Disassembly
1. Disconnect the cable from the negative (-) battery terminal.
2. Remove the cool air intake duct seal by removing the 11 clips.
3. Remove the engine compartment side cover LH by removing the 5 clips.
4. Remove the engine compartment side cover RH by removing the 2 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 disengage the 2 clips on the front of the cover and remove the cover.
NOTE:
Attempting to disengage both front and rear clips 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 P0171/P0172 (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 2 bolts.
8. Disconnect the No. 2 ventilation hose from the cylinder head.
9. Remove the air cleaner cap with air cleaner hose.
A. Disconnect the MAF connector.
B. Disconnect the clamp from the air cleaner.
C. Disconnect the VSV hose.
D. Disconnect the 4 clamps.
E. Remove the hose clamp and air cleaner cap with air cleaner hose.
10. Remove the air cleaner case sub-assembly by removing the 2 bolts and clamp.
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.
HINT:
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.1 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 fuel pipe No. 2.
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.
^ 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.
^ 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.
^ 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.
HINT:
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.
LH bank:
1. Loosen tension from the timing chain by rotating the crankshaft.
NOTE:
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.
RH bank:
1. Loosen tension from the timing chain by rotating the crankshaft.
NOTE:
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.
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.
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.
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.
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.
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 and replace the Bank 1 intake camshaft gear assemblies.
A. Clamp the hexagonal portion of the camshaft in a vice and remove the bolt.
B. Install the NEW intake camshaft gear assemblies and torque bolt.
Torque: 100 N.m (1020 kgf.cm, 74 ft.lbf)
C. Repeat for the Bank 2 intake camshaft gear assembly.