Reassembly
1. Install the No.3 camshaft.
A. Align the mark plate (yellow) of the No.2 chain with the timing marks of the camshaft timing gear assembly shown in the illustration.
B. Clean the camshaft journals and apply engine oil.
C. Make sure that the valve rocker arms are installed with the lash adjuster and valve stem cap properly as shown in the illustration.
D. Temporarily put the timing chain to the No. 3 camshaft on the camshaft timing gear assembly and place the No.3 camshaft on the camshaft housing LH.
NOTE
^ Temporarily put the timing chain on the camshaft timing gear assembly without installing to the sprocket.
^ Place the camshaft as the timing mark faces on the top.
2. Install the No. 1 camshaft using the same procedure as step 1.
3. Install the No.4 camshaft.
A. Clean the camshaft journals and apply engine oil to them.
B. Hold the No.2 chain and slide the No.4 camshaft in from the front of the vehicle.
C. Align the mark plate (yellow) with the timing marks of the camshaft timing exhaust gear LH.
D. Hold the No.2 chain and install the No.3 chain tensioner assembly.
Torque: 21 N*m (214 kgf*cm, 15 ft*lbf)
4. Install the No.2 camshaft using the same procedure as step 3.
5. Install the camshaft bearing cap.
A. LH bank:
(1) Clean the camshaft bearing caps and apply engine oil.
(2) Make sure that the valve rocker arms are properly installed with each lash adjuster and valve stem cap.
(3) Make sure of the marks and numbers on the camshaft bearing caps and temporarily tighten the 16 bolts.
(4) Tighten the 8 M6 bolts in the sequence shown.
Torque: 10 N*m (102 kgf*cm, 7ft*lbf)
(5) Tighten the 8 M8 bolts in the sequence shown.
Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)
(6) Tighten the 8 M6 bolts to their final torque value in the sequence shown in Figure 50.
Torque: 16 N*m (163 kgf*cm, 12 ft*lbf)
B. RH bank:
(1) Clean the camshaft bearing caps and apply engine oil.
(2) Make sure that the valve rocker arms are properly installed with each lash adjuster and valve stem cap.
(3) Make sure of the marks and numbers on the camshaft bearing caps and temporarily tighten the 16 bolts.
(4) Tighten the 9 M6 bolts in the sequence shown in the illustration.
Torque: 10 N*m (102 kgf*cm, 7ft*lbf)
(5) Tighten the 9 M8 bolts in the sequence shown in the illustration.
Torque: 28 N*m (286 kgf*cm, 21 ft*lbf)
(6) Tighten the 9 M6 bolts to their final torque value in the sequence shown in Figure 53.
Torque: 16 N*m (163 kgf*cm, 12 ft*lbf)
6. Install the timing chain.
A. LH bank:
Align the mark plate (yellow) of the timing chain with the timing marks of the camshaft timing gear assembly and install to the sprocket.
NOTE
If the paint mark is NOT aligned, turn the crankshaft slightly to adjust the position.
B. RH Bank:
(1) Align the mark plate (yellow) of the timing chain with the timing marks of the camshaft timing gear assembly and install to the sprocket.
NOTE
If the paint mark is NOT aligned, turn the crankshaft and adjust one notch each as shown in the illustration.
(2) Set the No.1 cylinder to TDC/compression by aligning the timing mark to 0 on the timing chain cover by rotating the crankshaft counterclockwise.
(3) Slightly turn the crankshaft and loosen tension for the timing chain where the No. 1 chain tensioner is attached.
7. Install the No. 1 chain tensioner assembly.
A. Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.
B. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.
C. Install the No.1 chain tensioner assembly with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
D. Remove the lock pin of the No. 1 chain tensioner assembly. Check that each timing mark is aligned with the crankshaft at the TDC/compression.
E. Turn the crankshaft 2 rotations and double-check that each timing mark is positioned properly.
8. Install the NEW gasket and the timing chain cover plate with the 4 bolts.
Torque: 9 N*m (93 kgf*cm, 7 ft*lbf)
9. Install the injector driver with the bolt and 2 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
10. Install the No.1 engine cover with the 3 clips.
11. Install the cylinder head cover RH.
A. Apply FIPG sealant as shown in the illustration.
FIPG sealant: P/N 08826-00080 (or equivalent)
^ Remove any oil from the contact surface.
^ Install the head cover within 3 minutes after applying the FIPG sealant.
^ Do NOT start the engine for at LEAST 2 hours after installing.
B. Install 3 NEW gaskets as shown in the illustration.
C. Install a NEW gasket to the head cover.
D. Install the head cover with the 14 bolts.
Torque:
Bolts A:
21 N*m (214 kgf*cm, 15 ft*lbf)
Torque:
Bolts except A:
10 N*m (102 kgf*cm, 7 ft*lbf)
12. Install the cylinder head cover LH.
A. Apply FIPG sealant as shown in the illustration.
FIPG sealant: P/N 08826-00080 (or equivalent)
NOTE
^ Remove any oil from the contact surface.
^ Install the head cover within 3 minutes after applying the FIPG sealant.
^ Do NOT start the engine for at LEAST 2 hours after installing.
B. Install 3 NEW gaskets as shown in the illustration.
C. Install a NEW gasket to the head cover.
D. Install the head cover with the 12 bolts.
Torque:
Bolts A:
21 N*m (214 kgf*cm, 15 ft*lbf)
Torque:
Bolts except A:
10 N*m (102 kgf*cm, 7 ft*lbf)
E. For 4WD:
Install the engine hanger with the 2 bolts.
Torque: 33 N*m (337 kgf*cm, 24 ft*lbf)
13. Install the oil pipe union bolt to the No.2 oil pipe.
Torque: 60 N*m (612 kgf*cm, 44 ft*lbf)
14. Install the oil pipe union bolt to the No.1 oil pipe.
Torque: 60 N*m (612 kgf*cm, 44 ft*lbf)
15. Install the ignition coil assemblies.
16. Install the fuel pump assembly.
A. Turn the crankshaft until the flat of the cam is facing the cylinder head cover fuel pump attachment hole as shown in the illustration.
B. Pour 30 cc of engine oil into the cylinder head oil collector through the cylinder head cover fuel pump attachment hole.
C. Apply a coat of engine oil to the pump activation cam and pump lifter.
D. Install the NEW fuel insulator to the cylinder head cover.
NOTE
The open sides of the metal eyelets must be facing upward as shown in the illustration.
E. Temporarily install the No. 2 fuel pipe sub-assembly to the fuel pump assembly.
NOTE
Be careful NOT to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.
F. Install the 2 studs.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
G. Install the 2 nuts and tighten them in several passes.
Torque: 25 N*m (255 kgf*cm, 18 ft*lbf)
H. Connect the fuel hose.
17. Connect the No.2 fuel pipe.
A. Install the No.2 fuel pipe to the delivery pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
B. Using a 19-mm union nut wrench connect the fuel pipe.
Torque: 30 N*m (306 kgf*cm, 22 ft*lbf)
C. Connect the connector to the fuel pump.
18. Install the No. 1 fuel pipe.
A. Install the No.1 fuel pipe with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
B. Connect the 2 fuel hoses.
19. Connect the fuel main tube.
20. Install the air surge tank assembly.
A. Install a NEW gasket to the intake air surge tank.
B. Using a 5-mm hexagon socket wrench install the 6 bolts.
Torque:
Bolts except A:
18 N*m (184 kgf*cm, 13 ft*lbf)
C. Install the bolt and 2 nuts to the intake air surge tank.
Torque:
Bolt A: 21 N*m (214 kgf*cm, 15 ft*lbf)
Torque:
Nut 16 N*m (163 kgf*cm, 12 ft*lbf)
D. Install the surge tank stay to the intake air surge tank.
Torque:
Nut: 21 N*m (214 kgf*cm, 15 ft*lbf)
E. Connect the water hose joint with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
F. Connect the ventilation hose to the intake air surge tank.
G. Connect the wire harness and hose to the intake air surge tank.
H. Connect the No. 1 vacuum switching valve assembly to the intake air surge tank.
Torque: 18 N*m (184 kgf*cm, 13 ft*lbf)
I. Connect the vacuum hose to the intake air surge tank.
21. Install the throttle body assembly (with motor).
A. Install a NEW gasket to the intake air surge tank.
^ Align the protrusion of the gasket on the intake air surge tank.
^ Make sure the direction of the gasket is as shown in the illustration.
B. Install the throttle body with the 4 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft*lbf)
C. Connect the throttle body connector.
22. Connect the No.2 fuel vapor hose.
Install the clamp and connect the No.2 fuel vapor feed hose.
23. Connect the union to check valve hose to the surge tank.
24. Install the air cleaner case sub-assembly with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)
25. Install the air cleaner cap with air cleaner hose.
A. Install the hose clamp and air cleaner cap with air cleaner hose.
B. Connect the 4 clamps.
C. Connect the purge line hose.
D. Connect the clamp to the air cleaner cap.
E. Connect the MAF meter connector and clamp to the air cleaner.
26. Connect the No.2 ventilation hose from the cylinder head.
27. Install the No.1 air cleaner inlet with the bolt and clip.
Torque: 5.0 N*m (51 kgf*cm, 44 in*lbf)
28. Connect the cable to the negative (-) battery terminal.
Torque: 5.4 N*m (55 kgf*cm, 48 in*lbf)
29. Check for fuel leaks.
A. Connect TIS Techstream to DLC3.
NOTE
Switch OFF all accessories and A/C before connecting the Techstream tester.
B. Turn the engine switch ON (IG). Do NOT start the engine.
C. Enter the following menus:
Powertrain / Engine / Active Test / FUEL PUMP / SPD.
D. Check for fuel leaks.
Check that there are NO fuel leaks anywhere in the system. If there is a fuel leak repair or replace parts as necessary.
30. Check for engine oil leaks.
31. Check the ignition timing.
A. Warm up the engine and then stop the engine.
NOTE
A warmed up engine should have an engine coolant temperature of over 176°F (80°C), have an engine oil temperature of 140°F (60°C), and the engine rpm should be stabilized.
B. Start the engine and maintain engine rpm at idle speed.
C. Enter the following menus on TIS Techstream:
Powertrain / Engine / Data List / IGN ADVANCE.
Ignition timing: 5 to 15° BTDC at idle
HINT
Refer to the TIS Techstream Help menu for further details.
D. Check that ignition timing advances as engine speed increases.
32. Check engine idle speed.
A. Warm up and then stop the engine.
A warmed up engine should have an engine coolant temperature of over 176°F (80°C), have an engine oil temperature of 140°F (60°C), and the engine rpm should be stabilized.
B. Raise the engine speed to 2,500 rpm for approximately 90 seconds, and then return to idle.
C. Enter the following menus:
Powertrain / Engine / Active Test / ENGINE SPD.
Idle speed: 650 to 750 rpm
NOTE
When checking the idle speed, the transmission should be in Neutral or Park.
HINT
^ Refer to the TIS Techstream Help menu for further details.
^ If the idle speed is NOT as specified, check the air intake system.
D. Clear all DTCs.
E. Disconnect TIS Techstream from DLC3.
33. Check the engine oil level.
Stop the engine, and wait 5 minutes. The oil level should be between the dipstick's low level mark and full level mark. If low, check for leakage and add oil up to the full level mark.
34. Install the V-bank cover sub-assembly. Attach the 3 clips to install the V-bank cover.
NOTE
^ Be sure to engage the clips securely.
^ Do NOT apply excessive force or hit the cover to engage the clips. This may cause the cover to break.
35. Install the engine compartment side cover LH with the 3 clips and nut.
36. Install the engine compartment side cover RH with the 2 clips.
37. Install the cool air intake duct seal with the 7 clips.
38. Check throttle body function and throttle control motor operating sounds.
A. Turn the engine switch ON (IG).
B. When pressing the accelerator pedal check the operating sound of the running motor. Make sure that NO friction noises emit from the motor. If friction noise exists replace the throttle body.
39. Re-initialize any affected power systems.
For 2007 model year refer to TSIB No. PD007-07, "Power System Initialization During PDS."
For 2008 model year refer to TSIB No. L-SB-0041-08, "Power System Initialization During PDS."
40. Road test to verify repair.