Removal and Installation
Removal and Installation
REMOVAL
1. Remove the timing chains.
2. Perform the Fuel Pressure Release Procedure, then remove the fuel rail and injectors.
3. Remove the intake manifold using power tool.
^ Loosen the bolts in the numerical order as shown.
4. Remove the coolant outlet housing.
5. Remove rear timing chain case bolts using power tool.
^ Loosen the bolts in the numerical order as shown.
6. Remove rear timing chain case using Tool.
7. Remove the O-rings from the front of the cylinder heads.
^ Discard the O-rings and use new O-rings for installation.
8. Remove the O-rings from the cylinder block.
^ Discard the O-rings and use new O-rings for installation.
9. Remove the IVT control valves.
^ Discard the IVT control valve gaskets and use new gaskets for installation.
10. Remove the intake and exhaust camshafts and camshaft brackets.
^ Mark the camshaft brackets so they are placed in the same position and direction for installation.
^ Equally loosen the camshaft bracket bolts in several steps in the numerical order shown
11. Remove the RH and LH cylinder head bolts, with power tool.
^ The bolts should be loosened gradually in three stages.
^ Loosen the bolts in the numerical order as shown.
12. Remove cylinder heads and gaskets.
^ Discard the cylinder head gaskets and use new gaskets for installation.
INSTALLATION
1. Before installing the rear timing chain case, remove the old Silicone RTV Sealant from mating surface using a scraper.
^ Also remove old sealant from mating surface of cylinder block.
^ Remove the old Silicone RTV Sealant from the bolt hole and thread.
2. Before installing the front cam bracket, remove the old RTV Silicone Sealant from the mating surface using a scraper.
^ Do not scratch the mating surface.
3. Turn the crankshaft until No. 1 piston is set at TDC on the compression stroke.
^ The crankshaft key should line up with the right bank cylinder center line as shown.
4. Install new gaskets on the cylinder heads.
CAUTION: Do not rotate crankshaft and camshaft will strike piston heads.
5. Inspect the cylinder head bolts before installing the cylinder head.
CAUTION: Cylinder head bolts are tightened by degree rotation tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace the bolts with new ones.
- Subtract the head bolt diameter measurement taken at d2 from the head bolt diameter measurement taken at d1. If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones.
Limit (d1 - d2): 0.11 mm (0.0043 inch)
^ Lubricate threads and seat surfaces of the bolts with new engine oil.
6. Install the cylinder heads on the cylinder block. Tighten the cylinder head bolts in the five stages in the numerical order as shown.
Tightening procedure:
Stage a: 98 Nm (10 kg-m, 72 ft. lbs.)
Stage b: Loosen in the reverse order of tightening.
Stage c: 34.3 - 44.1 Nm (3.5 - 4.4 kg-m, 26 - 32 ft. lbs.)
Stage d: 90° - 95° degrees clockwise
Stage e: 90° - 95° degrees clockwise
7. Install camshaft chain tensioners on both sides of cylinder head.
Camshaft chain tensioner bolts: 7 - 10 Nm (0.7 - 1.0 kg-m, 62 - 89 inch lbs.)
8. Install exhaust and intake camshafts and camshaft brackets.
Intake camshaft has a drill mark on camshaft sprocket mounting flange.
^ Follow your identification marks made during removal, or follow the identification marks that are present on the new camshaft components for proper placement
^ Position the camshafts:
RH exhaust camshaft dowel pin at about 10 o'clock
LH exhaust camshaft dowel pin at about 2 o'clock
9. Before installing camshaft brackets, apply sealant to mating surface of No. 1 journal head.
^ Use Genuine RTV Silicone Sealant, or equivalent.
^ Install camshaft brackets in their original positions and direction. Align the stamp marks as shown.
^ If any part of valve assembly or camshaft Clearance".
Valve clearance (cold) Intake: 0.26 - 0.34 mm (0.010 - 0.013 inch)
Valve clearance (cold) Exhaust: 0.29 - 0.37 mm (0.011 - 0.015 inch)
^ Lubricate the threads and seat surfaces of the camshaft bracket bolts with new engine oil before installation.
10. Tighten the camshaft brackets in the following five steps in the numerical order shown.
Camshaft bracket bolts
Step 1 (bolts 7 - 10): 1.96 Nm (0.2 kg-m, 17 inch lbs.)
Step 2 (bolts 1 - 6): 1.96 Nm (0.2 kg-m, 17 inch lbs.)
Step 3: 6 Nm (0.6 kg-m, 52 inch lbs.)
Step 4 (bolts 1 - 6): 9.02 - 11.8 Nm (0.92 - 1.20 kg-m, 79.9- 104.2 inch lbs.)
Step 5 (bolts 7 - 10): 8.3 - 10.3 Nm (0.9 - 1.0 kg-m, 74 - 91 inch lbs.)
11. Install the IVT control solenoid valves with new gaskets.
IVT control solenoid valve bolts: 10 - 12 Nm (1.0 - 1.3 kg-m, 87 - 112 inch lbs.)
12. Install the new O-rings on the cylinder block.
13. Install the new O-rings on the cylinder head.
14. Apply sealant to the specified portion of the rear timing chain case.
^ Use Genuine Silicone RTV Sealant, or equivalent.
Before installation, wipe off the protruding sealant.
15. Align rear timing chain case with dowel pins, then install on cylinder head and block.
16. Tighten rear chain case bolts in two stages.
a. Tighten bolts in numerical order shown.
b. Retighten bolts in numerical order shown.
17. Install the coolant outlet housing.
18. Install the intake manifold with a new gasket.
^ Tighten the bolts in the numerical order as shown.
Step 1: 5 - 10 Nm (0.5 - 1.0 kg-m, 44 - 86 inch lbs.)
Step 2: 26 - 31 Nm (2.7 - 3.2 kg-m, 20 - 23 ft. lbs.)
19. Install the fuel rail and injectors.
20. Install the timing chains.