Part 2 of 2
Camshaft1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 47.2mm (1.8582in.)
Exhaust : 45.8mm (1.8031in.)
If the cam lobe height is less than standard, replace the camshaft.
2. Inspect the camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journals.
(4) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque :
1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
CAUTION:
Do not turn the camshaft.
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Bearing oil clearance
[Standard value]
Intake
No.1 journal : 0.020 - 0.057mm (0.0008 - 0.0022in.)
No.2,3,4 journal : 0.030 - 0.067mm (0.0012 - 0.0026in.)
Exhaust
No.1 journal : 0.027 - 0.057mm (0.0010 - 0.0022in.)
No.2,3,4 journal : 0.030 - 0.067mm (0.0012 - 0.0026in.)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect the camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play
[Standard value] : 0.02 - 0.18mm(0.0008 - 0.0071in.)
If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(3) Remove the camshafts.
CVVT Assembly
1. Inspect the CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.
[Intake CVVT]
[Exhaust CVVT]
(3) Wrap tape around the tip of the air gun and apply air of approx. 150kpa(1.5kgf/cm2, 21psi) to the port of the camshaft.
(Perform this in order to release the lock pin for the maximum delay angle locking.)
NOTE:
When the oil splashes, wipe it off with a shop rag.
(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand.
(5) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and forth and check the movable range and that there is no interference.
Standard:Movable smoothly in the range about 30°
(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (clockwise).
Reassembly
NOTE:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install the valves.
(1) Using the SST(09222-3C100), push in a new oil seal.
NOTE:
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.
(2) Install the valve, valve spring and spring retainer.
NOTE:
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then install the retainer.
(3) Using the SST(09222 - 3K000, 09222-3C300), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
2. Install the MLAs.
Check that the MLA rotates smoothly by hand.
NOTE:
MLA can be reinstalled in its original position.
3. Install the OCV(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
NOTE:
- Install OCV with gray colored connector into LH bank.
- Install OCV with black colored connector into RH bank.
CAUTION:
- Do not reuse the OCV when dropped.
- Keep the OCV clean.
- Do not hold the OCV sleeve during servicing.
- When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.
Installation
NOTE:
- Thoroughly clean all parts to be assembled.
- Always use a new head and manifold gasket.
- The cylinder head gasket is a metal gasket. Take care not to bend it.
- Rotate the crankshaft, set the No.1 piston at TDC.
1. Install the cylinder head.
A. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
B. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.
NOTE:
Refer to below illustration to apply the sealant.
Bead width :
2.0 - 3.0 mm (0.078 - 0.118 in.)
Sealant locations :
1.0 - 1.5mm (0.039 - 0.059 in.) from block surface
Recommended sealant :Liquid sealant TB1217H
C. Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
NOTE:
Be careful of the installation direction.
D. Install the cylinder head.
NOTE:
Remove the extruded sealant after assembling cylinder heads.
2. Install the cylinder head bolts.
(1) Do not apply engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque
Head bolt: 37.3 - 41.2Nm (3.8 - 4.2kgf.m, 27.5 - 30.4lb-ft) + 118 - 122° + 88 - 92°
Bolt (A):18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
3. Install the CVVT assembly.
Tightening torque :
64.7 - 76.5N.m (6.6 - 7.8kgf.m, 47.7 - 56.4lb-ft)
CAUTION:
- Install camshaft-inlet to dowel pin of CVVT assembly.
At this time, attend not to be installed to oil hole of camshaft-inlet.
- Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
- Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.
4. Install the LH/RH camshaft assembly (A).
CAUTION:
- Apply a light coat of engine oil on camshaft journals.
- Assemble the key groove of camshaft rear side to the same level of head top surface.
- Be careful the right, left bank, intake, exhaust side before assembling.
Intake Camshaft
As for camshaft identification, refer to the table below.
Exhaust Camshaft
As for camshaft identification, refer to the table below.
5. Install the LH/RH camshaft bearing cap (A) and thrust bearing cap (B).
Tightening torque
1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
CAUTION:
Be sure to install the thrust bearing cap bolts and the bearing cap bolts in the correct place.
NOTE:
Be careful the right, left bank, intake, exhaust side before assembling.
A : L(LH),R(RH)
B : I(Intake), None(Exhaust)
C : Journal number
D : Front mark
CAUTION:
Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10mm(0.3937in.) from the top of cylinder block.
6. Install the LH/RH exhaust camshaft OCV (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
7. Install the LH/RH cylinder head cover (A).
NOTE:
- Install the cylinder head cover under the exhaust OCV cap is removed.
- To prevent engine oil leakage, surely install the new exhaust OCV cap after installing the cylinder head cover.
(1) Remove the exhaust OCV cap (A) from the cylinder head cover.
(2) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
(3) After applying sealant(TB1217H), it should be assembled within 5 minutes.
Bead width :2.5mm(0.1in.)
(4) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
(5) Install the cylinder head cover bolts as following method.
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
CAUTION:
Do not reuse cylinder head cover gasket.
(6) Install the new exhaust OCV cap (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
8. Install the LH/RH exhaust manifold (A) with a new gasket.
Tightening torque :
39.2 - 44.1N.m (4.0 - 4.5kgf.m, 28.9 - 32.5lb-ft)
9. Install the LH/RH exhaust manifold heat protector (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
10. Install the intake the manifold (B) with a new gasket, and connect the water vent hose (A).
CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.
Tightening torque
Step 1: 3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2:
Nut-18.62 - 23.52N.m (1.9 - 2.4kgf.m, 13.74 - 17.36lb-ft)
Bolt -26.5 - 31.4 N.m (2.7 - 3.2 kgf.m, 19.5 - 23.1lb-ft)
Step 3: Repeat 2nd step twice or more.
a - h : 1st step order
1 - 8 : 2nd step order
NOTE:
Confirm the manifold gasket identification mark (LH, RH) and be careful of the installation direction.
11. Install the water temperature control assembly (A) after installing a new gasket (B).
Tightening torque :
19.6 - 23.5Nm (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)
12. Connect the heater hoses (A).
13. Install the timing chain.
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
- Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.