Removal and Installation
Removal and Installation
REMOVAL
1. Remove the intake manifold. Refer to "REMOVAL".
2. Remove the timing chains. Refer to "REMOVAL".
3. Remove the three way catalysts (manifolds), exhaust manifold heat shields and RH exhaust manifold. Refer to "Removal and Installation".
4. Remove the intake and exhaust camshafts and the 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 order shown.
5. Remove the water outlet. Refer to "REMOVAL".
6. Remove the RH and LH cylinder head bolts, using power tool.
^ The bolts should be loosened gradually in three steps in the order shown.
7. Remove cylinder heads and gaskets.
^ Discard the cylinder head gaskets and use new gaskets for installation.
8. If necessary, remove the exhaust manifolds. Loosen the exhaust manifold nuts in the order shown.
INSPECTION AFTER REMOVAL
Outer Diameter of Cylinder Head Bolts
^ Inspect the cylinder head bolts before installing the cylinder heads.
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.
Limit (d1 - d2) : 0.11 mm (0.0043 inch)
^ If a reduction in outer diameter appears in a position other than d2, use it as the d2 measuring point.
^ Lubricate threads and seat surfaces of the bolts with new engine oil 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 No. 1 camshaft bracket, remove the old Silicone RTV 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 separately or valves will strike piston heads.
5. If necessary, install the exhaust manifolds. Tighten the exhaust manifold nuts in the order shown.
Exhaust manifold nuts :28.4 - 33.3 Nm (2.9 - 3.3 kg-m, 21 - 24 ft. lbs.)
6. Install the cylinder heads on the cylinder block. Tighten the cylinder head bolts in five steps in the order shown.
Step a :98 Nm (10 kg-m, 72 ft. lbs.)
Step b : 0 Nm Loosen in the reverse order of tightening.
Step c : 32.9 Nm (4.0 kg-m, 29 ft. lbs.)
Step d : 90° degrees clockwise
Step e : 90° degrees clockwise
7. Install the water outlet. Refer to "INSTALLATION".
8. Install camshaft chain tensioners on both sides of cylinder head.
Camshaft chain tensioner bolts : 7 - 10 Nm (0.8 - 1.0 kg-m, 62 - 88 inch lbs.)
9. 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.
10. Before installing No. 1 camshaft bracket, apply sealant to mating surface.
^ Use Genuine Silicone RTV Sealant, or equivalent. Refer to "RECOMMENDED CHEMICAL PRODUCTS AND SEALANTS".
^ Before installation, wipe off any protruding sealant.
^ Refer to "LIQUID GASKET APPLICATION PROCEDURE".
^ Install camshaft brackets in their original positions and directions. Align the stamp marks as shown.
^ If any part of the valve assembly or camshaft is replaced, check and adjust the valve clearance. Refer to "Valve Clearance".
11. Tighten the camshaft bracket bolts in five steps in the order shown.
NOTE: Lubricate the threads and seat surfaces of the camshaft bracket bolts with new engine oil before installation.
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 : 5.88 Nm (0.6 kg-m, 52 inch lbs.)
Step 4 (bolts 1 - 6) : 10.4 Nm (1.1 kg-m, 92 inch lbs.)
12. 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.)
13. Install the new O-rings on the cylinder block.
14. Install the new O-rings on the cylinder head.
15. Install the RH exhaust manifold, three way catalysts (manifolds) and exhaust manifold heat shields. Refer to "Removal and Installation".
16. Install timing chain. Refer to "Removal and Installation".
17. Install the intake manifold. Refer to "INSTALLATION".