Installation
Inspection
Check for cracks and excessive wear at roller links. Replace chain if necessary.
TIMING CHAIN
Before installation, wipe off the protruding sealant.
CAUTION: After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets.
Before disconnecting fuel hose, release fuel pressure.
When removing the oil pans, oil pump assembly and timing chain from engine, first remove the crankshaft position sensor (POS) from the assembly.
Be careful not to damage sensor edges.
Do not spill engine coolant on drive belts.
9�:
Camshaft Bracket:
Installation
1. Apply liquid gasket to rear timing chain case.
2. Align rear timing chain case and water pump assembly with dowel pins (RH and LH) on cylinder block. Then install it.
Do not allow O-ring to drop.
a. Tighten mounting bolts in order as shown in the figure.
Install two types of mounting bolts, referring to the following instructions and figure.
Bolt length:
20 mm (0.79 inch)............(1, 2, 3, 6, 7, 8, 9, and 10 in the figure)
16 mm (0.63 inch)..............(other than the above)
b. After all bolts are temporarily tightened, retighten them to specified torque in order shown in the figure.
3. Install chain tension guide.
4. Make sure that camshaft and crankshaft are at TDC position of No.1 cylinder.
Make sure that dowel pin hole, dowel pin and crankshaft key are located as shown in the figure.
Camshaft dowel pin hole (intake-side):......At cylinder head upper face side in each bank
Camshaft dowel pin (exhaust-side):........At cylinder head upper face side in each bank
Crankshaft key:............At cylinder head side of RH bank
CAUTION: Hole on small diameter side must be used for intake dowel pin. Do not misidentify (Ignore big diameter side).
5. Install crankshaft sprocket.
Install it, with matching mark to timing chain facing front of engine.
6. Install secondary timing chain and camshaft sprocket.
CAUTION: Matching marks between timing chain and sprockets slip easily. Confirm all matching mark positions repeatedly during the installation process.
Push sleeve of secondary chain tensioner, and keep it pressed with stopper pin.
a. Align matching marks on secondary timing chain (gold link) with the ones on intake and exhaust sprockets (stamped). Then install them.
Matching marks of intake sprocket are on back side of secondary sprocket.
There are two types of matching marks: round and oval types. They should be used for RH/LH banks respectively.
RH bank:........Use round type.
LH bank:............Use oval type.
b. Align dowel pin and pin hole on camshaft with groove and dowel pin on sprocket. Then install them.
On intake side, align pin hole on small diameter side of camshaft front end with dowel pin on back side of camshaft sprocket. Then install them.
On exhaust side, align dowel pin on camshaft front end with pin groove on camshaft sprocket. Then install them.
Mounting bolts for camshaft sprockets must be tightened in step 8. Tightening them by hand is enough to prevent dislocation of dowel pins.
It may be difficult to visually check the dislocation of mating marks during and after installation. To make the matching easier, make a mating mark on the sprocket teeth in advance using paint.
7. Install secondary timing chain and sprocket to the other bank. Install primary timing chain at the same time.
Installation of the secondary timing chain follows the procedure described in step 6.
Install primary timing chain so that mating mark (punched) on camshaft sprocket is aligned with that (yellow link) on the timing chain, and mating mark (notched) on crankshaft sprocket is aligned with that on the timing chain, respectively.
When it is difficult to align mating marks of the primary timing chain with each sprocket, gradually turn the camshaft hexagonal portion using a spanner so it is aligned with the mating mark.
During alignment, be careful to prevent dislocation of mating marks on the secondary timing chain.
8. After confirming the mating marks are aligned, tighten the camshaft sprocket mounting bolts.
Secure the camshaft hexagonal portion using a spanner to tighten mounting bolts.
9. Pull out the stopper pin from the secondary timing chain tensioner.
10. Install internal chain guide.
11. Install slack guide.
Take care not to overtighten mounting bolts for slack guide. It is normal for a gap to exist under bolt seats when mounting bolts are tightened to specified torque.
12. Install chain tensioner for slack guide.
When installing chain tensioner, push in sleeve and keep it pressed with stopper pin.
Remove dirt and foreign materials completely from back and mounting surfaces of chain tensioner.
After installing, pull out stopper pin by pressing slack guide.
13. Confirm again that matching marks on sprockets and timing chain have not slipped.
14. Install front oil seal to front timing chain case.
15. Apply liquid gasket to water pump cover and chain tensioner cover.
Before installation, wipe off the protruding sealant.
16. Install water pump cover and chain tensioner cover.
17. Install O-rings on rear timing chain case.
18. Apply liquid gasket to front timing chain case.
Before installation, wipe off the protruding sealant.
19. Apply liquid gasket to front timing chain case.
20. Install front timing chain case.
Align dowel pin on rear timing chain case with hole on front timing chain case.
21. Tighten bolts to the specified torque in order shown in the figure.
22. After installing front timing chain case, check surface height difference between following parts on oil pan mounting surface.
Standard
Front timing chain case to rear timing chain case: -0.14 to 0.14 mm (-0.0055 to 0.0055 inch)
Oil pump to cylinder block: -0.36 to -0.10 mm (-0.0142 to -0.0039 inch)
Rear timing chain case to cylinder block: -0.24 to 0.14 mm (-0.0094 to 0.0055 inch)
If not within standard, repeat above installation procedure.
23. Install intake valve timing control valve cover.
a. Install new O-rings at front timing chain case.
b. Install new seal ring at intake valve timing control valve cover with new engine oil applied on it.
c. Apply liquid gasket to intake valve timing control valve covers. Use genuine RTV silicone sealant or equivalent.
Being careful not to move the seal ring from the installation groove, align the dowel pins on the chain case with the holes to install the intake valve timing control valve cover.
Tighten in numerical order as shown in the figure.
Rocker Arm Cover:
24. Install RH and LH rocker covers.
Rocker cover tightening procedure:
Tighten in numerical order as shown in the figure.
a. Tighten bolts 1 to 10 in that order to .
. 0.96 to 2.96 Nm (0.10 to 0.30 kg-m, 9 to 26 inch lbs.).
b. Then tighten bolts 1 to 10 as indicated in figure to .
. 7.33 to 9.33 Nm (0.75 to 0.95 kg-m, 65 to 82 inch lbs.).
25. Install intake manifold. Tighten intake manifold nuts and bolts.
26. Install fuel tube assembly.
27. Install intake manifold collector gasket.
28. Install intake manifold upper and lower collectors.
29. Install RH and LH ignition coils.
30. Install crankshaft pulley to crankshaft.
a. Tighten to 39 to 49 Nm (4.0 to 5.0 kg-m, 29 to 36 ft. lbs.).
b. Put a paint mark on the crankshaft pulley.
c. Again tighten by turning 60° to 66°, about the angle from one hexagon bolt head corner to another.
31. Reinstall removed parts in reverse order of removal.
Make sure that crankshaft position sensor (POS) and heated oxygen sensor 1 (front) (bank 2) harness clamp are installed correctly as shown in figure.
When installing fuel tube assembly.
After starting engine, keep idling for three minutes. Then rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of the chain tensioners. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.