Disassembly
- Remove intake manifold collector. Refer to " «EXPLODED VIEW»(ref-404359-S25658804512011061100000) ".
- Remove intake manifold. Refer to " «EXPLODED VIEW»(ref-404359-S18939595832011061100000) ".
- Remove exhaust manifold. Refer to " «EXPLODED VIEW»(ref-404359-S42039101542011061100000) ".
- Remove oil pan (lower and upper). Refer to " «EXPLODED VIEW»(ref-404359-S11368718592011061100000) ".
- Remove ignition coil, spark plug and rocker cover. Refer to " «EXPLODED VIEW»(ref-404359-S01642703682011061100000) ".
- Remove fuel injector and fuel tube. Refer to " «EXPLODED VIEW»(ref-404359-S19322978222011061100000) ".
- Remove timing chain and rear timing chain case. Refer to " «EXPLODED VIEW»(ref-404359-S24048172242011061100000) " and " «EXPLODED VIEW»(ref-404359-S18675987462011061100000) ".
- Remove camshaft. Refer to " «EXPLODED VIEW»(ref-404359-S12393902742011061100000) ".
- Remove cylinder head. Refer to " «EXPLODED VIEW»(ref-404359-S40627608342011061100000) ".
Assembly
Assembly in the reverse order of disassembly.
Scheme 226
Refer to " COMPONENTS " for symbols in the figure.
Scheme 227
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Scheme 231
- Remove front timing chain case and timing chain. Refer to " «EXPLODED VIEW»(ref-404359-S24048172242011061100000) ".
- Remove water pump. Refer to " «EXPLODED VIEW»(ref-404360-S39039287302011061100000) ".
- Remove oil pans (upper and lower) and oil strainer. Refer to " «EXPLODED VIEW»(ref-404359-S11368718592011061100000) ".
- Remove rear timing chain case as follows: Loosen and remove mounting bolts in the reverse order as shown in the illustration. Cut liquid gasket using the seal cutter [SST: KV10111100 (J-37228)] and remove rear timing chain case. CAUTION: Never remove plate metal cover (1) of oil passage. After removal, handle rear timing chain case carefully so it does not tilt, cant, or warp under a load.
- Remove O-rings (1) from cylinder block.
- Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary. Remove camshaft brackets (No. 1). Refer to " «EXPLODED VIEW»(ref-404359-S12393902742011061100000) ". Remove timing chain tensioners (secondary) (1) with a stopper pin (B) attached.
- Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and opposite mating surfaces. Remove old liquid gasket from bolt hole (B) and thread.
Scheme 232
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Scheme 234
- Install rear timing chain case as follows: Install new O-rings (1) onto cylinder block. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as shown in the illustration. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-404349-S19299801482011061100000) ". CAUTION: For "A" in the figure, completely wipe out liquid gasket extended on a portion touching at engine coolant. Apply liquid gasket on installation position of water pump and cylinder head very completely. Align rear timing chain case with dowel pins (bank 1 and bank 2) on cylinder block and install rear timing chain case. Check O-rings stay in place during installation to cylinder block and cylinder head. Tighten mounting bolts in numerical order as shown in the illustration. There are two types of mounting bolts. Refer to the following for locating bolts. Bolt length: Bolt position 20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10 16 mm (0.63 in) : Except the above : 12.7 N.m (1.3 kg-m, 9 ft-lb) After all bolts tightening, retighten them to the specified in numerical order as shown in the illustration. If liquid gasket protrudes, wipe it off immediately. After installing rear timing chain case (1), check the surface height difference between the following parts on the oil pan (upper) mounting surface. Standard Rear timing chain case to cylinder block: -0.24 to 0.14 mm (-0.009 to 0.006 in) If not within the standard, repeat the installation procedure.
- Install water pump with new O-rings. Refer to " «EXPLODED VIEW»(ref-404360-S39039287302011061100000) ".
- Install front timing chain case and timing chain. Refer to " «EXPLODED VIEW»(ref-404359-S24048172242011061100000) ".
- After installing front timing chain case, check the surface height difference between the following parts on the oil pan (upper) mounting surface. Standard Front timing chain case to rear timing chain case: -0.14 to 0.14 mm (-0.006 to 0.006 in) If not within the standard, repeat the installation procedure.
- Install in the reverse order of removal after this step.
Scheme 235
Refer to " COMPONENTS " for symbols in the figure.
Scheme 236
Scheme 237
Scheme 238
- Remove front timing chain case, camshaft sprocket, timing chain and rear timing chain case. Refer to " «EXPLODED VIEW»(ref-404359-S24048172242011061100000) " and " «EXPLODED VIEW»(ref-404359-S18675987462011061100000) ".
- Loosen camshaft sensor bracket bolts in the reverse order as shown in the illustration. NOTE: The order of loosening bolts in the same for bank 1 and bank 2.
- Remove camshaft brackets. Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for installation. Equally loosen camshaft bracket bolts in several steps in the reverse order as shown in the illustration.
- Remove camshafts.
- Remove valve lifters. Identify installation positions, and store them without mixing them up.
- Remove timing chain tensioners (secondary) (1) from cylinder head. Remove timing chain tensioner (secondary) with its stopper pin (C) attached. NOTE: Stopper pin was attached when timing chain (secondary) was removed.
Scheme 239
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Scheme 247
- Install timing chain tensioners (secondary) (1) on both sides of cylinder head. Install timing chain tensioner (secondary) with its stopper pin (C) attached. Install timing chain tensioner (secondary) with sliding part facing downward on cylinder head (bank 1), and with sliding part facing upward on cylinder head (bank 2).
- Install valve lifters. Install it in the original position.
- Install camshafts. Follow your identification marks made during removal, or follow the identification marks that are present on new camshafts for proper placement and direction. PAINT MARK REFERENCE CHART Bank INT/EXH Dowel pin (1) Paint marks M1 (D) M2 (E) M3 (C) 1 EXH (B) Yes No Light blue Light blue INT (A) Yes Pink No Light blue 2 INT (A) Yes Pink No Light blue EXH (B) Yes No Light blue Light blue Install camshaft so dowel pin (A) on front end face are positioned as shown in the illustration. (No. 1 cylinder TDC on its compression stroke) NOTE: Though camshaft does not stop at the portion as shown in the illustration, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure.
- Install camshaft brackets. Remove foreign material completely from camshaft bracket backside and from cylinder head installation face. Install camshaft bracket in original position and direction as shown in the illustration. Install camshaft brackets (No. 2 to 4) aligning the stamp marks (A) as shown in the illustration. NOTE: There are no identification marks indicating left and right for camshaft bracket (No. 1). Apply liquid gasket to mating surface of camshaft bracket (No. 1) as shown on bank 1 and bank 2. Use Genuine RTV Silicone Sealant or equivalent. Refer to " «RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS»(ref-404349-S19299801482011061100000) ".
- Tighten camshaft bracket bolts in the following steps, in numerical order as shown in the illustration. Tighten No. 7 to 10 in order as shown. : 1.96 N.m (0.20 kg-m, 1 ft-lb) Tighten No. 1 to 6 in order as shown. : 1.96 N.m (0.20 kg-m, 1 ft-lb) Tighten No. 1 to 10 in numerical order as shown. : 5.88 N.m (0.60 kg-m, 4 ft-lb) Tighten No. 1 to 10 in numerical order as shown. : 10.4 N.m (1.1 kg-m, 8 ft-lb) CAUTION: After tightening mounting bolts of camshaft brackets (No. 1), be sure to wipe off excessive liquid gasket from the parts list below. Mating surface of rocker cover Mating surface of rear timing chain case
- Tighten camshaft sensor bracket bolts in numerical order as shown in the illustration. NOTE: The order of tightening bolts in the same for bank 1 and bank 2.
- Measure difference in levels between front end faces of camshaft bracket (No. 1) and cylinder head. Standard : -0.14 to 0.14 mm (-0.0055 to 0.0055 in) Measure two positions (both intake and exhaust side) for a single bank. If the measured value is out of the standard, reinstall camshaft bracket (No. 1).
- Inspect and adjust the valve clearance. Refer to " «INSPECTION AND ADJUSTMENT»(ref-404359-S00875838512011061100000) ".
- Install in the reverse order of removal after this step.