Repair Procedure: Disassembly
1. Disconnect the cable from the negative (-) battery terminal.2. Remove the cool air intake duct seal by removing the 7 clips.
3. Remove the engine compartment side cover RH by removing the nut and 2 clips.
4. Remove the engine compartment side cover LH by removing the 3 clips.
5. Remove the V-bank cover sub-assembly.
A. Raise the V-bank cover to disengage the clip on the rear of the cover.
B. Raise the cover again to remove the 2 nuts on the front of the cover and remove the cover.
NOTE
Attempting to disengage the rear clip and remove the 2 nuts at the same time may cause the cover to break.
6. Discharge the fuel system pressure.
FUEL SYSTEM CAUTIONS:
^ Do NOT smoke or work near an open flame when working on the fuel system.
^ Keep gasoline away from rubber or leather parts.
^ Do NOT allow fuel to spray when removing the pipe between the high pressure side fuel pump and the fuel injector. The fuel in the pipe is highly pressurized.
^ Wear safety goggles while working with the fuel system under pressure.
^ Do NOT disconnect any part of the fuel system until you have discharged the fuel system pressure.
^ Even after discharging the fuel pressure, place a shop rag over fittings as you separate them to reduce risk of fuel spray on yourself or in the engine compartment.
A. Disconnect the fuel pump connector.
B. Connect the cable to the negative (-) battery terminal.
C. Start the engine. After the engine has stopped on its own turn the engine switch OFF.
HINT
DTC P01711P0172 (System Too Lean) may be set.
D. Crank the engine again and then check that the engine does NOT start.
E. Loosen the fuel tank cap to discharge the pressure in the fuel tank completely.
F. Reconnect the fuel pump connector.
G. Disconnect the cable from the negative (-) battery terminal.
7. Remove the No.1 inlet air cleaner by removing the bolt and clip.
8. Disconnect the ventilation hose from the cylinder head.
9. Remove the air cleaner cap with air cleaner hose.
A. Disconnect the MAF meter connector.
B. Disconnect the clamp from the air cleaner.
C. Disconnect the EVAP VSV
D. Loosen the hose clamp and air cleaner cap with air cleaner hose.
10. Remove the air cleaner case sub-assembly by removing the 3 bolts.
11. Disconnect the union to check valve hose by removing the clamp.
12. Disconnect the No.2 fuel vapor feed hose by removing the clamp.
13. Disconnect the fuel main tube.
14. Remove the throttle body assembly (with motor).
A. Disconnect the throttle motor connector.
B. Remove the 4 bolts and disconnect the throttle body from the intake surge tank.
Do NOT disconnect the water bypass hose.
15. Remove the intake air surge tank assembly.
NOTE
Cover the top surface of the intake manifold with duct tape (or equivalent) to prevent foreign material from falling into the engine.
A. Disconnect the vacuum hose from the intake air surge tank.
B. Remove the bolt and disconnect the No. vacuum switching valve assembly from the intake air surge tank.
C. Disconnect the wire harness and hose from the surge tank.
D. Disconnect the ventilation hose from the intake air surge tank
E. Remove the bolt and water hose joint from the intake air surge tank.
F. Remove the bolt and disconnect the surge tank stay.
G. Using a 5-mm hexagon socket wrench remove the 7 bolts 2 nuts and gasket.
16. Remove fuel pipe No. 1.
A. Disconnect the No.3 fuel hose from the No.1 fuel pipe.
B. Disconnect the 2 fuel hoses.
C. Remove the 2 bolts and No.1 fuel pipe.
17. Disconnect the No.2 fuel pipe.
A. Disconnect the fuel high pressure side fuel pump connector.
B. Secure the union bolt in place on the fuel pump side with a 21-mm wrench. Using a 19-mm union nut wrench loosen the union and remove the fuel pipe.
NOTE
^ There must be absolutely NO free play in the union on the fuel pump side.
^ If the union on the fuel pump side has free play, replace the fuel pump.
C. Remove the 2 bolts on the delivery pipe side.
NOTE
^ Do NOT remove the fuel pipe from the delivery pipe. ONLY remove the 2 bolts.
^ If the No.2 fuel pipe is accidentally removed, replace its 0-ring, No. 1 backup ring, and No. 2 backup ring.
18. Remove the fuel pump assembly.
A. Remove the 2 nuts 2 stud bolts and fuel pump.
B. Remove the fuel insulator from the cylinder head cover.
NOTE
^ To keep the nipple joint for the fuel pipe free of foreign matter; cover with a plastic bag.
^ Remove the engine oil out of the oil pool from the cylinder head cover's fuel pump attachment hole.
19. Remove the ignition coil assemblies.
20. Remove the No.1 oil pipe union bolt from the oil pipe.
21. Remove No.2 oil pipe union bolt from the oil pipe.
22. Remove the cylinder head cover LH.
A. Remove the 12 bolts oil seal washer and cylinder head cover.
^ Cover the hole around the timing chain with shop rags to prevent foreign material from falling into the engine.
^ The baffle plate is located on the back of the portion shown in the illustration.
^ Do NOT damage the baffle plate when removing the cylinder head cover.
B. Remove the cylinder head cover gasket from the cylinder head cover.
C. Remove the 3 gaskets.
23. Remove the cylinder head cover RH.
A. Remove the 12 bolts 2 oil seal washers and cylinder head cover.
^ Cover the hole around the timing chain with shop rags to prevent foreign material from falling into the engine.
^ The baffle plate is located on the back of the portion shown in the illustration.
^ Do NOT damage the baffle plate when removing the cylinder head cover.
B. Remove the cylinder head cover gasket from the cylinder head cover.
C. Remove the 3 gaskets.
24. Remove engine cover No.1 by removing the 3 clips.
25. Remove the injector driver by removing the bolt and 2 nuts.
26. Remove the timing chain cover plate by removing the 4 bolts timing chain cover plate and timing chain cover plate gasket.
27. Set the No.1 cylinder to TDC/compression.
A. Set the timing mark to 0 on the timing chain cover by rotating the crankshaft clockwise.
B. Check that the timing marks of the camshaft timing gear assembly are aligned with the timing marks of the camshaft bearing cap.
HINT
If the timing marks are NOT aligned, turn the crankshaft one revolution (360°) clockwise and align the timing marks.
C. Using a paint marker mark the sprocket wheel timing mark of the camshaft timing gear assembly and the timing chain itself.
HINT
Wipe any oil off before marking.
28. Remove the chain tensioner assembly No.1.
A. Loosen tension from the timing chain by rotating the crankshaft 30 counterclockwise.
The procedure above is to prevent the valve and piston from hitting each other when turning the crankshaft.
B. Remove the 2 bolts and No.1 chain tensioner assembly.
NOTE
Do NOT drop the No.1 chain tensioner assembly and bolts inside the timing chain cover.
29. Remove the timing chain.
A. LH bank:
(1) Loosen tension from the timing chain by rotating the crankshaft.
Oil may spray out of the holes on top of the No.3 camshaft bearing cap when rotating the crankshaft. Use shop rags to prevent any spray.
(2) Remove the timing chain from the timing gear and rest it on the camshaft timing gear assembly temporarily.
B. RH bank:
(1) Loosen tension from the timing chain by rotating the crankshaft.
Oil may spray out of the holes on top of the No.1 camshaft bearing cap when rotating the crankshaft. Use shop rags to prevent any spray.
(2) Rotate the crankshaft clockwise until the flat surface of the timing exhaust gear assembly faces the vertical position.
(3) Remove the timing chain from the timing gear and rest it on the camshaft timing gear assembly temporarily.
30. Remove the camshaft bearing cap.
A. RH bank:
(1) Check that the camshafts are in the neutral position shown in the illustration.
(2) Uniformly loosen and remove the 9 camshaft bearing cap M6 bolts in the sequence shown in the illustration.
HINT
Keep the camshaft horizontal while loosening the bearing cap bolts.
(3) Uniformly loosen and remove the 9 camshaft bearing cap M8 bolts in the sequence shown in the illustration.
(4) Remove the 6 camshaft bearing caps.
B. LH bank:
(1) Check that the camshafts are in the neutral position shown in the illustration.
(2) Uniformly loosen and remove the 8 camshaft bearing cap M6 bolts in the sequence shown in the illustration.
HINT
Keep the camshaft horizontal while loosening the bearing cap bolts.
(3) Uniformly loosen and remove the 8 camshaft bearing cap M8 bolts in the sequence shown in the illustration.
(4) Remove the 5 camshaft bearing caps.
31. Remove the No.2 camshaft.
A. Remove the bolt for the No.2 chain tensioner assembly.
B. While holding No.2 camshaft remove the No.2 chain tensioner assembly.
C. While holding the No.2 chain, slide the No.2 camshaft out toward the front of the vehicle.
32. Remove the No. 1 camshaft.
A. Hold the rear portion of the No. 1 camshaft (with tilt position).
B. Hold the timing chain from the timing gear and slide the No.1 camshaft (with No.2 chain) out toward the rear of the vehicle.
HINT
Keep tension on the timing chain to avoid separation from the crankshaft timing gear.
C. Tie the timing chain to the oil pipe with a strap.
33. Remove camshaft No.4.
A. Remove the bolt for the No.3 chain tensioner assembly.
B. While holding the No.4 camshaft remove the No.3 chain tensioner assembly.
C. Hold the No.2 chain and slide the No.4 camshaft out toward the front of the vehicle.
34. Remove camshaft No.3.
A. Hold the rear portion of the No.3 camshaft (with tilt position).
B. Remove the timing chain from the timing gear and slide the No.3 camshaft (with the No.2 chain) out toward the rear of the vehicle.
NOTE
Keep tension on the timing chain to avoid separation from the crankshaft timing gear.
C. Tie the timing chain to the oil pipe with a strap.
35. Remove the valve rocker arms for all cylinders.
36. Remove the valve stem cap.
37. Attach the anti-rotation tool to the crankshaft.
Make sure that the anti-rotation tool is secured to prevent the crankshaft from turning either clockwise or counterclockwise.
38. Remove the spark plugs.
39. Attach the air lead pipe or equivalent tool to allow compressed air to be applied to the combustion chamber.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
40. Pressurize the combustion chamber.
Slowly apply air pressure into the combustion chamber. Recommended air pressure: 58 - 116 psi (4.1 - 8.2 kgf/sq.cm, 400 - 700 kPa)
NOTE
^ Pressurize the combustion chamber slowly to prevent unexpected crankshaft rotation.
^ Make sure that the anti-rotation tool is attached properly before putting air into the combustion chamber.
41. Remove the valve spring retainer lock using a valve spring removal tool or equivalent tool.
NOTE
^ Be careful as the valve spring may pop out when the valve spring retainer lock is disassembled.
^ Cover the oil holes on the cylinder head with shop rags to prevent the valve spring retainer lock from falling into the engine.
42. Remove the valve spring retainer.
43. Remove the valve spring.
44. Install the NEW valve spring.
45. Install the NEW valve spring retainer.
46. Install the valve spring retainer locks.
A. Using the valve spring installation tool or equivalent tool install the valve spring retainer lock.
NOTE
^ The valve spring may pop out if the valve spring retainer locks are NOT installed properly.
^ Cover the oil holes on the cylinder head with shop rags to prevent the valve spring retainer locks from falling into the engine.
HINT
Applying grease to the valve spring retainer locks may assist in holding them together.
B. Using a plastic hammer tap the valve spring retainer to check that the valve spring retainer lock fits properly.
47. Release the air inside the combustion chamber.
48. Remove the air lead pipe or equivalent tool.
49. Proceed to replace the remaining 23 valve springs and valve spring retainers following steps 40 - 48 above.
50. Remove the anti-rotation tool from the crankshaft.
51. Install the spark plugs. Torque: 25 N*m (255 kg*cm, 18 ft*lbf)
52. Install the valve stem caps.
53. Install the valve rocker arms.