EM-186
[VK45DE]
OIL PAN AND OIL STRAINER
Revision: 2005 July 2005 FX
Do not spill engine coolant on drive belts.
7. Remove drive belts. Refer to EM-173, "
DRIVE BELTS" .
8. Remove auto tensioner of power steering oil pump belt. Refer to EM-175, "
Drive Belt Auto Tensioner and
Idler Pulley" .
9. Remove power steering oil pump with piping connected, and temporarily secure it aside with ropes or equivalent. Refer to PS-31, "
POWER STEERING OIL PUMP" .
10. Remove A/C compressor with piping connected, and temporarily secure it aside with ropes or equivalent. Refer to ATC-140, "
Components" .
11. Remove A/C compressor fitting bolts, and install A/C compressor temporarily on vehicle side with ropes or equivalent.
12. Remove harness of lower side of oil pan.
13. Remove crankshaft position sensor (POS) from transmission. CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble it.
Do not allow metal powder to adhere to magnetic part at sensor tip.
Do not place sensors in a location where they are exposed to magnetism.
14. Install engine slinger and hang engine assembly to secure position. Refer to EM-240, "
ENGINE ASSEM-
BLY" .
15. Remove front suspension member with power tool. Refer to FSU-17, "
FRONT SUSPENSION MEMBER" .
16. Remove front final drive assembly. Refer to FFD-12, "
FRONT FINAL DRIVE ASSEMBLY" .
17. Remove oil filter. Refer to LU-28, "
OIL FILTER" .
18. Disconnect oil cooler water hoses, and remove oil cooler water pipe and oil cooler. Refer to LU-29, "
OIL
COOLER" .
19. Remove oil pan as the follows:
a. Remove rear plate cover.
b. Remove transmission joint bolts which pierce oil pan. Refer to AT- 2 7 3 , "
Removal and Installation (AWD
Models)" .
c. Loosen mounting bolts with power tool in reverse order as shown in the figure.
NOTE:
Disregard the numerical order No. 11 and 17 in removal.
d. Insert seal cutter (SST) between oil pan and cylinder block. Slide seal cutter by tapping on the side of seal cutter with ham-
mer. Remove oil pan.
CAUTION:
Be careful not to damage the mating surfaces.
Do not insert screwdriver, this will damage the mating
surface.
e. Remove O-rings from bottom of oil pump and front cover.
20. As necessary, pull axle pipe from oil pan.
Hold pipes and pull them out to front drive shaft (left) installing side.
21. Remove oil strainer.
PBIC0194E
SEM365E
OIL PAN AND OIL STRAINER EM-187
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INSPECTION AFTER REMOVAL
Clean oil strainer if any object attached.
INSTALLATION
1. Install oil strainer.
2. Install axle pipe to oil pan, if removed.
Lubricate O-ring groove of axle pipe, O-ring, and O-ring joint
of oil pan with new engine oil.
Right/left O-ring diameters differ from each other. O-ring with
identification paint mark is installed on front drive shaft (left)
installing side.
Install axle pipe to oil pan from (left) side.
CAUTION:
Insert it with care to prevent O-ring from sliding.
3. Install oil pan as follows:
a. 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.
b. Install new O-rings to oil pump and front cover side.
c. Apply a continuous bead of liquid gasket with tube presser [SST: WS39930000 ( — )] to the cylinder block mating surfaces of
oil pan to a limited portion as shown in the figure.
Use Genuine RTV Silicone Sealant or equivalent. Refer to
GI-48, "
RECOMMENDED CHEMICAL PRODUCTS AND SEAL-
ANTS".
CAUTION:
Attaching should be done within 5 minutes after coating.
d. Install oil pan. CAUTION:
Install avoiding misalignment of O-rings.
Tighten mounting bolts in numerical order as shown in the fig-
ure.
NOTE:
Tighten mounting bolts No. 1 and 2 in two steps. The numeri-
cal order No. 11 and 17 shown second steps.
There are three types of mounting bolts. Refer to the following
for locating bolts.
e. Tighten transmission joint bolts. Refer to AT- 2 7 3 , "
Removal and Installation (AWD Models)" .
f. Install rear plate cover.
4. Install oil pan drain plug with new drain plug washer.
Refer to the figure of components of former page for installation direction of drain plug washer. Refer to
EM-185, "
Removal and Installation" .
5. Install in the reverse order of removal after this step.
PBIC2336E
PBIC0195E
M6 × 30 mm (1.18 in) : 18, 19
M8 × 100 mm (3.94 in) : 5, 9
M8 × 45 mm (1.77 in) : Except the above
PBIC0194E
TIMING CHAIN EM-211
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f. Further tighten by 90 degrees. (Angle tightening)
Check the tightening angle by referencing to the notches. The
angle between two notches is 90 degrees.
15. Rotate crankshaft pulley in normal direction (clockwise when viewed from engine front) to confirm it turns smoothly.
16. Install in the reverse order of removal after this step. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in guide may gen-
erate a pounding noise during and just after engine start. However, this does not indicate an unusualness.
Noise will stop after hydraulic pressure rises.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "
RECOMMENDED FLUIDS AND LUBRICANTS"
Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.
PBIC2346E
Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
OIL SEAL EM-227
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Install front oil seal so that each seal lip is oriented as shown
in the figure.
Using front oil seal drift, press fit until the height of front oil
seal is level with the mounting surface.
Make sure the garter spring is in position and seal lips not
inverted.
CAUTION:
Be careful not to damage front cover and oil pump drive
spacer.
Press fit straight and avoid causing burrs or tilting oil seal.
3. Install in the reverse order of removal.
Removal and Installation of Rear Oil SealABS006IO
REMOVAL
1. Remove transmission (with transfer) assembly. Refer to AT- 2 7 0 , "TRANSMISSION ASSEMBLY" .
a. Remove drive plate. Refer to EM-245, "
CYLINDER BLOCK" .
b. Remove engine rear plate. Refer to EM-245, "
CYLINDER BLOCK" .
2. Remove rear oil seal using suitable tool. CAUTION:
Be careful not to damage crankshaft and oil seal retainer
surface.
INSTALLATION
1. Apply new engine oil to both oil seal lip and dust seal lip of new rear oil seal.
2. Install rear oil seal.
Install rear oil seal so that each seal lip is oriented as shown
in the figure.
SEM715A
Front oil seal drift
Outer diameter : 56 mm (2.20 in)
Inner diameter : 49 mm (1.93 in)
SBIA0359E
SBIA0360E
SEM715A
ENGINE ASSEMBLY EM-241
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Preparation
1. Release fuel pressure. Refer to EC-789, "FUEL PRESSURE RELEASE" .
2. Drain engine coolant from radiator. Refer to CO-37, "
Changing Engine Coolant" .
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
3. Disconnect both battery terminal. Refer to SC-4, "
BATTERY" .
4. Remove crankshaft position sensor (POS) from transmission. CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble.
Do not allow metal powder to adhere to magnetic part at sensor tip.
Do not place sensors in a location where they are exposed to magnetism.
5. Remove the following parts:
Hood assembly; Refer to BL-13, "HOOD" .
Engine cover; Refer to EM-172, "ENGINE ROOM COVER" .
Front and rear engine undercover
Air duct (inlet), air duct and air cleaner case assembly; Refer to EM-176, "AIR CLEANER AND AIR
DUCT" .
Drive belts; Refer to EM-173, "DRIVE BELTS" .
Radiator and radiator hoses (upper and lower); Refer to CO-41, "RADIATOR" .
Front road wheels and tires
Engine Room LH
1. Disconnect engine room harness from the engine side and set it aside for easier work.
2. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Discharge refrigerant from A/C circuit. Refer to ATC-138, "
REFRIGERANT LINES" .
6. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to AT C -
140, "Components" .
Engine Room RH
1. Disconnect fuel feed hose and EVAP hose. Refer to EM-192, "FUEL INJECTOR AND FUEL TUBE" .
CAUTION:
Fit plugs onto disconnected hose to prevent fuel leak.
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work. CAUTION:
When temporarily securing, keep reservoir tank upright to avoid a fluid leak.
Vehicle Underbody
1. Remove front cross bar. Refer to FSU-6, "FRONT SUSPENSION ASSEMBLY" .
2. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for eas- ier work. Refer to PS-33, "
Removal and Installation (VK45DE Models)" .
3. Remove A/T fluid cooler tube. Refer to AT- 2 7 0 , "
TRANSMISSION ASSEMBLY" .
4. Remove exhaust front tube and center muffler with power tool. Refer to EX-3, "
EXHAUST SYSTEM" .
5. Remove RH and LH transverse link mounting bolts and nuts. Refer to FSU-14, "
TRANSVERSE LINK" .
6. Disconnect stabilizer connecting rod lower. Refer to FSU-6, "
FRONT SUSPENSION ASSEMBLY" .
7. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so that it does not sag. Refer to AT- 2 3 3 , "
SHIFT CONTROL SYSTEM" .
EM-242
[VK45DE]
ENGINE ASSEMBLY
Revision: 2005 July 2005 FX
8. Remove rear plate cover from oil pan. Then remove bolts fixing drive plate to torque converter. Refer to
EM-185, "
OIL PAN AND OIL STRAINER" and AT- 2 7 0 , "TRANSMISSION ASSEMBLY" .
9. Remove transmission joint bolts which pierce at oil pan lower rear side. Refer to AT- 2 7 0 , "
TRANSMIS-
SION ASSEMBLY" .
10. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to PS-12, "
STEERING COLUMN" .
11. Remove rear propeller shaft. Refer to PR-7, "
REAR PROPELLER SHAFT" .
After disconnection, plug the opening on transmission side.
12. Remove front drive shaft (both side). Refer to FAX-12, "
FRONT DRIVE SHAFT" .
13. Remove front propeller shaft. Refer to PR-4, "
FRONT PROPELLER SHAFT" .
14. Remove three way catalyst (both bank). Refer to EM-182, "
EXHAUST MANIFOLD AND THREE WAY
CATALYST" .
Removal Work
1. Install engine slingers into front of cylinder head (left bank) and
front of cylinder head (right bank).
2. Lift with hoist and secure engine in position.
3. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission.
CAUTION:
Put a piece of wood or something similar as the supporting surface, secure a completely stable
condition.
4. Remove engine rear member mounting bolts.
5. Remove front suspension member mounting nuts with power tool. Refer to FSU-6, "
FRONT SUSPEN-
SION ASSEMBLY" .
6. Carefully lower jack, or raise lift to remove engine, transmission front final drive and front suspension member assembly. When
performing work, observe the following caution:
CAUTION:
Confirm there is no interference with vehicle.
Make sure that all connection points have been discon-
nected.
Keep in mind the center of vehicle gravity changes. If
necessary, use jack(s) to support vehicle at rear jacking
point(s) to prevent it from falling it off the lift. Slinger bolts:
:33.4 N·m (3.4 kg-m, 25 ft-lb)
PBIC1556E
PBIC1557E
ENGINE ASSEMBLY EM-243
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Separation Work
1. Change engine slinger installing to cylinder head (right bank).
NOTE:
In order to keep secure position when hoisting engine.
2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine and transmission assembly from front suspension member. CAUTION:
Before and during this lifting, always make sure that any harnesses are left connected.
Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator. Refer to SC-23, "
CHARGING SYSTEM" .
5. Remove starter motor. Refer to SC-10, "
STARTING SYSTEM" .
6. Separate engine from transmission assembly. Refer to AT- 2 7 3 , "
Removal and Installation (AWD Models)"
.
7. Remove front final drive from engine. Refer to FFD-12, "
FRONT FINAL DRIVE ASSEMBLY" .
8. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
9. Remove engine rear member and engine mounting insulator (rear) from transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
For a location with a positioning pin, insert it securely into hole of mating part.
For a part with a specified installation orientation, refer to component figure in EM-240, "Removal and
Installation" .
When installing engine mounting brackets (RH and LH) on cylin-
der block, tighten two upper bolts (shown as “A” in the figure)
first. Then tighten two lower bolts (shown as “B” in the figure).
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-12, "
RECOMMENDED FLUIDS AND LUBRICANTS"
Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant. Slinger bolts:
:33.4 N·m (3.4 kg-m, 25 ft-lb)
PBIC2447E
PBIC2365E
EM-244
[VK45DE]
ENGINE ASSEMBLY
Revision: 2005 July 2005 FX
Bleed air from lines and hoses of applicable lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc. Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —