Page 1953 of 5121
EM-78
< DISASSEMBLY AND ASSEMBLY >
ENGINE UNIT
ENGINE UNIT
DisassemblyINFOID:0000000003802279
1. Remove intake manifold collector. Refer to EM-28, "Exploded View".
2. Remove intake manifold. Refer to EM-32, "
Exploded View".
3. Remove exhaust manifold. Refer to EM-34, "
Exploded View".
4. Remove oil pan (lower). Refer to EM-38, "
Exploded View".
5. Remove ignition coil, spark plug and rocker cover. Refer to EM-49, "
Exploded View".
6. Remove fuel injector and fuel tube. Refer to EM-44, "
Exploded View".
7. Remove timing chain and rear timing chain case. Refer to EM-52, "
Exploded View" and EM-79, "Exploded
View".
8. Remove camshaft. Refer to EM-84, "
Exploded View".
9. Remove cylinder head. Refer to EM-96, "
Exploded View".
AssemblyINFOID:0000000003802280
Assembly in the reverse order of disassembly.
Page 1954 of 5121
REAR TIMING CHAIN CASE
EM-79
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
REAR TIMING CHAIN CASE
Exploded ViewINFOID:0000000003802281
1.Timing chain tensioner (secondary)
(bank 2)2. Internal chain guide 3.Timing chain tensioner (secondary)
(bank 1)
4. Camshaft sprocket (EXH) 5. O-ring 6. Timing chain (secondary)
7. Timing chain (primary) 8. Camshaft sprocket (INT) 9. Slack guide
10. Timing chain tensioner (primary) 11. Crankshaft sprocket 12. Rear timing chain case
13. Tension guide 14. O-ring 15. O-ring
16. O-ring 17. Front timing chain case 18. Valve timing control cover gasket (bank 1)
JPBIA1638GB
Page 1955 of 5121

EM-80
< DISASSEMBLY AND ASSEMBLY >
REAR TIMING CHAIN CASE
Disassembly and Assembly
INFOID:0000000003802282
DISASSEMBLY
1. Remove front timing chain case and timing chain. Refer to EM-52, "Exploded View".
2. Remove water pump. Refer to CO-18, "
Exploded View".
3. Remove oil pans (upper and lower) and oil strainer. Refer to EM-38, "
Exploded View".
4. Remove rear timing chain case as follows:
a. Loosen and remove mounting bolts in reverse order as shown in
the figure.
b . C u t l i q u i d g a s k e t u s i n g t h e s e a l c u t t e r [ S S T: K V 1 0 1111 0 0
(J37228)] and remove rear timing chain case.
CAUTION:
Never remove plate metal cover (1) of oil passage.
After removal, handle rear timing chain case carefully so
it does not tilt, cant, or warp under a load.
5. Remove O-rings (1) from cylinder block.
6. Remove timing chain tensioners (secondary) from cylinder head as follows, if necessary.
a. Remove camshaft brackets (No. 1). Refer to EM-84, "
Exploded View".
19. Valve timing control cover (bank 1) 20.Intake valve timing control sole-
noid valve (bank 1)21. Seal ring
22. Water pump cover 23. Front oil seal 24. Crankshaft pulley
25. Crankshaft pulley bolt 26.Intake valve timing control sole-
noid valve (bank 2)27. Valve timing control cover (bank 2)
28.Valve timing control cover gasket
(bank 2)
A. Refer to EM-80
Refer to GI-4, "Components" for symbols in the figure.
JPBIA1641ZZ
JPBIA0088ZZ
: Engine front
JPBIA0090ZZ
Page 1956 of 5121
REAR TIMING CHAIN CASE
EM-81
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
b. Remove timing chain tensioners (secondary) (1) with a stopper
pin (B) attached.
7. Use a scraper to remove all traces of old liquid gasket from front and rear timing chain cases, and oppo-
site mating surfaces.
Remove old liquid gasket from bolt hole (B) and thread.
ASSEMBLY
1. Install rear timing chain case as follows:
Install new O-rings (1) onto cylinder block.
a. Apply liquid gasket with the tube presser (commercial service tool) to rear timing chain case back side as
shown in the figure.
Use Genuine Liquid Gasket or equivalent.
CAUTION:
For “A” in the figure, completely wipe out liquid gasket extended on a portion touching at engine
coolant.
A : Bank 1
B : Bank 2
JPBIA1727ZZ
A : Remove sticking old liquid gasket
JPBIA0051ZZ
: Engine front
JPBIA0090ZZ
Page 1957 of 5121

EM-82
< DISASSEMBLY AND ASSEMBLY >
REAR TIMING CHAIN CASE
Apply liquid gasket on installation position of water pump and cylinder head very completely.
b. Align rear timing chain case with dowel pins (bank 1 and bank 2) on cylinder block and install rear timing
chain case.
Check O-rings stay in place during installation to cylinder block and cylinder head.
c. Tighten mounting bolts in numerical order as shown in the fig-
ure.
There are two types of mounting bolts. Refer to the following
for locating bolts.
d. After all bolts tightening, retighten them to the specified in
numerical order as shown in the figure.
If liquid gasket protrudes, wipe it off immediately.
e. After installing rear timing chain case (1), check the surface
height difference between the following parts on the oil pan
(upper) mounting surface.
If not within the standard, repeat the installation procedure.Bolt length: Bolt position
20 mm (0.79 in) : 1, 2, 3, 6, 7, 8, 9, 10
16 mm (0.63 in) : Except the above
: 12.7 N·m (1.3 kg-m, 9 ft-lb)
PBIC2616E
JPBIA1641ZZ
2 : Cylinder block
Standard
Rear timing chain case to cylinder block:
−0.24 to 0.14 mm (−0.009 to 0.006 in)
JPBIA1944ZZ
Page 1958 of 5121
REAR TIMING CHAIN CASE
EM-83
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
2. Install water pump with new O-rings. Refer to CO-18, "Exploded View".
3. Install front timing chain case and timing chain. Refer to EM-52, "
Exploded View".
4. After installing front timing chain case, check the surface height
difference between the following parts on the oil pan (upper)
mounting surface.
If not within the standard, repeat the installation procedure.
5. Install in the reverse order of removal after this step.Standard
Front timing chain case to rear timing chain case:
−0.14 to 0.14 mm (−0.006 to 0.006 in)
SEM943G
Page 1959 of 5121
EM-84
< DISASSEMBLY AND ASSEMBLY >
CAMSHAFT
CAMSHAFT
Exploded ViewINFOID:0000000003802283
Removal and InstallationINFOID:0000000003802284
REMOVAL
1. Remove front timing chain case, camshaft sprocket, timing chain and rear timing chain case. Refer to EM-
52, "Exploded View" and EM-79, "Exploded View".
1. Camshaft bracket (No. 3, 4) 2. Camshaft bracket (No. 2) 3. Seal washer
4. Camshaft bracket (No. 1) 5. Dowel pin 6. Camshaft (EXH) (bank 1)
7. Camshaft (INT) (bank 1) 8. Valve lifter 9.Timing chain tensioner (secondary)
(bank 1)
10. Spring 11. Plunger 12.Timing chain tensioner (secondary)
(bank 2)
13. Cylinder head (bank 2) 14. Dowel pin 15. Camshaft sensor bracket
16. Camshaft (EXH) 17. Camshaft signal plate (INT) 18. Camshaft (INT)
19. Cylinder head (bank 1) 20. Camshaft signal plate (INT) 21. Camshaft sensor bracket
A. Refer to EM-84
Refer to GI-4, "Components" for symbols in the figure.
JPBIA1719GB
Page 1960 of 5121
CAMSHAFT
EM-85
< DISASSEMBLY AND ASSEMBLY >
C
D
E
F
G
H
I
J
K
L
MA
EM
N
P O
2. Loosen camshaft sensor bracket bolts in reverse order as
shown in the figure.
NOTE:
The order of loosening bolts in the same for bank 1 and bank 2.
3. Remove camshaft brackets.
Mark camshafts, camshaft brackets and bolts so they are placed in the same position and direction for
installation.
Equally loosen camshaft bracket bolts in several steps in
reverse order as shown in the figure.
4. Remove camshafts.
5. Remove valve lifters.
Identify installation positions, and store them without mixing them up.
6. Remove timing chain tensioners (secondary) (1) from cylinder
head.
Remove timing chain tensioner (secondary) with its stopper
pin (C) attached.
NOTE:
Stopper pin should be attached when timing chain (secondary)
is removed.
INSTALLATION
: Engine front
JPBIA1960ZZ
: Engine front
JPBIA0257ZZ
A: Bank 1
B: Bank 2
JPBIA0121ZZ