Installation
ASSEMBLY^ Install valve component parts.
^ Always use new valve oil seal.
^ Before installing valve oil seal, install valve spring seat.
^ Install valve spring (uneven pitch type) with its narrow pitch side toward cylinder head side (paint mark).
^ After installing valve component parts, tap valve stem tip with plastic hammer to assure a proper fit.
INSTALLATION
NOTE:
^ When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
^ Apply new engine oil to threads and seat surfaces when installing cylinder head, camshaft sprocket, crankshaft pulley, and camshaft bracket.
1. Before installing rear timing chain case, remove all traces of liquid gasket from the mating surface using a scraper. Also, remove traces of liquid gasket from mating surface of cylinder block.
NOTE: Remove old liquid gasket from the bolt hole and thread.
2. Before installing cam bracket, remove all traces of liquid gasket from mating surface using a scraper.
3. Remove O-rings from cylinder block.
4. Turn crankshaft until No. 1 piston is set at approximately 240° before TDC on compression stroke to prevent interference of valves and pistons.
5. Install cylinder heads with new gaskets.
CAUTION: Do not rotate crankshaft and camshaft separately, or valves will strike piston heads.
NOTE: Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new ones. The limit (d1 - d2) is 0.11 mm (0.0043 inch). Lubricate threads and seat surfaces of the bolts with new engine oil. Tighten in numerical order as shown in the figure.
a. Tighten all bolts to 93 Nm (72 ft. lbs.).
b. Completely loosen all bolts.
c. Tighten all bolts to 34 to 44 Nm (25 to 33 ft. lbs.).
d. Turn all bolts 90 to 95° clockwise.
e. Turn all bolts 90 to 95° clockwise.
6. Install cylinder head outside bolts.
7. Install camshaft chain tensioners on both sides of cylinder head.
8. Install exhaust and intake camshafts and camshaft brackets. Install the RH exhaust camshaft dowel pin at about 10 o'clock and the LH exhaust camshaft dowel pin at about 2 o'clock.
NOTE: Identification marks are present on camshafts. The LH camshaft is marked with paint between the 2nd and 3rd journal and has been stamped with "L3". The RH camshaft is marked with paint between the 2nd and 3rd journal and has been stamped with "R3".
9. Before installing camshaft brackets, apply sealant to mating surface of No. 1 journal head. Please note the following:
^ Use Genuine Liquid Gasket or equivalent.
^ Refer to Positioning Liquid Gasket.
^ Install camshaft brackets in their original positions.
^ Tighten camshaft bracket bolts gradually in two or three stages.
^ If any part of the valve assembly or camshaft is replaced, check valve clearance according to the reference data. After completing assembly check valve clearance.
^ Reference data for (cold) valve clearance is 0.26 - 0.34 mm (0.010 - 0.013 inch) for the intake and 0.29 - 0.37 mm (0.011 - 0.015 inch) for the exhaust.
^ Lubricate threads and seat surfaces of camshaft bracket bolts with new engine oil before installing them.
^ Align the stamp mark as shown in the figure.
^ Refer to the illustrations and tighten the camshaft bracket bolt Nos. 7 - 10 to 1.96 Nm (17 inch lbs.) then tighten bolt Nos. 1 - 6 to the same value. Next, in numerical order, tighten all bolts to 6 Nm (52 inch lbs.). Tight all bolts in numerical order to 9.02 - 11.8 Nm (79.9 - 104.2 inch lbs.)
10. Install O-rings to cylinder block.
11. Apply a continuous bead of liquid gasket to mating surface of rear timing chain case and apply sealant to the hatched portion of rear timing chain case. Refer to Positioning Liquid Gasket.
NOTE: Before installation, wipe off the protruding sealant.
12. Align rear timing chain case with dowel pins, then install on cylinder head and block.
13. Tighten the rear chain case bolts in the order shown. Pass over the bolts once again to ensure the specifications are met.
NOTE:
^ 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.
1. Install crankshaft sprocket on crankshaft. Make sure that mating marks on crankshaft sprocket face front of engine.
2. Position crankshaft so that No. 1 piston is set at TDC on compression stroke.
3. Install lower chain guide on dowel pin, with front mark on the guide facing upside.
4. Align the marks on RH and LH intake camshaft sprockets 2ND, exhaust camshaft sprockets 2ND and camshaft chain, as shown.
5. Put LH camshaft dowel pin into camshaft sprocket dowel groove and install these on camshaft. Tighten LH exhaust camshaft sprocket 2ND bolt.
6. Put RH camshaft dowel pin in camshaft sprocket dowel groove and install sprocket on camshaft.
7. Tighten RH exhaust camshaft sprocket 2ND bolt.
^ Make sure that the timing marks on RH and LH intake camshaft sprockets 2ND are aligned with the camshaft chain mark.
^ Lubricate threads and seat surfaces of camshaft sprocket bolts with new engine oil.
^ Be careful not to confuse intake and exhaust camshaft sprockets 2ND (their thicknesses are different).
8. Remove RH and LH camshaft chain tensioner stopper pins.
9. Align mating mark on crankshaft sprocket with matchmark on chain as shown.
10. Attach lower timing chain on the water pump sprocket.
11. Install RH and LH camshaft sprockets 1ST onto camshafts by matching sprocket dowel grooves with camshaft.
12. Tighten RH and LH camshaft sprocket 1ST bolts.
NOTE: Lubricate threads and seat surfaces of the bolts with new engine oil.
13. Install timing chain. Make sure that mating marks on crankshaft sprocket and RH and LH camshaft sprockets are aligned with matchmarks on timing chain.
14. Install internal chain guide.
15. Install upper chain guide.
16. Install timing chain tensioner and slack side chain guide.
17. Wipe off the protruding sealant and apply liquid gasket to front timing chain case.
18. Install rear case pin into dowel pin hole on front timing chain case.
19. Tighten bolts to the specified torque in order shown in the figure. Leave the bolts unattended for 30 minutes or more after tightening.
20. Apply a continuous bead of liquid gasket to mating surface of water pump cover.
21. Install water pump cover.
22. Use genuine liquid gasket or equivalent and apply to the RH and LH rocker covers.
23. Install RH and LH rocker covers and tighten as follows:
^ Tighten in numerical order as shown in the figure.
^ Tighten bolts (1) to (10) in that order to 1 to 3 Nm (9 to 26 inch lbs.).
^ Tighten bolts (1) to (10) as indicated in figure to 5.4 to 7.4 Nm (47.7 to 65.1 inch lbs.).
24. Install intake manifold and tighten intake manifold nuts and bolts to specifications.
25. Install fuel tube assembly.
26. Install intake manifold collector gasket, with its front mark facing forwards.
27. Install intake manifold collector, supports and intake manifold collector bolt.
28. Install EGR guide tube as follows:
^ Tighten all bolts to 9 - 10 Nm (6.5 - 8.0 ft. lbs.).
^ Tighten all bolts to 21 - 26 Nm (15 - 20 ft. lbs.).
29. Install RH and LH ignition coils.
30. Install rocker cover ornament on left side.
31. Install crankshaft pulley to crankshaft.
NOTE: Lubricate thread and seat surface of the bolt with new engine oil.
a. Tighten to 39 to 49 Nm (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.
32. Install Camshaft Position Sensor (PHASE), Crankshaft Position Sensors (REF)/(POS) and the front heated oxygen sensor (left bank) harness clamp. Make sure that POS sensor and the front heated oxygen sensor (left bank) harness clamp are installed correctly as shown in figure.
33. Reinstall removed parts in reverse order of removal.
NOTE:
^ When installing fuel tube assembly, refer to Powertrain Management.
^ After installing the tensioner, race the engine at about 3,000 RPM under no load to purge air from the high-pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.