Engine Mechanical: Removal & Installation Nissan Versa II

Removal and Disassembly

1. When instructed to use SST, use specified tools. Always be careful to work safely, avoid forceful or uninstructed operations.
2. Use 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 reassembly.
6. When loosening nuts and bolts, 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. Tighten nuts and bolts in order exactly as specified in the procedure. If a tightening order or procedure is not specified, tighten nuts and bolts equally in several different steps. Start with the nuts or bolts in the center and then tighten diagonally starting with the inside and moving to the outside in a spiral pattern.
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 restrictions and blockages.
5. Avoid damaging sliding or mating surfaces. Before assembling, completely remove foreign materials such as cloth lint or dust, and oil the sliding surfaces.
6. After refilling engine coolant, bleed the air from the cooling system.
7. After repairing, start the engine and increase engine speed to check for engine coolant leaks, fuel leaks, engine oil leaks, and exhaust gas leaks.

REMOVAL OF LIQUID GASKET SEALANT

1. After removing the bolts and nuts, separate the mating surface and remove the old liquid gasket sealant using Tool. Tool number: KV10111100 (J-37228) CAUTION: Do not damage mating surfaces.

1. Tap the seal cutter to insert it (1).
2. In areas where the Tool is difficult to use, lightly tap to slide it (2).

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1. Remove the old liquid gasket from the gasket application surface and the mating surface using suitable tool. Remove the liquid gasket completely from the groove of the liquid gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove moisture, grease and foreign material.
3. Attach the liquid gasket tube to the suitable tool. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-605927-S20340231952014032500000) ".
4. Apply the liquid gasket without breaks to the specified location with the specified dimensions. If there is a groove for the liquid gasket application, apply the liquid gasket to the groove. Normally apply the liquid gasket on the inside edge of the bolt holes. Also apply to the outside edge of the bolt holes when specified in the procedure. Within five minutes of liquid gasket application, install the mating component. If the liquid gasket protrudes, wipe it off immediately. Do not retighten after the installation. Wait 30 minutes or more after installation before refilling the engine with oil or coolant. CAUTION: Carefully follow all of the warnings, cautions, notes, and procedures contained in this information.

INSTALLATION

Installation is in the reverse order of removal.

Note. Check that the air cleaner filter is securely placed in the air cleaner body.

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1. Remove ignition coil. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S31436862372014032500000) ". CAUTION: Do not drop or shock ignition coil.
2. Remove spark plug using a suitable tool. Diameter (a): 14 mm (0.55 in) CAUTION: Do not drop or shock spark plug.

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1. If the spark plug tip is covered with carbon, a spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (6 kg/cm 2 , 85 psi) Cleaning time: Less than 20 seconds CAUTION: Do not use a wire brush for cleaning.

1. Checking and adjusting spark plug gap is not required between change intervals. Do not adjust the gap; replace the spark plug as necessary if out of specification.

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Installation is in the reverse order of removal.

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REMOVAL

1. Remove the fender protector (RH). Refer to " «REMOVAL AND INSTALLATION»(ref-605937-S06682139002014032500000) ".
2. Remove the air duct inlet assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S28177087482014032500000) ".
3. Remove drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S42764128112014032500000) ".
4. Remove the lock nut, and then remove the plate, idler pulley, and washer.
5. Remove the center shaft together with the spacer and the adjusting bolt.

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1. Insert the center shaft (1) into the slide groove of the spacer (2). Fully screw in the adjusting bolt (3) in the belt loosening direction (-->). At that time, place the flange (a) of the adjusting bolt and the seat (b) of the center shaft on the spacer.
2. Place each surface (c and d) of the spacer on the generator bracket. Install the washer, idler pulley, and plate, and then temporarily tighten the lock nut. Lock nut (Temporary tightening): 4.4 N.m (0.45 kg-m, 39 in-lb)
3. Installation is in the reverse order of removal.

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Note. Mass air flow sensor is removable as an assembly with the air cleaner cover.

1. Remove air duct (inlet) from the air cleaner body.
2. Disconnect PCV hose from the air duct.
3. Remove the air duct (between air cleaner case and electric throttle control actuator). Add matching marks if necessary for easier installation.
4. Remove air cleaner assembly with the following steps: Disconnect the harness connector from mass air flow sensor. Remove the two air cleaner body bolts. Pull up on the air cleaner assembly to disengage it from the grommet and remove the air cleaner assembly. CAUTION: Do not shock the mass air flow sensor. Do not disassemble the mass air flow sensor. Do not touch the sensor of the mass air flow sensor.

Installation is in the reverse order of removal.

Note. Align marks, attach each joint and screw clamps firmly.

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

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1. Remove air duct (inlet), air duct and air cleaner assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S28177087482014032500000) ".
2. Disconnect water hoses from electric throttle control actuator. CAUTION: Perform this step when the engine is cold. Do not spill engine coolant on drive belt.
3. Remove electric throttle control actuator. CAUTION: Handle carefully to avoid any shock to electric throttle control actuator. Do not disassemble electric throttle control actuator.
4. Disconnect harness connector and vacuum hose from EVAP purge control solenoid valve. CAUTION: Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.
5. Disconnect vacuum hose for brake booster from intake manifold.
6. Remove intake manifold bolts at the rocker cover.
7. Loosen bolts in reverse order as shown below. CAUTION: Cover engine openings to avoid entry of foreign materials.
8. Remove intake manifold.
9. Remove EVAP purge control solenoid valve from intake manifold if necessary. CAUTION: Handle EVAP canister purge volume control solenoid valve carefully and avoid impacts.
10. Remove intake manifold support (1) if necessary. CAUTION: The intake manifold support functions as a guide for installing the intake manifold.

Installation is in the reverse order of removal.

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1. Install the new gasket to the intake manifold. Align the protrusions used for checking gasket installation condition with the clearance grooves (A) of the intake manifold groove. CAUTION: Do not reuse the gasket. NOTE: New gasket for electronically-controlled throttle can be installed when the electronically-controlled throttle is installed.
2. Place the intake manifold into position. CAUTION: Check that the oil level gauge guide is not detached from the securing clip of the water inlet due to interference of intake manifold.
3. Tighten the bolts to specification in the numerical order as shown below.
4. Tighten the intake manifold bolts to specification at the rocker cover.

Installation is in the reverse order of removal. Note the following

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1. Tighten nuts in numerical order as shown below.
2. Tighten nuts in numerical order to the specified torque again.

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1. Use Tool (A) to install the air-fuel ratio sensor 1 (if removed). Tool number: KV10117100 (-) CAUTION: Handle it carefully and avoid impacts. Before installing a new air-fuel ratio sensor 1, clean the exhaust tube threads using suitable tool and approved anti-seize lubricant. Do not over-tighten the air-fuel ratio sensor 1. Doing so may damage the air-fuel ratio sensor 1, resulting in the MIL coming on. Oxygen sensor thread cleaner: - (J-43897-12) Oxygen sensor thread cleaner: - (J-43897-18)

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1. Drain engine oil. Refer to " «DRAINING»(ref-605939-S05113950672014032500000) ".
2. Loosen bolts in reverse order as shown below.
3. Insert Tool (A) between oil pan (upper) and oil pan (lower). Tool number: KV10111100 (J-37228) CAUTION: Do not damage mating surfaces. Do not insert a screwdriver. This damages the mating surfaces.
4. Slide the Tool (A) by tapping on the side of tool with a suitable tool to loosen the oil pan (lower).
5. Remove oil pan (lower).

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1. Use a scraper (A) 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: Do not scratch or damage the mating surface when cleaning off old liquid gasket.
2. Apply a continuous bead of liquid gasket (A) with a tube presser as shown below. Use Genuine Silicone RTV Sealant or equivalent. CAUTION: The components must be installed within 5 minutes of the liquid gasket application. Do not confirm torque after the 5 minutes have elapsed. Then allow 30 minutes for the liquid gasket to set before adding oil to the engine.
3. Tighten bolts in numerical order as shown below.
4. Install oil pan drain plug. Refer to the figure for installation direction of drain plug washer. Refer to " «EXPLODED VIEW»(ref-605933-S39058516462014032500000) ". CAUTION: Installation should be done within 5 minutes after applying liquid gasket. Do not fill the engine with oil for at least 30 minutes after the oil pan (lower) is installed to allow the sealant to cure.
5. Add the specified oil after waiting for at least 30 minutes. Refer to " «FLUIDS AND LUBRICANTS»(ref-605940-S11091129442014032500000) ".

Removal and Installation

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1. Release the fuel pressure. Refer to " «WORK PROCEDURE»(ref-605934-S17108709862014032500000) ".
2. Remove intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S32064008432014032500000) ".
3. Disconnect fuel feed hose from fuel tube. Disconnect quick connector: NOTE: There is no fuel return path. Remove quick connector cap (engine side) (1) from quick connector connection. Disconnect fuel feed hose from hose clamp. With the sleeve (B) side of quick connector release (A) facing quick connector (2), install quick connector release (A) onto fuel tube (1) as shown below. Insert quick connector release (A) into quick connector (2) until sleeve (B) contacts and goes no further. Hold quick connector release (A) in that position (D). 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 (E) straight up from fuel tube (1). CAUTION: Pull quick connector up (E) from holding position (C) as shown below. 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. Discard O-ring, do not reuse. Avoid fire and sparks. Keep parts away from heat source. Be especially careful when welding is performed. Do not expose parts to battery electrolyte or other acids. Do not bend or twist connection between quick connector and fuel feed tube during installation or removal. Be sure to cover openings of disconnected fuel feed hose (A) and fuel tube (C) with plug or plastic bag (B) to avoid fuel leaks and entry of foreign material.
4. Disconnect fuel feed hose from fuel pipe as follows: NOTE: There is no fuel return path. Remove quick connector cap (floor piping side) (1) from quick connector connection. Disconnect fuel feed hose from hose clamp (1). Hold the quick connector (1) while pushing in tabs (F), and pull out the hard tube (A). CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. Do not use any tools to remove the quick connector. Keep the resin tube away from heat. Be especially careful when welding near the tube. Prevent acid such as battery electrolyte etc. from getting on the resin tube. Do not bend or twist the tube during installation and removal. Remove the remaining retainer only when the tube is replaced. When the tube is replaced, also replace the retainer. Be sure to cover openings of disconnected pipes with plug or plastic bag (B) to avoid fuel leaks and entry of foreign material.
5. Disconnect harness connector from fuel injector.
6. Remove fuel tube protector. Loosen bolts in reverse order as shown below.
7. Remove fuel injector and fuel tube assembly: Loosen two nuts in reverse order as shown below. Pull the fuel tube straight out until injector lower O-rings are clear. Remove the nuts and the fuel tube. CAUTION: When removing, be careful to avoid interference with fuel injectors. Use a shop cloth to absorb any fuel leaks from fuel tube.
8. Remove fuel injector from fuel tube: Open and remove clip (1). Remove fuel injectors (3) and (4) from fuel tube (2) by pulling straight out. CAUTION: Be careful with remaining fuel that may leak from fuel tube. Be careful not to damage fuel injector nozzle during removal. Do not bump or drop fuel injector. Do not disassemble fuel injector. Do not reuse O-rings.

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1. Note the following, and install new O-rings on the fuel injector. FUEL INJECTOR AND FUEL TUBE CAUTION: Upper and lower O-rings are different. Be careful not to interchange them. Fuel tube side: Black Nozzle side: Green Handle O-ring with bare hands. Do not wear gloves. Lubricate O-ring with new engine oil. Do not 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. Do not twist or stretch O-ring. If O-ring was stretched while it was being attached, allow it to retract before inserting it into fuel tube. Insert O-ring straight into fuel tube. Do not angle or twist it.
2. Install fuel injector (4) to fuel tube (1): Insert new clip (2) into clip groove (G) on fuel injector (4). Insert new clip (2) so that protrusion (F) of fuel injector matches cut-out (D) of clip. CAUTION: Do not 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 (4) into fuel tube (1) with clip (2) attached. Insert fuel injector (4) while matching it to the axial center. Insert fuel injector (4) so that protrusion (B) of fuel tube matches cut-out (C) of clip (2). Check that fuel tube flange (A) is securely located in flange groove (E) on clip (2). Check that installation is complete by checking that fuel injector (4) does not rotate or come off.
3. Set fuel tube and fuel injector assembly in position for installation on cylinder head. CAUTION: For installation, be careful not to interfere with fuel injector nozzle. Tighten bolts in numerical order as shown below.
4. Install fuel tube protector. Tighten bolts in numerical order as shown below.
5. Connect harness connector to fuel injector.
6. Connect fuel feed tube (engine side): Check for damage or foreign material on the fuel tube and quick connector. Apply new engine oil lightly to area around the top of fuel tube. Align center to insert quick connector straight into fuel tube. Insert quick connector (1) to fuel tube until the top spool (C) on fuel tube is inserted completely and the 2nd level spool (D) is positioned slightly below quick connector bottom end. CAUTION: Hold in position (A) as shown 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, pull quick connector hard by hand. Check it is completely engaged (connected) so that it does not come out from fuel tube. Install quick connector cap (engine side) (1) to quick connector connection. Install quick connector cap (engine side) (1) with the side arrow facing quick connector side (fuel feed tube side) as shown below. CAUTION: Check that the quick connector and fuel tube are securely engaged with the quick connector cap (engine side) groove. If the quick connector cap (engine side) cannot be installed easily the quick connector may not be connected correctly. Remove and reconnect. Install fuel feed hose to hose clamp.
7. Connect fuel feed tube (floor piping side): Check the connection for damage or any foreign materials. Align the quick connector with the tube, then insert the connector straight into the centralized under floor piping until a click is heard. After connecting, check that the connection is secure: Visually confirm that the two retainer tabs are connected to the connector. With the fuel feed hose not fixed to the clamp, pull quick connector (A) hard by hand to check that the quick connector (A) is not disconnected from the centralized underfloor piping (1) and that the quick connector (1) is securely connected.
8. Install remaining parts in the reverse order of removal.

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1. Install the rocker cover: Press gasket onto the bosses for the rocker cover bolt holes as shown below to prevent the gasket from dropping off. Apply liquid gasket to the cylinder head (1) and front cover (2) as shown below. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-605927-S20340231952014032500000) ". CAUTION: The components must be installed within 5 minutes of the liquid gasket application. Then allow 30 minutes for the liquid gasket to set before putting oil in the engine. Install rocker cover to cylinder head. CAUTION: Check that the gasket has not slipped out of position. Tighten bolts in numerical order in two separate stages as shown below.
2. Installation of the remaining components is in the reverse order of removal.

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

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1. Remove front road wheel (RH).
2. Remove front fender protector (RH). Refer to " «REMOVAL AND INSTALLATION»(ref-605937-S06682139002014032500000) ".
3. Drain engine oil. Refer to " «DRAINING»(ref-605939-S05113950672014032500000) ". CAUTION: Perform this step when engine is cold. Do not spill engine oil on drive belt.
4. Drain coolant. Refer to " «DRAINING ENGINE COOLANT»(ref-605935-S26294057612014032500000) ".
5. Remove the following parts. Intake manifold. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S32064008432014032500000) ". Drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S42764128112014032500000) ". Rocker cover. Refer to " «EXPLODED VIEW»(ref-605933-S07534786442014032500000) ". Water pump pulley. Refer to " «REMOVAL AND INSTALLATION»(ref-605935-S19850841722014032500000) ".
6. Support the bottom surface of engine using a transmission jack, and then remove the engine bracket and insulator (RH). Refer to " «EXPLODED VIEW»(ref-605933-S41359413582014032500000) ".
7. Set No. 1 cylinder at TDC of its compression stroke: Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover. Check the matching marks on each camshaft sprocket are positioned as shown below. If not, rotate crankshaft pulley one more turn to align matching marks to the positions.
8. Remove crankshaft pulley: Secure crankshaft pulley (1) using suitable tool (A). Loosen and pull out crankshaft pulley bolt. CAUTION: Do not remove the bolts as they will be used as a supporting point for the pulley puller. Attach Tool (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley. Tool number: KV11123000 (-)
9. Remove front cover: Loosen bolts in the reverse order as shown below. Cut liquid gasket by prying the position (<--) as shown below, and then remove the front cover.
10. Remove front oil seal from front cover using a suitable tool. CAUTION: Be careful not to damage the front cover.
11. Remove chain tensioner (1): Fully push down the chain tensioner lever (A), and then push the plunger (C) into the inside of tensioner. The tab (B) is released by fully pushing the lever down. Then the plunger can be moved. Pull up the lever to align its hole position with the body hole position. When the lever hole is aligned with the body hole position, the plunger is secured. When the protrusion parts of the plunger ratchet and the tab face each other, both hole positions are not aligned. At that time, correctly engage them and align these hole positions by slightly moving the plunger. Insert the stopper pin (D) into the body hole through the lever hole, and then secure the lever at the upper position. NOTE: A hexagonal wrench of 2.5 mm (0.098 in) is used as a stopper pin (D). Remove chain tensioner.
12. Remove the timing chain tension guide (2) and the timing chain slack guide (1).
13. Remove the timing chain (2). Pull the timing chain slack toward the camshaft sprocket (EXH) (1), and then remove the timing chain and start the removal from camshaft sprocket (EXH) side. CAUTION: Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston.
14. Remove the crankshaft sprocket and the oil pump drive related parts: Remove oil pump drive chain tensioner (1). Pull out from the shaft (B) and spring attaching holes (A). Hold the top of the oil pump shaft using the socket (size: E8), and then loosen the oil pump sprocket nut and remove it. Remove the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time.

Note. For installation follow the relationship between the matching mark on each timing chain and that of the corresponding sprocket, with the components installed.

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1. Install the crankshaft sprocket and the oil pump drive related parts: Install the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time. Install the crankshaft sprocket so that its invalid gear area (A) is toward the back of the engine. Install the oil pump sprocket so that its protrusion faces the front of engine. NOTE: There is no matching mark in the oil pump drive related parts. Hold the top of the oil pump shaft using the socket (size: E8), and then tighten the oil pump sprocket nut. Install oil pump drive chain tensioner (1). Insert the body into the shaft (B) while inserting the spring into the attaching hole (A) of cylinder block front surface. Check that the tension is applied to the oil pump drive chain after installing.
2. Install timing chain: Install by aligning matching marks on each sprocket and timing chain. If these matching marks are not aligned, rotate the camshaft slightly to correct the position. CAUTION: After the matching marks are aligned, keep them aligned by holding them. To avoid skipped teeth, do not rotate crankshaft and camshaft until front cover is installed.
3. Install timing chain tension guide (2) and timing chain slack guide (1).
4. Install chain tensioner (1). Secure the plunger at the most compressed position using a stopper pin (A), and then install it. Pull out the stopper pin after installing the chain tensioner.
5. Check matching mark position of timing chain and each sprocket again.
6. Install the front oil seal to the front cover. Refer to " «FRONT OIL SEAL: REMOVAL AND INSTALLATION»(ref-605933-S23516262842014032500000) ".
7. Install front cover with the following procedure: Apply a continuous bead of liquid gasket to the front cover as shown below. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-605927-S20340231952014032500000) ". Tool number: WS39930000 (-) Apply a continuous bead of liquid gasket to front cover as shown below. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-605927-S20340231952014032500000) ". Tighten bolts in the numerical order as shown below. After all bolts are tightened, retighten them to specified torque in numerical order as shown below. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface.
8. Insert crankshaft pulley by aligning with crankshaft key. When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). CAUTION: Do not damage front oil seal lip section.
9. Tighten crankshaft pulley bolt: Secure crankshaft pulley with a suitable tool and tighten crankshaft pulley bolt. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. Tighten crankshaft pulley bolt. Crankshaft pulley bolt: 35.0 N.m (3.6 kg-m, 26 ft-lb) Put a paint mark (B) on crankshaft pulley, mating with any one of six easy to recognize angle marks (A) on crankshaft bolt flange (1). Turn another 60 degrees clockwise (angle tightening). Check the tightening angle with movement of one angle mark.
10. Check that crankshaft turns smoothly by rotating by hand clockwise.
11. Installation of the remaining components is in the reverse order of removal.

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1. Hold the bottom surface of the engine with a jack to remove the right engine mount assembly and the insulator. Refer to " «EXPLODED VIEW»(ref-605933-S41359413582014032500000) ".
2. Remove rocker cover. Refer to " «EXPLODED VIEW»(ref-605933-S07534786442014032500000) ".
3. Place cylinder No. 1 at TDC of its compression stroke: Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover. Check that the matching marks on each of the camshaft sprockets are in the position as shown below. If not, rotate crankshaft pulley one more turn to align matching marks to the positions as shown below. Paint matching marks (A) on the timing chain links.
4. Remove crankshaft pulley. Refer to " «EXPLODED VIEW»(ref-605933-S22486553002014032500000) ".
5. Remove front cover. Refer to " «EXPLODED VIEW»(ref-605933-S22486553002014032500000) ".
6. Secure the plunger of chain tensioner in the fully compressed position. Then, loosen the timing chain tension. Fully push down the lever (B) of chain tensioner (2) from the plug hole, and then insert the stopper pin (A) into the body side hole and secure the lever at the lowest position. The tab is released by fully pushing the lever down. As a result, the plunger (1) can be moved. NOTE: Hexagonal wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example. CAUTION: The stopper pin must use a shape that cannot fall in the front cover if dropped. Turn the crankshaft pulley (2) counterclockwise with the camshaft (EXH) (1) held. Apply the tension to the timing chain, and then push the plunger into the inside of chain tensioner. CAUTION: Hold the camshaft hexagonal part (A), and then secure the camshaft. Pull out the stopper pin (A) of chain tensioner (2) side from plug hole. Lift the lever (B) up to align its hole position with the hole of the body. When the lever hole (C) is aligned with the body hole position, the plunger (1) is secured. When the protrusion parts of the plunger ratchet and the tab face each other, both hole positions are not aligned. At that time, correctly engage them and align these hole positions by slightly moving the plunger. Insert the stopper pin into the body hole through the lever hole, and then secure the lever at the upper position.
7. Remove timing chain.
8. Remove camshaft sprocket (EXH) (1). CAUTION: Hold the camshaft hexagonal part (A), and then secure the camshaft. Do not rotate crankshaft and camshaft separately, so as not to contact valve with piston. NOTE: The timing chain with the front cover installed is not disengaged from the crankshaft sprocket and it is not dropped into the front cover. Therefore, the timing chain tension holding device is not necessary.
9. Turn the camshaft sprocket (INT) to the most advanced position. CAUTION: Installation and removal of the camshaft sprocket (INT) must be done in the most advanced position. Make sure to follow the procedure exactly. The sprocket (C) and vane (camshaft coupling) (B) are designed to spin and move within the range of a certain angle. With the engine stopped and the vane in the most retarded angle, it will not spin because it is locked to the sprocket side by the internal lock pin (A). If the camshaft sprocket bolts are turned in the situation described above, the lock pin will become damaged and cause malfunctions because of the increased horizontal load (cutting force) on the lock pin. Put the camshaft sprocket (INT) in the most advanced position: Remove camshaft bracket (No. 1) (1). Loosen the bolts in several steps, and then remove them. Apply the following air pressure to the No. 1 journal oil hole (A) of camshaft (INT) (1) shown using an air gun. Air pressure: 300 kPa (3.1 kg/cm 2 , 44 psi) or more Apply the air pressure into the oil hole on the second groove from the front of camshaft thrust (B). Proceed all the way through step "e" with the air pressure on. Attach the rubber nozzle narrowed to the top of the air gun to prevent air leakage from the oil hole (A). Securely apply the air pressure to the oil hole. WARNING: Eye protection should be worn as needed. CAUTION: There are other oil holes in the side grooves. Do not use the incorrect oil holes. Be sure not to damage the oil path with the tip of the air gun. Wipe all the oil off the air gun to prevent oil from being blown all over along with the air, and the area around the air gun should be wiped with a rag when applying air pressure. Eye protection should be worn as needed. NOTE: The air pressure is used to move the lock pin into the disengage position. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alternately. Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the arrow (<--)]. Perform the work while continuously applying the air pressure to the oil hole. If the lock pin is not released, tap the camshaft sprocket (INT) lightly with a plastic hammer (A). If the camshaft sprocket (INT) is not rotated counterclockwise even if the above procedures are performed, check the air pressure and the oil hole position. While doing the above, once you hear a click (the sound of the internal lock pin disengaging) from inside the camshaft sprocket (INT), start turning the camshaft sprocket (INT) in the counterclockwise direction in the most advanced angle position. Keep the air pressure on. If there is no click, as soon as the vane side (camshaft side) starts moving independently of the sprocket, the lock pin has become disengaged. Check that it is in the most advanced angle position by seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown below. Stop applying air pressure and release the camshaft (INT). Insert the stopper pin (A) into the stopper pin holes in the camshaft sprocket (INT) and lock in the most advanced angle position. CAUTION: No load is exerted on the stopper pin (spring reaction, etc.). Since it comes out easily, secure it with tape (B) to prevent it from falling out. NOTE: The stopper pin shows one example of a hexagonal wrench for 2.5 mm (0.098 in) [length of inserted section: approximately 15 mm (0.59 in)].
10. Remove the camshaft sprocket (INT): Keeping the camshaft hexagonal part (A) in place with the wrench, loosen the bolts for the camshaft sprocket (INT) (2). CAUTION: Do not drop stopper pin. Tape (C) the stopper pin (B) so it does not come out. Do not subject it to impact by dropping. Do not disassemble. [Do not loosen the three bolts (A)]. NOTE: While removing the camshaft sprocket (INT), if you have taken out the stopper pin and the lock pin has been rejoined in the most retarded angle, do the following to restore it. Install the camshaft (INT) and tighten the bolts enough to prevent air from leaking out. CAUTION: The internal lock pin will get damaged, so keep the torque on the bolts to the minimum required to prevent air from escaping. ii. Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position. iii. Insert the stopper pin. iv. Remove camshaft sprocket (INT) from the camshaft.
11. Remove camshaft brackets (No. 2 to 5). Loosen bolts in several steps in the reverse order as shown below. NOTE: The camshaft bracket (No. 1) has been already removed.
12. Remove camshaft (EXH).
13. Remove camshaft (INT).
14. Remove valve lifter. Identify installation positions, and store lifters without mixing them up.
15. Remove intake valve timing control solenoid valve (1).
16. Remove the alternator and bracket, remove the plug (2), and then remove the oil filter. Refer to " «EXPLODED VIEW»(ref-605933-S40974854352014032500000) ".
17. Remove exhaust valve timing control solenoid valve.
18. Remove the plug on the exhaust valve timing control solenoid valve and the oil filter. Refer to " «EXPLODED VIEW»(ref-605933-S40974854352014032500000) ".
19. For component inspection after removal, refer to " «INSPECTION»(ref-605933-S02851483852014032500000) ".

Scheme 126

Scheme 127

Scheme 128

Scheme 129

Scheme 130

Scheme 131

Scheme 132

Scheme 133

Scheme 134

Scheme 135

Scheme 136

Scheme 137

Scheme 138

Scheme 139

1. Install oil filter (1) for intake and exhaust valve timing control solenoid valves. CAUTION: Do not reuse washers. NOTE: The intake side is shown as an example. The oil filter (1) and washer (2) are assembled to the plug (3), and then install them in to the cylinder head. Refer to " «EXPLODED VIEW»(ref-605933-S40974854352014032500000) ".
2. Install intake and exhaust valve timing control solenoid valves. Insert it straight into the cylinder head. Tighten bolts.
3. Install valve lifters. If they are reused, install them in the original positions.
4. Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT): NOTE: This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (INT). Put the matching marks (A) on a line extending from the knock pin position of camshaft (INT) (1) front surface. Put the marks on the visible position with the camshaft sprocket installed as shown below. Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (INT) (2) as shown below. Put the marks on the visible position with it installed to the camshaft.
5. Put a matching mark for positioning the camshaft (EXH) and the camshaft sprocket (EXH): NOTE: This helps prevent the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (EXH). Put the matching marks (A) on a line extending from the knock pin position of camshaft (EXH) (1) front surface. Put the marks on the visible position with the camshaft sprocket installed as shown below. Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (EXH) (2) as shown below. Put the marks on the visible position with it installed to the camshaft.
6. Install camshaft. Note that the camshafts (INT and EXH) have different shapes at the rear. Install camshafts to the cylinder head so that knock pins (A) on front end are positioned as shown below. NOTE: Though camshaft does not stop at the portion as shown for the placement of cam nose, it is generally accepted camshaft is placed for the same direction as shown below.
7. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown below. Install so that identification mark can be correctly read when viewed from the INT side.
8. Tighten bolts of camshaft brackets in the following steps, in numerical order as shown below. Tighten No. 9 to 11 in numerical order. Camshaft bracket bolts: 1.96 N.m (2.0 kg-m, 14 in-lb) Tighten No. 1 to 8 in numerical order. Camshaft bracket bolts: 1.96 N.m (2.0 kg-m, 14 in-lb) Tighten all bolts in numerical order. Camshaft bracket bolts: 5.88 N.m (0.60 kg-m, 52 in-lb) Tighten all bolts in numerical order. Camshaft bracket bolts: 10.4 N.m (1.1 kg-m, 8 ft-lb)
9. Install the camshaft sprocket (INT and EXH) to the camshaft (INT and EXH): Refer to the matching mark (A) added in step 4. Securely align the knock pin and the pin hole, and then install them. NOTE: The intake side is shown as an example.
10. Tighten the camshaft sprocket bolt (INT and EXH). CAUTION: Hold the camshaft hexagonal part (A), using a suitable tool to secure the camshaft.
11. Install the camshaft (INT and EXH) to the camshaft sprocket (INT and EXH) (2 and 3) while aligning the matching mark (marked when timing chain is removed) (A) and the pink link (B) of camshaft sprocket (INT and EXH). If the positions of knock pin and pin groove are not aligned, move the camshaft (EXH) slightly to correct these positions.
12. Pull out the stopper pin (A), and then apply the tension to the timing chain by rotating the crankshaft pulley clockwise slightly.
13. Pull out the stopper pin of chain tensioner.
14. Install front cover.
15. Return the camshaft sprocket (INT) in the most retarded position: Remove the stopper pin (A) from the camshaft sprocket (INT). Turn the crankshaft pulley (1) slowly clockwise (A) and return the camshaft sprocket (INT) to the most retarded angle position. When first turning the crankshaft, the camshaft sprocket (INT) will turn. Once it is turned more, and the vane (camshaft) also turns, then it has reached the most retarded angle position. The most retarded angle position can be checked by seeing if the stopper pin groove (A) is shifted clockwise. After spinning the crankshaft slightly in the counterclockwise direction, you can check the lock pin has joined by seeing if the vane (camshaft) and the sprocket move together.
16. Install the camshaft position sensor (PHASE) to the rear end of cylinder head. Tighten bolts with it completely inserted.
17. Check and adjust valve clearance. Refer to " «INSPECTION AND ADJUSTMENT»(ref-605933-S16783894212014032500000) ".
18. Installation of the remaining components is in the reverse order of removal.

1. Remove the following parts. Remove wheel and tire. Refer to " «ADJUSTMENT»(ref-605936-S10289281402014032500000) " Front fender protector (RH). Refer to " «REMOVAL AND INSTALLATION»(ref-605937-S06682139002014032500000) ". Drive belt. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S42764128112014032500000) ". Crankshaft pulley. Refer to " «EXPLODED VIEW»(ref-605933-S22486553002014032500000) ".
2. Remove front oil seal with a suitable tool. CAUTION: Be careful not to damage front cover and crankshaft.

Scheme 140

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 below. Press-fit front oil seal using a suitable drift with outer diameter 50 mm (1.97 in) and inner diameter 44 mm (1.73 in). CAUTION: Be careful not to damage front cover and crankshaft. Press-fit oil seal straight to avoid causing burrs or tilting.
3. Installation of the remaining components is in the reverse order of removal.

1. Remove transaxle assembly. Refer to " «REMOVAL AND INSTALLATION»(ref-605942-S08446001142014032500000) " (M/T models), " «REMOVAL AND INSTALLATION»(ref-605943-S12318648592014032500000) " (A/T models), " «REMOVAL AND INSTALLATION»(ref-605943-S12318648592014032500000) " (CVT models).
2. Remove clutch cover and clutch disk (M/T models). Refer to " «REMOVAL AND INSTALLATION»(ref-605944-S16912234912014032500000) ".
3. Remove flywheel (M/T models) or drive plate (A/T or CVT models). Refer to " «EXPLODED VIEW»(ref-605933-S34097784992014032500000) ".
4. Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block.

Scheme 141

Scheme 142

Scheme 143

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-605927-S20340231952014032500000) ".
2. Install rear oil seal so that each seal lip is oriented as shown below. Press-fit rear oil seal with a suitable drift (A) outer diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in). 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. Press in rear oil seal (1) to the position as shown below.
3. Installation of the remaining components is in the reverse order of removal.

Scheme 144

Scheme 145

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

Scheme 146

1. Release fuel pressure. Refer to " «WORK PROCEDURE»(ref-605934-S17108709862014032500000) ".
2. Remove the following components and related parts. Air duct. Refer to " «REMOVAL AND INSTALLATION»(ref-605933-S28177087482014032500000) ". Fuel tube and fuel injector. Refer to " «EXPLODED VIEW»(ref-605933-S28131376412014032500000) ". Water outlet. Refer to " «REMOVAL AND INSTALLATION»(ref-605935-S03044450092014032500000) ". Exhaust manifold. Refer to " «EXPLODED VIEW»(ref-605933-S05351681892014032500000) ". Front cover and timing chain. Refer to " «EXPLODED VIEW»(ref-605933-S22486553002014032500000) ". Camshaft. Refer to " «EXPLODED VIEW»(ref-605933-S40974854352014032500000) ".
3. Remove cylinder head loosening bolts in reverse order as shown below.
4. Remove cylinder head gasket.

Scheme 147

Scheme 148

1. Install new cylinder head gasket.
2. Tighten cylinder head bolts in numerical order as shown below. CAUTION: If cylinder head bolts are reused, check their outer diameters before installation. Refer to " «INSPECTION»(ref-605933-S05165464112014032500000) ". Apply new engine oil to threads and seating surfaces of bolts. Tighten all bolts. Turn all bolts 60 degrees clockwise (angle tightening) using Tool (A) in the specified order. CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Avoid judgment by visual inspection without the tool. Tool number: KV10112100 (BT-8653-A) Completely loosen all bolts. Cylinder head bolts: 0 N.m (0 kg-m, 0 ft-lb) CAUTION: In this step, loosen bolts in reverse order of that indicated as shown below. Tighten all bolts. Cylinder head bolts: 40.0 N.m (4.1 kg-m, 30 ft-lb) Turn all bolts 75 degrees clockwise (angle tightening). Turn all bolts 75 degrees clockwise again (angle tightening).
3. Installation of the remaining components is in the reverse order of removal.

Scheme 149

Scheme 150

1. Remove spark plug with a suitable tool.
2. Remove valve lifter. Identify installation positions, and store lifters without mixing them up.
3. Remove valve collet. Compress valve spring with Tool (A). Remove valve collet with a magnet tool (B). CAUTION: Be careful not to damage valve lifter holes. Tool number: KV10116200 (J-26336-B): KV10115900 (J-26336-20): KV10109220 (-)
4. Remove valve spring retainer and valve spring.
5. Push valve stem to combustion chamber side, and remove valve. Identify installation positions, and store without mixing them up.
6. Remove valve oil seal using Tool (A). Tool number: KV10107902 (J-38959)
7. Remove valve spring seat.
8. When valve seat must be replaced, refer to " «INSPECTION»(ref-605933-S05165464112014032500000) " for removal.
9. When valve guide must be replaced, refer to " «INSPECTION»(ref-605933-S05165464112014032500000) " for removal.

Scheme 151

Scheme 152

1. Install valve guide if removed. Refer to " «INSPECTION»(ref-605933-S05165464112014032500000) ".
2. Install valve seat if removed. Refer to " «INSPECTION»(ref-605933-S05165464112014032500000) ".
3. Install valve oil seal. Install with Tool (A) to match dimension as shown below. Height "H": 13.2 - 13.8 mm (0.520 - 0.543 in) Tool number: KV10115600 (J-38958)
4. Install valve spring seat.
5. Install valve. Install larger diameter to intake side.
6. Install valve spring. NOTE: It can be installed in either direction.
7. Install valve spring retainer.
8. Install valve collet. Compress valve spring with Tool (A). Install valve collet with a magnet hand (B). CAUTION: Be careful not to damage valve lifter holes. Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition. Tool number: KV10116200 (J-26336-B) : KV10115900 (J-26336-20) : KV10109220 (-)
9. Install valve lifter.
10. Install spark plug with a suitable tool.

Scheme 153

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 154

Scheme 155

Scheme 156

Scheme 157

Scheme 158

Scheme 159

1. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) force] or suitable tool. WARNING: Cylinder head contains heat; when working, wear protective equipment to avoid getting burned.
3. Ream cylinder head valve guide hole with a suitable tool. Valve guide hole diameter (for service parts): Intake and exhaust : 9.175 - 9.201 mm (0.3612 - 0.3622 in)
4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil.
5. Using a suitable tool, press valve guide (1) from camshaft side to dimensions as shown below. Projection "H":: 11.4 - 11.8 mm (0.448 - 0.464 in) WARNING: Cylinder head contains heat; when working, wear protective equipment to avoid getting burned.
6. Apply reamer finish to valve guide with a suitable tool. Standard 5.000 - 5.018 mm (0.1968 - 0.1975 in)

Scheme 160

1. After confirming that the dimensions of valve guides and valves are within the specifications, perform this procedure.
2. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface.
3. Check if the contact area band is continuous all around the circumference.
4. If not, grind to adjust valve fitting and check again. If the contacting surface still has "NG" conditions (B) even after the recheck, replace valve seat. Refer to " «DISASSEMBLY AND ASSEMBLY»(ref-605933-S27718448432014032500000) ".

VALVE SEAT REPLACEMENT

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

Scheme 161

Scheme 162

Scheme 163

Scheme 164

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 " «FLUIDS AND LUBRICANTS»(ref-605940-S11091129442014032500000) ". CAUTION: Prevent scoring cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)] Intake: 32.500 - 32.527 mm (1.2795 - 1.2805 in) Exhaust: 26.400 - 26.427 mm (1.0393 - 1.0404 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.
4. Provide valve seats cooled well with dry ice. Press-fit valve seats into cylinder head. WARNING: Cylinder head contains heat; when working, wear protective equipment to avoid getting burned. CAUTION: Avoid directly touching cold valve seats.
5. Using a suitable tool a valve seat grinder, finish valve seat to the specified dimensions. For dimensions, refer to " «FLUIDS AND LUBRICANTS»(ref-605940-S11091129442014032500000) ". CAUTION: When using a valve seat cutter, firmly grip the cutter handle with both hands. Then, press the contacting surface evenly around the valve seat to cut in a single attempt. Improper pressure or cutting several times may result in wavy valve seat.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to " «VALVE SEAT CONTACT»(ref-605933-S04753446432014032500000) ". VALVE SPRING SQUARENESS Set a tri-square (A) along the side of valve spring and rotate spring. Measure the maximum clearance between the top of spring and tri-square. Limit: Refer to " «CYLINDER HEAD»(ref-605933-S38619464092014032500000) ". If it exceeds the limit, replace valve spring.

Scheme 165

1. Check valve spring pressure with valve spring seat installed at the specified spring height. CAUTION: Do not remove valve spring seat from valve spring. Standard: Refer to " «CYLINDER HEAD»(ref-605933-S38619464092014032500000) ".
2. If the installation load or load with valve open is out of the standard, replace valve spring (with valve spring seat).

Note. When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling. Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle.

Installation is in the reverse order of removal.

Note. The oil strainer is included in the oil pan (upper) and cannot be removed.

Scheme 166

Scheme 167

1. Remove the oil pan (lower). Refer to " «EXPLODED VIEW»(ref-605933-S39058516462014032500000) ".
2. Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain. Refer to " «EXPLODED VIEW»(ref-605933-S22486553002014032500000) ".
3. Remove oil pan (upper). Loosen oil pan (upper) bolts in the reverse of the order as shown below. Insert a flat-bladed offset screwdriver into the arrow (<--) as shown and open up a crack between the oil pan (upper) cylinder block. Insert the Tool between the oil pan (upper) and cylinder block. Slide Tool by tapping on the side of Tool with a hammer. Tool number: KV10111100 (J-37228) CAUTION: Be careful not to damage the mating surface. The liquid gasket used at the factory is very strong. Pry only in the areas shown below. Do not remove oil pump and oil strainer from oil pan (upper).
4. Remove rear oil seal from crankshaft.

Scheme 168

Scheme 169

Scheme 170

Scheme 171

1. Install the oil pan (upper): Use 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: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket. Install O-ring to the cylinder block. Apply a continuous bead of liquid gasket with the Tool or suitable tool to areas as shown below. Use Genuine Silicone RTV Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-605927-S20340231952014032500000) ". CAUTION: Attaching should be done within 5 minutes after coating. Tighten bolts in the numerical order as shown below. CAUTION: Install avoiding misalignment of both oil pan gasket and O-ring. The bolts are different according to the installation position. Refer to the numbers as shown below. M8x180 mm (7.09 in): No. 9, 10 M8x25 mm (0.98 in): No. 4, 7, 8 M8x90 mm (3.54 in): No. 1, 2, 3, 5, 6
2. Install rear oil seal: CAUTION: The installation of rear oil seal should be completed within 5 minutes after installing oil pan (upper). Do not touch oil seal lip. Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block using a suitable tool. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine Liquid Gasket or equivalent. Press-fit the rear oil seal using a drift with outer diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial service tool) (A). Press-fit to the dimensions specified as shown below. CAUTION: Do not touch the grease applied to the oil seal lip. Be careful not to damage the rear oil seal mounting part of oil pan (upper) and cylinder block or the crankshaft. Press-fit straight and check that oil seal does not curl or tilt. After press-fitting the rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side.
3. Installation of the remaining components is in the reverse order of removal.
4. Add the specified oil after waiting for at least 30 minutes. Refer to " «FLUIDS AND LUBRICANTS»(ref-605940-S11091129442014032500000) ". CAUTION: The components must be installed within 5 minutes of the liquid gasket application. Allow 30 minutes for the liquid gasket to set before adding oil to the engine.