injector from fuel tube with the following procedure: 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 fuel injector nozzle during removal. Never bump or drop fuel injector. Never disassemble fuel injector.

Scheme 74

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. 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. 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, never insert it quickly into fuel tube. Insert O-ring straight into fuel tube. Never twist it.
2. Install fuel injector (4) to fuel tube (1) with the following procedure: Insert clip (2) into clip groove (F) on fuel injector. Insert clip so that protrusion (G) of fuel injector matches cutout (D) 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 (B) of fuel tube matches cut-out (C) of clip. Make sure that fuel tube flange (A) is securely fixed in flange fixing groove (E) on clip. Make sure that installation is complete by making sure that fuel injector does not rotate or come off.
3. Set fuel tube and fuel injector assembly at its position for installation on cylinder head. CAUTION: For installation, be careful not to interfere with fuel injector nozzle.
4. Tighten bolts in numerical order as shown.
5. Installation of the remaining components is in the reverse order of removal.

Scheme 75

Removal and Installation

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Scheme 85

1. Remove front RH wheel. Refer to " «ROAD WHEEL TIRE ASSEMBLY»(ref-319468-S26727440902009062600000) ".
2. Remove front fender protector (RH). Refer to " «FENDER PROTECTOR»(ref-337622-S32446512262009080600000) ".
3. Drain engine oil. Refer to " «ENGINE OIL»(ref-337626-S07834940802009080600000) ". NOTE: Perform this step when engine is cold.
4. Remove the following parts. Rocker cover: Refer to " «COMPONENTS»(ref-337614-S30203279342009080600000) ". Drive belt: Refer to " «COMPONENTS»(ref-337614-S08255717852009080600000) ". Water pump pulley: Refer to " «COMPONENTS»(ref-337624-S10907508622009080600000) ". Ground cable (between engine bracket (RH) and radiator core support)
5. Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and insulator (RH). Refer to " «ENGINE ASSEMBLY»(ref-337614-S05448959292009080600000) ".
6. Set No. 1 cylinder at TDC on its compression stroke with the following procedure: Rotate crankshaft pulley (1) clockwise and align TDC mark (no paint) (B) to timing indicator (A) on front cover. At the same time, make sure that the cam noses of the No.1 cylinder are located ( <-- ) as shown. If not, rotate crankshaft pulley one revolution (360 degrees) and align as shown.
7. Hold crankshaft pulley (1) using suitable tool (A) loosen crankshaft pulley bolt, and locate bolt seating surface at 10 mm (0.39 in) from its original position. CAUTION: Never remove the crankshaft pulley bolt as it will be used as a supporting point for the pulley puller.
8. Attach a pulley puller (A) in the M6 thread hole on crankshaft pulley (1), and remove crankshaft pulley. Tool number: KV11103000 ( - )
9. Remove oil pan (lower). Refer to " «OIL PAN»(ref-337614-S07878258822009080600000) ". NOTE: When crankshaft sprocket, oil pump sprocket and other related parts are not removed, this step is unnecessary.
10. Remove intake valve timing control solenoid valve.
11. Remove drive belt auto-tensioner.
12. Loosen bolts in reverse order as shown.
13. Cut liquid gasket by prying the position ( <-- ) shown, and then remove the front cover. CAUTION: Be careful not to damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
14. Remove front oil seal from front cover. Lift up front oil seal using a suitable tool. CAUTION: Be careful not to damage front cover.
15. Push in timing chain tensioner plunger.
16. Insert a stopper pin (A) into the body hole to retain the plunger in collapsed position. NOTE: Use approximately 1.5 mm (0.059 in) diameter hard metal pin as a stopper pin.
17. Remove timing chain tensioner (1).
18. Remove timing chain slack guide (2), timing chain tension guide (3) and timing chain (1). CAUTION: Never rotate each crankshaft and camshaft individually while timing chain is removed. It causes interference between valve and piston.
19. Press stopper tab (A) in the direction shown to push the timing chain slack guide (B) toward timing chain tensioner (for oil pump) (1). The slack guide (B) is released by pressing the stopper tab (A). As a result, the slack guide (B) can be moved.
20. Insert stopper pin (D) into tensioner body hole (C) to secure timing chain slack guide (B). NOTE: Use a hard metal pin with a diameter of approximately 1.2 mm (0.047 in) as a stopper pin.
21. Remove timing chain tensioner (for oil pump).
22. Hold the WAF part of oil pump shaft (A), and then loosen the oil pump sprocket bolt and remove them. CAUTION: Secure the oil pump shaft with the WAF part. Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
23. Remove crankshaft sprocket, oil pump sprocket and oil pump drive chain as a set.
24. Remove timing chain tension guide (front cover side) from front cover if necessary.

Scheme 86

1. Check timing chain and oil pump drive chain for cracks (A) and any excessive wear (B) at the roller links of timing chain.
2. Replace timing chain and/or oil pump drive chain if necessary.

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

Scheme 87

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Scheme 94

1. Make sure that crankshaft key points straight up. NOTE: *: There are two outer grooves in camshaft sprocket (INT). The wider one is a matching mark.
2. If the timing chain tension guide (front cover side) is removed, install it to the front cover. CAUTION: Check the joint condition by sound or feeling.
3. Install crankshaft sprocket (2), oil pump sprocket (3) and oil pump drive chain (1). Install it by aligning matching marks on each sprocket and oil pump drive chain. If these matching marks are not aligned, rotate the oil pump shaft slightly to correct the position. CAUTION: Check matching mark position of each sprocket after installing the oil pump drive chain.
4. Hold the WAF part of oil pump shaft (A), and then tighten the oil pump sprocket bolt. CAUTION: Secure the oil pump shaft with the WAF part. Never loosen the oil pump sprocket bolt by tightening the oil pump drive chain.
5. Install chain tensioner (for oil pump) (1). Fix the plunger at the most compressed position using a stopper pin (A), and then install it. Securely pull out ( <-- ) the stopper pin after installing the chain tensioner (for oil pump). Check matching mark position of oil pump drive chain and each sprocket again.
6. Align the matching marks of each sprocket with the matching marks of timing chain. NOTE: *: There are 2 outer grooves in camshaft sprocket (INT). The wider one is a matching mark. If these matching marks are not aligned, rotate the camshaft slightly by holding the hexagonal portion to correct the position. CAUTION: Check matching mark position of each sprocket and timing chain again after installing the timing chain.
7. Install the timing chain tension guide (3) and the timing chain slack guide (2).
8. Install timing chain tensioner (1). Fix the plunger at the most compressed position using a stopper pin (A), and then install it. Securely pull out the stopper pin after installing the timing chain tensioner.
9. Check matching mark position of timing chain and each sprocket again.
10. Apply new engine oil to new front oil seal joint surface.
11. Using a suitable tool install front oil seal so that each seal lip is oriented as shown. Press-fit front oil seal until it is flush with front end surface of front cover as shown below with a suitable tool. Within 0.3 mm (0.012 in) toward engine front Within 0.5 mm (0.020 in) toward engine rear CAUTION: Be careful not to damage front cover and crankshaft. Press-fit oil seal straight to avoid causing burrs or tilting. Never touch grease applied onto oil seal lip.
12. Install new O-ring to cylinder block. CAUTION: Be sure O-rings a aligned properly.
13. Apply the sealant without breaks to the specified location using Tool. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-337611-S41912038972009080600000) ". Tool number WS39930000 ( - )
14. Make sure that matching marks of timing chain and each sprocket are still aligned. CAUTION: Make sure O-ring on cylinder block is correctly installed. Be careful not to damage front oil seal by interference with front end of crankshaft.
15. Install front cover, and tighten bolts in numerical order as shown. CAUTION: Attaching should be done within 5 minutes after liquid gasket application. NOTE: Refer to the following for the installation position of bolts. M6 bolts: No. 1 M10 bolts: No. 6, 7, 10, 11, 14 M12 bolts: No. 2, 4, 8, 12 M8 bolts: Except the above
16. Tighten all bolts are in two stages to specified torque in numerical order as shown. CAUTION: Be sure to wipe off any excessive liquid gasket leaking.
17. Install crankshaft pulley. CAUTION: Never damage front oil seal lip section. If needed use a plastic hammer, tap on its center portion (not circumference) to seat crankshaft pulley.
18. Secure crankshaft pulley (1) using tool (A).
19. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt.
20. Tighten crankshaft pulley bolt in three steps. Step 1: 68.6 N.m (7.0 kg-m, 51 ft-lb) Step 2: 0 N.m (0 kg-m, 0 ft-lb) Step 3: 29.4 N.m (3.0 kg-m, 22 ft-lb)
21. Put a paint mark (B) on crankshaft pulley (2), matching with any one of six easy to recognize angle marks (A) on crankshaft pulley bolt (1) flange.
22. Turn another 60 degrees clockwise (angle tightening) using Tool. Check the tightening angle with movement of one angle mark. Tool number: KV10112100 (BT-8653-A)
23. Make sure that crankshaft rotates clockwise smoothly.
24. Installation of the remaining components is in the reverse order of removal.

Scheme 95

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Scheme 99

1. Release the fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-319464-S13067058452009062600000) ".
2. Disconnect negative battery cable. Refer to " «REMOVAL AND INSTALLATION»(ref-319467-S37376541412009062600000) ".
3. Remove front RH wheel. Refer to " «ROAD WHEEL TIRE ASSEMBLY»(ref-319468-S26727440902009062600000) ".
4. Remove front fender protector (RH). Refer to " «FENDER PROTECTOR»(ref-337622-S32446512262009080600000) ".
5. Drain engine coolant. Refer to " «ENGINE COOLANT»(ref-337624-S42844068652009080600000) ". NOTE: Perform this step when engine is cold.
6. Remove the following parts. Intake manifold; Refer to " «INTAKE MANIFOLD»(ref-337614-S01782696042009080600000) ". Rocker cover; Refer to " «IGNITION COIL, SPARK PLUG AND ROCKER COVER»(ref-337614-S21513790022009080600000) ". Fuel tube and fuel injector assembly; Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-337614-S23572676422009080600000) ". Front cover, timing chain and related parts; Refer to " «TIMING CHAIN»(ref-337614-S34589023372009080600000) ".
7. Remove camshaft position sensor (PHASE) from camshaft bracket. 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.
8. Put the matching mark (A) on the camshaft sprocket (INT) (2) and the camshaft bracket (1) as shown. NOTE: It prevents the knock pin of the camshaft (INT) from engaging with the incorrect pin hole when installing the camshaft sprocket (INT).
9. Remove camshaft sprockets (INT) (1) and (EXH) (2). Secure hexagonal part (A) of camshaft with a wrench. Loosen camshaft sprocket bolts and remove camshaft sprocket. CAUTION: Never rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. Never loosen the bolts with securing anything other than the camshaft hexagonal part or with tensioning the timing chain.
10. Loosen bolts in reverse order as shown.
11. Cut liquid gasket by prying the position ( <-- ) shown, and then remove the camshaft bracket. CAUTION: Be careful not to damage the mating surface. A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off the position not specified.
12. Remove camshafts.
13. Remove valve lifters. NOTE: Identify installed positions, and store them without mixing them up.

Scheme 100

1. Put V-block on a precise flat table, and support No. 2 and 5 journal of camshaft. CAUTION: Never support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations.
2. Set dial indicator (A) vertically to No. 3 journal.
3. Turn camshaft to one direction with hands, and measure the camshaft runout on dial indicator. (Total indicator reading) Standard: Less than 0.02 mm (0.0008 in). Limit: 0.05 mm (0.0020 in)
4. If it exceeds the limit, replace camshaft.

Scheme 101

1. Measure the camshaft cam height with a micrometer (A). Standard: Intake: 44.605 - 44.795 mm (1.7560 - 1.7635 in) Exhaust: 43.175 - 43.365 mm (1.6997 - 1.7072 in) Limit: Intake: 44.405 mm (1.7482 in) Exhaust: 42.975 mm (1.6919 in)
2. If it exceeds the limit, replace camshaft.

1. Remove the following parts. Front fender protector (RH); Refer to " «FENDER PROTECTOR»(ref-337622-S32446512262009080600000) ". Drive belt; Refer to " «COMPONENTS»(ref-337614-S08255717852009080600000) ". Crankshaft pulley; Refer to " «COMPONENTS»(ref-337614-S32754547322009080600000) ".
2. Remove front oil seal using a suitable tool. CAUTION: Be careful not to damage front cover and crankshaft.

Scheme 102

1. Apply new engine oil to new front oil seal joint surface and seal lip.
2. Install front oil seal so that each seal lip is oriented as shown in the figure. Install front oil seal (2) using a suitable tool with outer diameter 57 mm (2.24 in) and inner diameter 45 mm (1.77 in) (A) to the dimension as shown. CAUTION: Be careful not to damage front cover and crankshaft. Press-fit oil seal straight to avoid causing burrs or tilting. Do not touch grease applied on oil seal lip. Within 0.3 mm (0.012 in) toward engine front Within 0.5 mm (0.020 in) toward engine rear
3. Installation of the remaining components is in the reverse order of removal.

1. Remove transaxle assembly. Refer to " «TRANSAXLE ASSEMBLY»(ref-337627-S02741312692009080600000) " (M/T models), " «TRANSAXLE ASSEMBLY»(ref-337615-S12033858802009080600000) " (A/T models) or " «TRANSAXLE ASSEMBLY»(ref-337628-S38291791102009080600000) " (CVT models).
2. Remove clutch cover and clutch disk (M/T models). Refer to " «CLUTCH DISC, CLUTCH COVER AND FLYWHEEL»(ref-337629-S31955275502009080600000) ".
3. Remove drive plate (A/T or CVT models) or flywheel (M/T models). Refer to " «COMPONENTS»(ref-337614-S25782248812009080600000) ".
4. Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block.

Scheme 103

1. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-337611-S41912038972009080600000) ".
2. Install rear oil seal so that each seal lip is oriented as shown. Install rear oil seal with a suitable tool with an outer diameter 115 mm (4.53 in) and inner diameter 90 mm (3.54 in) (A). CAUTION: Be careful not to damage crankshaft and cylinder block. Press-fit oil seal straight to avoid causing burrs or tilting. Do not touch grease applied onto oil seal lip. Install rear oil seal (1) to the position as shown. NOTE: The standard surface of the dimension is the rear end surface of cylinder block.
3. Installation of the remaining components is in the reverse order of removal.

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1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-319464-S13067058452009062600000) ".
3. Disconnect fuel pump fuse (1) to avoid fuel injection during measurement.
4. Remove engine cover. Refer to " «COMPONENTS»(ref-337614-S39048302092009080600000) ".
5. Remove ignition coil and spark plug from each cylinder. Refer to " «IGNITION COIL, SPARK PLUG AND ROCKER COVER»(ref-337614-S21513790022009080600000) ".
6. Connect an engine tachometer (not required in use of CONSULT-III).
7. Install a suitable compression tester with an adapter onto spark plug hole. Use the adapter 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 the engine RPM. Perform these steps to check each cylinder. Compression pressure: COMPRESSION PRESSURE Specifications Unit: kPa (bar, kg/cm 2 psi)/RPM Standard Minimum Differential limit between cylinders 1,500 (15.0, 15.3, 217.6)/200 1,200 (12.0, 12.2, 174)/200 100 (1, 1, 15)/200 CAUTION: Always use a fully charged battery to obtain the specified engine speed. If the engine speed is out of the specified range, check battery liquid for proper gravity. Check 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 the compression pressure again. If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole of the 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 gasket is leaking. In such a case, replace cylinder head gasket.
9. After inspection is completed, install removed parts.
10. Start the engine, and confirm that the engine runs smoothly.
11. Perform trouble diagnosis. If DTC appears, erase it. Refer to " «TROUBLE DIAGNOSIS»(ref-319464-S13164045092009062600000) " .

Scheme 107

For A, go to INSTALLATION .

Scheme 108

1. Release the fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-319464-S13067058452009062600000) ".
2. Drain engine coolant and engine oil. Refer to " «ENGINE COOLANT»(ref-337624-S42844068652009080600000) " and " «ENGINE OIL»(ref-337626-S07834940802009080600000) ".
3. Remove front fender protector (RH). Refer to " «FENDER PROTECTOR»(ref-337622-S32446512262009080600000) ".
4. Remove drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-337614-S23052367982009080600000) ".
5. Remove the following components and related parts. Exhaust manifold; Refer to " «EXHAUST MANIFOLD»(ref-337614-S41603211252009080600000) ". Intake manifold; Refer to " «INTAKE MANIFOLD»(ref-337614-S01782696042009080600000) ". Fuel tube and fuel injector assembly; Refer to " «FUEL INJECTOR AND FUEL TUBE»(ref-337614-S23572676422009080600000) ". Water outlet; Refer to " «WATER OUTLET AND WATER CONTROL VALVE»(ref-337624-S23806719352009080600000) ". Rocker cover; Refer to " «IGNITION COIL, SPARK PLUG AND ROCKER COVER»(ref-337614-S21513790022009080600000) ". Front cover, timing chain; Refer to " «TIMING CHAIN»(ref-337614-S34589023372009080600000) ". Camshaft; Refer to " «CAMSHAFT»(ref-337614-S28421166032009080600000) ".
6. Remove cylinder head. Loosen bolts in reverse order as shown. Using TORX socket (size E18), loosen cylinder head bolts.
7. Remove cylinder head gasket.

Scheme 109

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 a new one. Limit ("d1" - "d2"): 0.15 mm (0.0059 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 110

Scheme 111

Scheme 112

Scheme 113

1. To remove valve guide, heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil (A).
2. Drive out valve guide using suitable tools. CAUTION: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
3. Ream cylinder head valve guide hole using suitable tool (A). Valve guide hole diameter (for service parts): : 9.675 - 9.696 mm (0.3809 - 0.3817 in)
4. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil (A).
5. Press valve guide (1) from camshaft side to dimensions as shown. Projection "H": 13.35 - 13.65 mm (0.526 - 0.537 in) CAUTION: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
6. Apply reamer finish to valve guide using suitable tool (A). Standard : 5.500 - 5.518 mm (0.2165 - 0.2172 in)

Scheme 114

1. After confirming that the dimensions of valve guides and valves are within 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.

VALVE SEAT REPLACEMENT

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

Scheme 115

Scheme 116

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-337614-S23541113492009080600000) ".
2. Ream cylinder head (1) recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)] Intake: 35.200 - 35.227 mm (1.3858 - 1.3869 in) Exhaust: 29.200 - 29.227 mm (1.1496 - 1.1507 in) Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly.
3. Heat cylinder head to 110° to 130°C (230° to 266°F) by soaking in heated oil (A).
4. Provide valve seats cooled well with dry ice. Press-fit valve seat into cylinder head. CAUTION: Never touch cold valve seats directly. Cylinder head contains heat, when working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set or valve seat grinder, finish valve seat to the specified dimensions. For dimensions, refer to " «VALVE SEAT»(ref-337614-S23541113492009080600000) ". CAUTION: When using valve seat cutter, firmly grip the 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 the 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-337614-S35945524152009080600000) ".

Scheme 117

1. Set try square along the side of valve spring and rotate the spring. Measure the maximum clearance between the top of valve spring and try square. CAUTION: Never remove valve spring seat from valve spring. Limit: 1.9 mm (0.075 in)
2. If it exceeds the limit, replace valve spring (with valve spring seat).

Scheme 118

1. Check valve spring pressure with valve spring seat installed at the specified spring height. CAUTION: Never remove valve spring seat from valve spring.

Standard

VALVE SPRING Specifications

1. If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring seat).

Scheme 119

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

Scheme 120

Scheme 121

Scheme 122

1. Remove engine undercover
2. Drain engine coolant from radiator. Refer to " «CHANGING ENGINE COOLANT»(ref-337624-S02375434402009080600000) ". CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belt.
3. Remove front fender protector (RH and LH); Refer to " «FENDER PROTECTOR»(ref-337622-S32446512262009080600000) ".
4. Remove exhaust front tube; Refer to " «EXHAUST SYSTEM»(ref-337625-S33815019452009080600000) ".
5. Remove drive shafts (LH and RH) from steering knuckle. Refer to " «FRONT DRIVE SHAFT»(ref-337630-S38746900872009080600000) ".
6. Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to " «TRANSAXLE ASSEMBLY»(ref-337615-S12033858802009080600000) " (A/T models), " «TRANSAXLE ASSEMBLY»(ref-337628-S38291791102009080600000) " (CVT) or " «TRANSAXLE ASSEMBLY»(ref-337627-S02741312692009080600000) " (M/T models).
7. Remove rear torque rod (1). NOTE: A/T model shown CVT and M/T models similar.
8. Remove hood assembly. Refer to " «HOOD»(ref-319465-S31515070792009062600000) " .
9. Remove cowl top cover and cowl top extension assembly. Refer to " «COWL TOP»(ref-337622-S01330544742009080600000) " .
10. Release fuel pressure. Refer to " «FUEL PRESSURE RELEASE»(ref-319464-S13067058452009062600000) " .
11. Remove battery and battery tray; Refer to " «BATTERY»(ref-319467-S12713775672009062600000) " .
12. Remove drive belt; Refer to " «COMPONENTS»(ref-337614-S08255717852009080600000) ".
13. Remove air duct and air cleaner case assembly; Refer to " «AIR CLEANER AND AIR DUCT»(ref-337614-S10865575882009080600000) ".
14. Remove cooling fan assembly.
15. Remove radiator hose (upper and lower). Refer to " «RADIATOR»(ref-337624-S35187671372009080600000) ".
16. Disconnect A/T, CVT fluid cooler hoses. Refer to " «RADIATOR»(ref-337624-S35187671372009080600000) ".
17. 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 to protect against foreign materials during the operation.
18. Disconnect fuel feed hose at engine side. Refer to " «COMPONENTS»(ref-337614-S39983622312009080600000) ".
19. Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to " «COMPONENTS»(ref-337624-S31265886092009080600000) ".
20. Disconnect control cable from transaxle. Refer to " «SHIFT CONTROL SYSTEM»(ref-337628-S41748345632009080600000) " (CVT) or " «SHIFT CONTROL SYSTEM»(ref-337615-S00061795292009080600000) " (A/T), " «CONTROL LINKAGE»(ref-337627-S26353431392009080600000) " (MT).
21. Remove ground cable at transaxle side.
22. Remove ground cable between front cover and vehicle.
23. Remove generator. Refer to " «CHARGING SYSTEM»(ref-319467-S19561322532009062600000) ".
24. Remove A/C compressor with piping connected from the engine. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to " «REMOVAL AND INSTALLATION OF COMPRESSOR»(ref-337616-S41931503632009080600000) ".
25. Remove the intake manifold to prevent the hanging chain from interfering. Refer to " «COMPONENTS»(ref-337614-S39048302092009080600000) ".
26. Install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine position with a hoist. Slinger bolts: 25.5 N.m (2.6 kg-m, 19 ft-lb)
27. Support engine and transaxle assembly with a hoist and secure the engine in appropriate position.
28. Use a manual lift table caddy (A) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle, and simultaneously adjust hoist tension. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
29. Remove torque rod (RH) (1), engine insulator (RH) (2) and engine bracket (RH) (3).
30. Remove engine through bolt-securing nut (C).
31. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating supporting tools. CAUTION: During the operation, make sure that no part interferes with the vehicle side. Before and during this lifting, always check if any harnesses are left connected. During the removal operation, 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. During operation, securely support the engine by placing a piece of wood under the engine oil pan and transaxle oil pan. Securely support the engine slingers with a hoist.
32. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left side and rear right side. Refer to " «COMPONENTS»(ref-337614-S20942156252009080600000) ".
33. Remove starter motor. Refer to " «STARTING SYSTEM»(ref-319467-S03391858252009062600000) ".
34. Lift with a hoist and position above engine.
35. Separate the engine and the transaxle. Refer to " «TRANSAXLE ASSEMBLY»(ref-337615-S12033858802009080600000) " (A/T models), " «TRANSAXLE ASSEMBLY»(ref-337628-S38291791102009080600000) " (CVT models) or " «TRANSAXLE ASSEMBLY»(ref-337627-S02741312692009080600000) " (M/T models).

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

Scheme 123

Scheme 124

1. Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insulator.
2. When installation directions are specified, install parts according to the directions. Refer to " «COMPONENTS»(ref-337614-S20942156252009080600000) ".
3. Prior to installing the upper torque rod, apply a light coat of silicone lubricant (A) to the washer facing side of the bushing inner tube as shown. NOTE: Apply silicone lubricant (A) by dabbing the outward facing tube surface with a sponge or suitable tool. Do not apply excess lubricant.
4. Make sure that each mounting insulator is seated properly, and tighten nuts and bolts.
5. Tighten engine mounting insulator (RH) bolts in the numerical order shown.