Installation
WARNING: DO NOT ROTATE CRANKSHAFT AND CAMSHAFT SEPARATELY, OR VALVES WILL HIT PISTON HEADS.TDC:
1. Position crankshaft so that No.1 piston is set at T.D.C. on compression stroke.
45 Degrees Before TDC:
2. Turn crankshaft until No.1 piston is set at approximately 45° before T.D.C. on compression stroke.
Note: At this point, No.3 piston will be at the same height as No.1 piston to prevent interference of valves and pistons.
3. Install cylinder heads with new gaskets and temporarily tighten cylinder head bolts for both right and left bank cylinder heads when installing front cover.
- Temporarily tighten cylinder head bolts.
Note: This is necessary to avoid damaging cylinder head gaskets.
- Be sure to install washers between bolts and cylinder head.
- Do not rotate crankshaft and camshaft separately, or valves will hit piston heads.
4. Install hydraulic lash adjusters and check them.
HLA Checking:
a) When rocker arm can be moved at least 1 mm (0.04 in) by pushing at hydraulic lash adjuster location, it indicates that there is air in the high pressure chamber.
Note: Noise will be emitted from hydraulic lash adjuster if engine is started without bleeding air.
HLA Bleeding:
b) Remove hydraulic lash adjuster and dip in a container filled with engine oil. While pushing plunger as shown in figure, lightly push check ball using a thin rod. Air is completely bled when plunger no longer moves.
Note: Air cannot be bled from this type of lash adjuster by running the engine.
Camshaft Bracket Tightening Sequence:
5. Install rocker arm, camshaft and camshaft bracket for right bank.
Valve Timing Control (V.T.C.) Assembly Tightening:
6. Install V.T.C. assembly and exhaust cam sprocket on right bank.
7. After making sure that camshafts are still correctly positioned turn crankshaft clockwise to set No.1 piston at T.D.C. on compression stroke.
8. Install two sprockets on crankshaft.
9. While aligning matching marks on crankshaft sprocket and camshaft sprockets (on both intake and exhaust sides) with those on chain, install chain on right bank.
- Be careful not to damage cylinder head gasket when installing chain.
10. Install chain tensioner on right bank.
11. Turn crankshaft approximately 12O° clockwise from the point where No.1 piston is at T.D.C. on compression stroke. (At this point, valves in left bank still remain unlifted.)
12. Correctly position camshafts for left cylinder head.
13. Install V.T.C. assembly and exhaust cam sprocket on left bank.
14. While aligning matching marks on crankshaft sprocket and camshaft sprockets (on both intake and exhaust sides) with those on chain, install chain on left bank.
15. Install oil pump chain and sprockets.
16. Install oil pump chain guides.
- Place a 1 mm (0.04 in) feeler gauge between the upper chain guide and chain before assembling chain guides. Force applied to chain is equivalent to upper chain guide weight.
17. Install front covers.
- Be careful not to damage cylinder head gasket when installing front cover.
18. Install chain tensioner for left bank.
19. Install the following parts.
Crank Angle Sensor:
- Crank angle sensor
- V.T.C. solenoid
20. Install crank pulley.
21. Set No.1 piston at T.D.C. on its compression stroke.
Cylinder Head Tightening Sequence:
22. Tighten cylinder head bolts.
Tightening procedure:
a) Tighten bolts to 29 Nm (3.0 kg/m, 22 ft/lb).
b) Tighten bolts to 93 Nm (9.5 kg/m, 69 ft/lb).
c) Loosen bolts completely.
d) Tighten bolts to 25 to 34 Nm (2.5 to 3.5 kg/m, 18 to 25 ft/lb).
e) Turn bolts 90 to 95 degrees clockwise or if angle wrench is not available, tighten bolts to 93 to 98 Nm (9.5 to 10.0 kg/m, 69 to 72 ft/lb).
23. Install rubber plugs as follows:
a) Apply liquid gasket to rubber plugs.
- Before applying liquid gasket, clean mating surface of oily stains and make sure that mating surface is free from dirt and dust particles.
- Rubber plugs should be installed within 5 minutes of applying liquid gasket.
b) Install rubber plugs, then move them with your fingers to uniformly spread the gasket on cylinder head surface.
- Rubber plugs should be installed flush with the surface.
- Do not start the engine for 30 minutes after installing rocker cover.
- Install rocker cover within 5 minutes of Installing rubber plugs.
Suitable Guide Pin:
24. Install rocker cover.
a) Install a suitable guide pin to cylinder head.
b) Apply liquid gasket to rocker cover.
c) Install rocker cover using guide pin.
d) Remove guide pin.
- Always use a suitable guide pin to Install rocker cover.
Type 1:
Type 2:
e) Tighten rocker cover bolts.
Intake Manifold (non-unitized):
25. Install intake manifolds, fuel tube assemblies (including fuel injectors) and intake collector.
Note: The intake manifold assembly utilizes a nonunitized design. Use the following procedure when installing the eight intake manifolds to make installation of the fuel tube assemblies and collectors less difficult.
Intake Manifold (installed):
a) Install the eight intake manifolds in their proper positions on cylinder head, and lightly tighten mounting bolts.
b) Connect injector tube assemblies (including fuel injectors) to intake manifolds, and lightly tighten mounting bolts.
- Be careful not to let rubber washer fall into Intake manifold.
Intake Collector:
c) Install intake collector and lightly tighten mounting bolts.
c) Tighten intake manifolds mounting bolts at cylinder head.
e) Remove intake collectors.
f) Tighten intake manifolds to 16-21 Nm (1.6 - 2.1 kg/m, 12-15 ft/lbs).
g) Tighten sub-fuel tubes in numerical order.
Tightening procedure:
1) Tighten all bolts to 4.2 to 5.9 Nm (0.43 to 0.60 kg/m, 3.1 to 4.3 ft/lb).
2) Tighten all bolts to 8.4 to 10.8 Nm (0.86 to 1.1 kg/m, 6.2 to 8.0 ft/lb).
h) Tighten injector tube assemblies in numerical order.
Tightening procedure:
1) Tighten all bolts to 9.3 to 10.8 Nm (0.95 to 1.1 kg/m, 6.9 to 8.0 ft/lb).
2) Tighten all bolts to 21 to 26 Nm (2.1 to 2.7 kg/m, 15 to 20 ft/lb).
i) Install intake collectors and tighten to 12-15 Nm (1.2 - 1.5 kg/m, 9-11 ft/lbs).
26. Install exhaust manifolds.