Removal and Installation
CAUTION:
^ When installing camshaft and oil seal, lubricate contacting surfaces with new engine oil.
^ When tightening cylinder head bolts, camshaft sprocket bolts and camshaft bracket bolts, lubricate bolt threads and seat surfaces with new engine oil.
^ Attach tags to valve lifters so as not to mix them up.
Removal
1. Drain engine coolant from radiator and cylinder block. Be careful not to spill coolant on drive belts.
2. Release fuel pressure.
Refer to Powertrain Management; Fuel Deliver.
3. Remove air duct to intake manifold collector.
4. Remove engine drive belts.
5. Remove front splash undercovers.
6. Remove front exhaust tube.
7. Before removing intake manifold collector from engine, the following parts should be disconnected to remove intake manifold collector:
^ EGR tube
^ Fuel injector connectors
^ Ground harness
^ Breather pipe
Harness connectors for:
^ IACV-AAC valve
^ Throttle position sensor
^ Throttle position switch
^ EGR temperature sensor
^ Water hoses from collector
^ Heater hoses
^ PCV hose
Vacuum hoses for:
^ EVAP canister
^ Power brake booster
^ Fuel pressure regulator
8. Remove intake manifold rear supports.
9. Remove exhaust manifold.
10. Remove ignition coils.
11. Remove spark plugs.
12. Remove rocker cover bolts in numerical order as shown in the figure.
13. Set No. 1 piston at TDC on its compression stroke.
^ Rotate crankshaft until mating mark on camshaft sprocket is set at position indicated in figure at left.
14. Remove camshaft position sensor (PHASE).
^ Do not allow any magnetic materials to contact the camshaft position sensor (PHASE).
^ Be careful not to damage sensor.
15. Remove intake valve timing control solenoid.
16. Remove cylinder head front cover.
17. Remove timing chain guide from camshaft bracket.
18. Attach a suitable stopper pin to chain tensioner.
19. Remove chain tensioner.
20. Remove camshaft sprocket bolts.
^ Apply paint to timing chain and cam sprockets for alignment during installation.
21. Remove camshaft sprockets.
22. Remove camshaft brackets and camshafts.
^ Apply I.D. marks to brackets to ensure correct reassembly.
^ Bolts should be loosened in two or three steps.
23. Remove cylinder head bolts.
24. Remove cylinder head with intake manifold.
^ Head warpage or cracking could result from removing in incorrect order.
^ Cylinder head bolts should be loosened in two or three steps.
Installation
1. Before installing cylinder head gasket, apply a bead of Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent to mating surface of cylinder block as shown.
2. Install cylinder head gasket.
^ When installing cylinder head with manifolds, use a new cylinder head gasket.
3. Install cylinder head with intake manifolds.
^ Be sure to install washers between bolts and cylinder head.
^ Do not rotate crankshaft and camshaft separately, or valves will strike piston heads.
^ Apply new engine oil to cylinder head bolt threads and seat surfaces.
Tightening Sequence
Torque Graph
Torque Table
^ Tightening procedure
a) Tighten bolts to 29 Nm (3 kg-m, 22 ft. lbs.).
b) Tighten bolts to 59 Nm (6 kg-m, 43 ft. lbs.).
c) Loosen bolts completely.
d) Tighten bolts to 29 Nm (3 kg-m, 22 ft. lbs.).
e) Turn bolts 50 to 55 degrees clockwise or if angle wrench is not available, tighten bolts to 59 ±4.9 Nm (6 ±0.5 kg-m, 43 ±3.6 ft. lbs.).
f) Tightening bolts (11 - 14) to 6.3 to 8.3 Nm (0.64 to 0.85 kg-m, 55.8 to 73.5 inch lbs.).
4. Install camshaft.
^ Make sure camshafts are aligned as shown in figure.
5. Install camshaft brackets.
^ Make sure camshaft brackets are aligned as marked during disassembly.
^ Apply new engine oil to bolt threads and seat surface.
^ Tighten camshaft bracket bolts in the following steps.
a) a Tighten bolts 9 - 12, then 1 - 8.
2.0 Nm (0.204 kg-m, 17.7 inch lbs.)
b) b Tighten bolts 1 - 12.
5.9 Nm (0.60 kg-m, 52.2 inch lbs.)
c) c Tighten bolts 1 - 12.
9.0 - 11.8 Nm (0.91 - 1.20 kg-m, 79 - 104 inch lbs.)
^ If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data. After completing assembly check valve clearance. Refer to Valve Clearance; Testing and Inspection.
Reference data valve clearance (Cold):
Intake 0.25 - 0.33 mm (0.010 - 0.013 inch)
Exhaust 0.32 - 0.40 mm (0.013 - 0.016 inch)
6. Install camshaft sprockets.
^ Set timing chain by aligning mating marks with those of camshaft sprockets.
7. Install camshaft sprocket bolts to correct torque. Refer to Timing Components; Timing Chain; Diagrams; Exploded Views.
^ Apply new engine oil to bolt threads and seat surface.
8. Install chain tensioner.
^ Before installing chain tensioner, insert a suitable pin into pin hole of chain tensioner.
^ After installing chain tensioner, remove the pin.
9. Install timing chain guide.
10. Install cylinder head front cover.
^ Apply RTV silicone sealant to cylinder head front cover.
^ Use Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent.
11. Install camshaft position sensor (PHASE).
12. Install intake valve timing control solenoid.
13. Before installing rocker cover, apply a bead of Genuine RTV silicone sealant Part No. 999MP-A7007 or equivalent to mating surface of cylinder head as shown.
14. Install rocker cover with rocker cover gasket and tighten bolts in numerical order as shown in the figure.
15. Install spark plugs.
16. Install ignition coils.
17. Install exhaust manifold.
18. Install intake manifold rear supports.
19. Connect the following components.
^ EGR tube
^ Ignition coils
^ Fuel injector connectors
^ Ground harness
^ Breather pipe
Harness connectors for:
^ IACV-AAC valve
^ Throttle position sensor
^ Throttle position switch
^ EGR temperature sensor
^ Water hoses from collector
^ Heater hoses
^ PCV hose
Vacuum hoses for:
^ EVAP canister
^ Power brake booster
^ Fuel pressure regulator
20. Install front exhaust tube.
21. Install front engine side covers.
22. Install air duct to intake manifold collector.
23. Install drive belts.
24. Install fuel pump fuse. Erase DTC if any DTC appears.