INSTALLATION PROCEDURE 1. SET NO. 1 CYLINDER TO TDC (COMPRESSION)
| (a)
Confirm that the timing mark (cutout) on the crankshaft pulley is
aligned with the "0" timing mark of the timing chain cover assembly. |
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*a | Timing Mark (Cutout) | |
*b | "0" Timing Mark | | |
2. SET CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 2) HINT: Perform Inspection After Repair after replacing the camshaft timing gear assembly.
Click here 
| (a)
Align the mark plate (yellow) with the timing mark of the camshaft
timing gear assembly as shown in the illustration and install the No. 2
chain sub-assembly to the camshaft timing gear assembly. |
 |
|
*a | Timing Mark | |
*b | Mark Plate | | |
| (b)
Install the chain sub-assembly to the camshaft timing gear assembly,
and then set the camshaft timing gear assembly to the camshaft housing
sub-assembly LH.
HINT:
- Place the chain sub-assembly on the camshaft timing gear assembly but do
not engage the teeth of the sprocket and the chain sub-assembly.
- Be sure to install the camshaft timing gear assembly with the timing mark facing upward.
|
 |
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*a | Place on camshaft timing gear assembly | | |
3. SET CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 2) HINT:
Perform Inspection After Repair after replacing the camshaft timing exhaust gear assembly.
Click here
| (a)
Align the mark plate (yellow) with the timing mark of the camshaft
timing exhaust gear assembly as shown in the illustration and install
the No. 2 chain sub-assembly to the camshaft timing exhaust gear
assembly. |
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|
*a | Timing Mark | |
*b | Mark Plate | | |
(b) Set the camshaft timing exhaust gear assembly to the camshaft housing sub-assembly LH.
4. SET NO. 3 CHAIN TENSIONER ASSEMBLY
| (a)
While lifting up the camshaft timing exhaust gear assembly, pass the
No. 3 chain tensioner assembly through the No. 2 chain sub-assembly and
set it in place. NOTICE: Temporarily set the No. 3 chain tensioner assembly only, do not install the bolt. |
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5. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY HINT: Perform Inspection After Repair after replacing the No. 3 camshaft sub-assembly.
Click here (a) Clean the camshaft housing sub-assembly LH and No. 3 camshaft sub-assembly journals and apply engine oil to them.
| (b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. |
 |
|
*1 | No. 1 Valve Rocker Arm Sub-assembly | |
*2 | Valve Lash Adjuster Assembly | |
*3 | Valve Stem | |
*4 | Valve Stem Cap | | |
| (c)
Align the straight pin of the No. 3 camshaft sub-assembly and the pin
hole of the camshaft timing gear assembly, and install the No. 3
camshaft sub-assembly to the camshaft timing gear assembly. NOTICE:
Be
careful not to damage the contact surface of the camshaft timing gear
assembly with the straight pin of the No. 3 camshaft sub-assembly. |
 |
|
*a | Pin Hole | |
*b | Straight Pin | | |
(d) Check that there is no clearance between the camshaft timing gear assembly and No. 3 camshaft sub-assembly flange.
6. INSTALL NO. 4 CAMSHAFT SUB-ASSEMBLY HINT: Perform Inspection After Repair after replacing the No. 4 camshaft sub-assembly.
Click here (a) Clean the camshaft housing sub-assembly LH and No. 4 camshaft sub-assembly journals and apply engine oil to them.
| (b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. |
|
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*1 | No. 1 Valve Rocker Arm Sub-assembly | |
*2 | Valve Lash Adjuster Assembly | |
*3 | Valve Stem | |
*4 | Valve Stem Cap | | |
| (c)
Align the straight pin of the No. 4 camshaft sub-assembly and the pin
hole of the camshaft timing exhaust gear assembly, and install the No. 4
camshaft sub-assembly to the camshaft timing exhaust gear assembly. NOTICE:
Be
careful not to damage the contact surface of the camshaft timing
exhaust gear assembly with the straight pin of the No. 4 camshaft
sub-assembly. |
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|
*a | Pin Hole | |
*b | Straight Pin | | |
(d) Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 4 camshaft sub-assembly flange.
7. SET CAMSHAFT BEARING CAP (for Bank 2) (a) Clean the camshaft bearing caps and apply engine oil to them.
| (b) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
HINT: To
ensure there is sufficient space for installing the No. 3 camshaft
bearing cap and No. 4 camshaft bearing cap, slide the camshaft timing
gear assembly and camshaft timing exhaust gear assembly. | |
| (c) Remove the replacement bolts and washers (No. 3 camshaft bearing cap and No. 4 camshaft bearing cap side).
NOTICE: Do
not remove any of the replacement bolts and washers other than those on
the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap side. |
 |
|
*a | Replacement Bolt and Washer | |
*b | No. 3 Camshaft Bearing Cap | |
*c | No. 4 Camshaft Bearing Cap | | |
(d) Temporarily set the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
NOTICE:
- Do not install the bolts of the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
- Do not install any camshaft bearing caps other than the No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.
| (e) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
NOTICE: Securely
insert the straight pins of the No. 3 camshaft sub-assembly and No. 4
camshaft sub-assembly into the pin holes of the camshaft timing gear
assembly and camshaft timing exhaust gear assembly. | |
8. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2)
(a) Check that there is no clearance between the camshaft timing gear assembly and No. 3 camshaft sub-assembly flange.
| (b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration. |
|
(c) Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly.
|
*a | Hold |
 |
Turn | (d) Temporarily install the camshaft timing gear bolt to the camshaft timing gear assembly.
Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}
NOTICE:
- Installing the camshaft timing gear bolt while there is external force
applied to the camshaft timing gear assembly could result in damage to
the engine, so make sure that the camshaft bearing cap is not installed
when temporarily installing the camshaft timing gear bolt.
- Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
- Make sure that the flange part of the camshaft timing gear bolt is directly contacting the camshaft timing gear assembly.
9. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2)
(a) Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 4 camshaft sub-assembly flange.
| (b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration. |
|
(c) Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly.
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*a | Hold | |
|
Turn | (d) Temporarily install the camshaft timing gear bolt to the camshaft timing exhaust gear assembly.
Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}
NOTICE:
- Installing the camshaft timing gear bolt while there is external force
applied to the camshaft timing exhaust gear assembly could result in
damage to the engine, so make sure that the camshaft bearing cap is not
installed when temporarily installing the camshaft timing gear bolt.
- Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
- Make sure that the flange part of the camshaft timing gear bolt is
directly contacting the camshaft timing exhaust gear assembly.
10. INSTALL CAMSHAFT BEARING CAP (for Bank 2) (a) Clean the camshaft bearing caps and apply engine oil to them.
(b)
Check the marks and numbers on the camshaft bearing caps, and then
remove the replacement bolts and washers in the order shown in the
illustration. Immediately after removing the replacement bolts and
washers in the location for a camshaft bearing cap, install the camshaft
bearing cap with the bolts in the order shown in the illustration. Torque:
Bolt (A) : 28 N·m {286 kgf·cm, 21 ft·lbf} Bolt (B) : 16 N·m {163 kgf·cm, 12 ft·lbf}
NOTICE:
- Be sure to follow the numerical order when performing this procedure.
- Do not drop replacement bolts and washers into the cylinder head LH.
|
*a | Replacement Bolt and Washer | |
*b | Replacement Bolt and Washer Removal | |
*c | Part Installation | |
|
Bolt (A) |
 |
Bolt (B) | (c) Check the torque of each bolt again.
11. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 2) (a) Use a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly.
|
*a | Hold | |
|
Turn | (b) Tighten the camshaft timing gear bolt.
Torque: 95 N·m {969 kgf·cm, 70 ft·lbf} NOTICE: Be careful not to damage the No. 3 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
12. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 2) (a) Use a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly.
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*a | Hold | |
|
Turn | (b) Tighten the camshaft timing gear bolt.
Torque: 95 N·m {969 kgf·cm, 70 ft·lbf} NOTICE: Be careful not to damage the No. 4 camshaft sub-assembly, camshaft housing sub-assembly LH or spark plug tube with the wrench.
13. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY (a) Install the No. 3 chain tensioner assembly with the bolt.
Torque: 21 N·m {214 kgf·cm, 15 ft·lbf} 14. CONNECT CHAIN SUB-ASSEMBLY (for Bank 2)
| (a)
Align the paint marks on the camshaft timing gear assembly and chain
sub-assembly and install the chain sub-assembly to the camshaft timing
gear assembly. HINT: If the paint marks are not aligned, align them by turning the No. 3 camshaft sub-assembly slightly. |
|
15. SET CAMSHAFT TIMING GEAR ASSEMBLY (for Bank 1) HINT: Perform Inspection After Repair after replacing the camshaft timing gear assembly.
Click here
| (a)
Align the mark plate (yellow) with the timing mark of the camshaft
timing gear assembly as shown in the illustration and install the No. 2
chain sub-assembly to the camshaft timing gear assembly. |
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|
*a | Timing Mark | |
*b | Mark Plate | | |
| (b)
Install the chain sub-assembly to the camshaft timing gear assembly,
and then set the camshaft timing gear assembly to the camshaft housing
sub-assembly.
HINT:
- Place the chain sub-assembly on the camshaft timing gear assembly but do
not engage the teeth of the sprocket and the chain sub-assembly.
- Be sure to install the camshaft timing gear assembly with the timing mark facing upward.
|
 |
|
*a | Place on camshaft timing gear assembly | | |
16. SET CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY (for Bank 1) HINT:
Perform Inspection After Repair after replacing the camshaft timing exhaust gear assembly.
Click here
| (a)
Align the mark plate (yellow) with the timing mark of the camshaft
timing exhaust gear assembly as shown in the illustration and install
the No. 2 chain sub-assembly to the camshaft timing exhaust gear
assembly. |
 |
|
*a | Timing Mark | |
*b | Mark Plate | | |
(b) Set the camshaft timing exhaust gear assembly to the camshaft housing sub-assembly.
17. SET NO. 2 CHAIN TENSIONER ASSEMBLY
| (a)
While lifting up the camshaft timing exhaust gear assembly, pass the
No. 2 chain tensioner assembly through the No. 2 chain sub-assembly and
set it in place. NOTICE: Temporarily set the No. 2 chain tensioner assembly only, do not install the bolt. |
|
18. INSTALL CAMSHAFT HINT: Perform Inspection After Repair after replacing the camshaft.
Click here
| (a)
Turn the crankshaft clockwise until it is in the position shown in the
illustration so that the chain sub-assembly can be installed easily. HINT:
When turning the crankshaft, engine oil may spray out of the oil holes. |
|
(b) Clean the camshaft housing sub-assembly and camshaft journals and apply engine oil to them.
| (c) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. |
|
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*1 | No. 1 Valve Rocker Arm Sub-assembly | |
*2 | Valve Lash Adjuster Assembly | |
*3 | Valve Stem | |
*4 | Valve Stem Cap | | |
| (d)
Align the straight pin of the camshaft and the pin hole of the camshaft
timing gear assembly, and install the camshaft to the camshaft timing
gear assembly. NOTICE: Be careful not to damage the contact surface of the camshaft timing gear assembly with the straight pin of the camshaft. |
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|
*a | Pin Hole | |
*b | Straight Pin | | |
(e) Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.
19. INSTALL NO. 2 CAMSHAFT HINT: Perform Inspection After Repair after replacing the No. 2 camshaft.
Click here (a) Clean the camshaft housing sub-assembly and No. 2 camshaft journals and apply engine oil to them.
| (b) Make sure that the No. 1 valve rocker arm sub-assembly is installed as shown in the illustration. |
|
|
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*1 | No. 1 Valve Rocker Arm Sub-assembly | |
*2 | Valve Lash Adjuster Assembly | |
*3 | Valve Stem | |
*4 | Valve Stem Cap | | |
| (c)
Align the straight pin of the No. 2 camshaft and the pin hole of the
camshaft timing exhaust gear assembly, and install the No. 2 camshaft to
the camshaft timing exhaust gear assembly. NOTICE: Be
careful not to damage the contact surface of the camshaft timing
exhaust gear assembly with the straight pin of the No. 2 camshaft. |
 |
|
*a | Pin Hole | |
*b | Straight Pin | | |
(d) Check that there is no clearance between the camshaft timing gear assembly and No. 2 camshaft flange.
20. SET CAMSHAFT BEARING CAP (for Bank 1) (a) Clean the camshaft bearing caps and apply engine oil to them.
| (b) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
HINT: To
ensure there is sufficient space for installing the No. 1 camshaft
bearing cap and No. 2 camshaft bearing cap, slide the camshaft timing
gear assembly and camshaft timing exhaust gear assembly. | |
| (c) Remove the replacement bolts and washers (No. 1 camshaft bearing cap and No. 2 camshaft bearing cap side).
NOTICE: Do
not remove any of the replacement bolts and washers other than those on
the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap side. |
 |
|
*a | Replacement Bolt and Washer | |
*b | No. 1 Camshaft Bearing Cap | |
*c | No. 2 Camshaft Bearing Cap | | |
(d) Temporarily set the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.
NOTICE:
- Do not install the bolts of the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.
- Do not install any camshaft bearing caps other than the No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.
| (e) Slide the camshaft timing gear assembly and camshaft timing exhaust gear assembly as shown in the illustration.
NOTICE: Securely
insert the straight pins of the camshaft and No. 2 camshaft into the
pin holes of the camshaft timing gear assembly and camshaft timing
exhaust gear assembly. | |
21. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1)
(a) Check that there is no clearance between the camshaft timing gear assembly and camshaft flange.
| (b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration. |
|
(c) Use a wrench to hold the hexagonal portion of the camshaft.
|
*a | Hold | |
|
Turn | (d) Temporarily install the camshaft timing gear bolt.
Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}
NOTICE:
- Installing the camshaft timing gear bolt while there is external force
applied to the camshaft timing gear assembly could result in damage to
the engine, so make sure that the camshaft bearing cap is not installed
when temporarily installing the camshaft timing gear bolt.
- Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
- Make sure that the flange part of the camshaft timing gear bolt is directly contacting the camshaft timing gear assembly.
22. TEMPORARILY INSTALL CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1)
(a) Check that there is no clearance between the camshaft timing exhaust gear assembly and No. 2 camshaft flange.
| (b) Apply engine oil to the areas of the camshaft timing gear bolt shown in the illustration. |
|
(c) Use a wrench to hold the hexagonal portion of the No. 2 camshaft.
|
*a | Hold | |
|
Turn | (d) Temporarily install the camshaft timing gear bolt.
Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}
NOTICE:
- Installing the camshaft timing gear bolt while there is external force
applied to the camshaft timing exhaust gear assembly could result in
damage to the engine, so make sure that the camshaft bearing cap is not
installed when temporarily installing the camshaft timing gear bolt.
- Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
- Make sure that the flange part of the camshaft timing gear bolt is
directly contacting the camshaft timing exhaust gear assembly.
23. INSTALL CAMSHAFT BEARING CAP (for Bank 1) (a) Clean the camshaft bearing caps and apply engine oil to them.
(b)
Check the marks and numbers on the camshaft bearing caps, and then
remove the replacement bolts and washers in the order shown in the
illustration. Immediately after removing the replacement bolts and
washers in the location for a camshaft bearing cap, install the camshaft
bearing cap with the bolts in the order shown in the illustration. Torque:
Bolt (A) : 28 N·m {286 kgf·cm, 21 ft·lbf} Bolt (B), (C) :
16 N·m {163 kgf·cm, 12 ft·lbf}
NOTICE:
- Be sure to follow the numerical order when performing this procedure.
- Do not drop replacement bolts and washers into the cylinder head sub-assembly.
|
*a | Replacement Bolt and Washer | |
*b | Replacement Bolt and Washer Removal | |
*c | Part Installation | |
|
Bolt (A) | |
|
Bolt (B) |
 |
Bolt (C) | (c) Check the torque of each bolt again.
24. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Intake Side of Bank 1) (a) Use a wrench to hold the hexagonal portion of the camshaft.
|
*a | Hold | |
|
Turn | (b) Tighten the camshaft timing gear bolt.
Torque: 95 N·m {969 kgf·cm, 70 ft·lbf} NOTICE: Be careful not to damage the camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
25. TIGHTEN CAMSHAFT TIMING GEAR BOLT (for Exhaust Side of Bank 1) (a) Use a wrench to hold the hexagonal portion of the No. 2 camshaft.
|
*a | Hold | |
|
Turn | (b) Tighten the camshaft timing gear bolt.
Torque: 95 N·m {969 kgf·cm, 70 ft·lbf} NOTICE: Be careful not to damage the No. 2 camshaft, camshaft housing sub-assembly or spark plug tube with the wrench.
26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (a) Install the No. 2 chain tensioner assembly with the bolt.
Torque: 21 N·m {214 kgf·cm, 15 ft·lbf} 27. CONNECT CHAIN SUB-ASSEMBLY (for Bank 1)
| (a)
Align the paint marks on the camshaft timing gear assembly and chain
sub-assembly and install the chain sub-assembly to the camshaft timing
gear assembly. HINT: If the paint marks are not aligned, align them by turning the camshaft slightly. |
|
28. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
| (a)
Turn the crankshaft counterclockwise 30° past the "0" timing mark, and
then turn it clockwise to align the notch with the "0" timing mark. |
|
(b) Turn the crankshaft slightly to eliminate the slack in the chain sub-assembly.
HINT: Make sure there is some slack in the chain sub-assembly around the area where the No. 1 chain tensioner assembly is installed.
| (c) Turn the stopper plate clockwise to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly. |
 |
|
*a | Stopper Plate | |
*b | Plunger | | |
(d)
Turn the stopper plate counterclockwise to set the lock, and insert a
1.0 mm (0.0394 in.) diameter pin into the hole of the stopper plate. (e) Install the No. 1 chain tensioner assembly to the cylinder head sub-assembly with the 2 bolts.
Torque: 10 N·m {102 kgf·cm, 7 ft·lbf} (f) Remove the 1.0 mm (0.0394 in.) diameter pin from the No. 1 chain tensioner assembly.
29. INSPECT VALVE TIMING (a) Check the camshaft timing marks.
NOTICE:
- Check each timing mark from a viewpoint directly in line with the center
of the camshaft and the timing mark on each camshaft timing gear
assembly and each camshaft timing exhaust gear assembly.
- If the timing marks are checked from any other viewpoint, the valve timing may appear misaligned.
(b) Check that each camshaft timing mark is positioned as shown in the illustration.
|
*a | Timing Mark |
*b | Viewpoint |
HINT: For the camshaft or No. 3 camshaft sub-assembly: Be
sure to check mark (A) at the point where marks (B), (C) and (D) are
positioned in line. If the marks are checked from any other viewpoint,
they cannot be checked correctly.
 (c) If the valve timing is misaligned, reinstall the chain sub-assembly.
(d) Turn the crankshaft 2 revolutions, set the No. 1 cylinder to TDC/compression and check the timing marks again.
30. INSTALL TIMING CHAIN COVER PLATE Click here
31. INSTALL SPARK PLUG TUBE GASKET
Click here 32. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
Click here 33. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
Click here 34. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 2)
Click here 35. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 2)
Click here 36. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Exhaust Side of Bank 1)
Click here 37. INSTALL CAMSHAFT TIMING OIL CONTROL SOLENOID ASSEMBLY (for Intake Side of Bank 1)
Click here 38. INSTALL WATER FILLER BRACKET
Click here 39. INSTALL WIRE HARNESS CLAMP BRACKET
Click here 40. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Click here 41. INSTALL VACUUM PUMP ASSEMBLY
Click here 42. INSTALL IGNITION COIL ASSEMBLY
Click here 43. INSTALL AIR SURGE TANK TO INTAKE MANIFOLD GASKET
Click here 44. INSTALL INTAKE AIR SURGE TANK ASSEMBLY
Click here 45. CONNECT PURGE VALVE (PURGE VSV)
Click here 46. CONNECT VENTILATION HOSE
Click here 47. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
Click here 48. INSTALL ENGINE HANGERS
Click here 49. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND
Click here | 
