Installation
Components
CAUTION:
^ When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
^ Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft bracket.
^ Attach tags to valve lifters so as not to mix them up.
Installation
1. Before installing rear timing chain case, remove old liquid gasket from mating surface using a scraper.
^ Also remove old liquid gasket from mating surface of cylinder block.
^ Remove old liquid gasket from the bolt hole and thread.
2. Before installing cam bracket, remove old liquid gasket from mating surface using a scraper.
3. Before installing the cylinder head gasket, be sure that No. 1 cylinder is at TDC.
^ At this time, the crankshaft key should face toward the right bank.
4. Install cylinder heads with new gaskets.
^ Do not rotate crankshaft and camshaft separately, or valves will strike piston heads.
CAUTION: Cylinder head bolts are tightened by using the plastic zone (Torque-to-yeild) tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them 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.
5. Install cylinder head outside bolts.
^ Tightening procedure:
a. Tighten all bolts to 98 Nm (10 kg-m, 72 ft. lbs.).
b. Completely loosen all bolts.
c. Tighten all bolts to 34.3 to 44.1 Nm (3.5 to 4.4 kg-m, 26 to 32 ft. lbs.).
d. Turn all bolts 90 to 95 degrees clockwise.
e. Turn all bolts 90 to 95 degrees clockwise again.
^ Tighten in numerical order shown in the figure.
6. Install camshaft chain tensioners on both sides of cylinder head.
7. Install exhaust and intake camshafts and camshaft brackets.
^ Exhaust camshaft has a dowel pin on camshaft sprocket mounting flange. Install it on the exhaust side.
^ Identification marks are present on camshafts.
^ Position camshaft
RH exhaust camshaft dowel pin at about 10 o'clock
LH exhaust camshaft dowel pin at about 2 o'clock
8. Before installing camshaft brackets, apply sealant to mating surface of No. 1 camshaft bracket.
^ Use Genuine RTV silicone sealant or equivalent.
^ Install camshaft brackets in their original positions. Align stamp mark as shown in the figure. If any part of valve assembly or camshaft is replaced, check valve clearance according to reference data. After completing assembly check valve clearance.
Reference data valve clearance (Cold):
Intake 0.26- 0.34 mm (0.010 - 0.013 inch)
Exhaust 0.29 - 0.37 mm (0.011 - 0.015 inch)
^ Lubricate threads and seat surfaces of camshaft bracket bolts with new engine oil before installing them.
^ Tighten the camshaft brackets in the following steps.
9. Install intake valve timing control solenoid valves.
10. Install O-rings to cylinder block.
11. Install O-rings to cylinder head.
12. Apply sealant to the hatched portion of rear timing chain case.
^ Apply continuous bead of liquid gasket to mating surface of rear timing chain case.
^ Before installation, wipe off the protruding sealant.
13. Align rear timing chain case with dowel pins, then install on cylinder head and block.
14. Tighten rear chain case bolts.
a. Tighten bolts in numerical order shown in the figure with smaller torque than specified.
b. Tighten bolts to the specified torque repeating above step a.
15. Reinstall all removed parts in reverse order of removal.