CAMSHAFT VALVE CLEARANCEEM-19
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7. Measure valve clearances at the locations marked “×
” as shown
in the table below (locations indicated with black arrow).
• : Engine front
• (black): Measurable at No.1 cylinder compression top dead center
• (white): Measurable at No. 3 cylinder compression top dead center
•A: RH
•B: LH
• C: Exhaust
• D: Intake
NOTE:
Firing order 1-8-7-3-6-5-4-2
• No. 1 cylinder compression TDC
• Measure valve clearance using suitable tool. Refer to EM-108,
"Standard and Limit".
CAUTION:
If the inspection was carried out with a cold engine, make
sure the values with a fully warmed up engine are still
within specifications.
8. Turn the crankshaft pulley clockwise 270 ° from the position of No. 1 cylinder compression TDC to obtain
No. 3 cylinder compression TDC.
Measuring position (RH bank) No. 2 cyl
(E) No. 4 cyl
(F) No. 6 cyl
(G) No. 8 cyl
(H)
No. 1 cylinder at TDC EXH
×
INT ××
Measuring position (LH bank) No. 1 cyl
(J) No. 3 cyl
(K) No. 5 cyl
(L) No. 7 cyl
(M)
No. 1 cylinder at TDC INT
××
EXH ××
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KBIA0185E
Revision: April 20092010 QX56
CAMSHAFT VALVE CLEARANCEEM-21
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10. Turn the crankshaft pulley clockwise 90°
from the position of No.
3 cylinder compression TDC (clockwise by 360 ° from the posi-
tion of No. 1 cylinder compression TDC) to measure the intake
and exhaust valve clearances of No. 6 cylinder (G) and the
exhaust valve clearance of No. 2 cylinder (E).
• : Front
•A: RH
•B: LH
• C: Exhaust
• D: Intake
• E: No. 2 cylinder
• F: No. 4 cylinder
• G: No. 6 cylinder
• H: No. 8 cylinder
• J: No. 1 cylinder
• K: No. 3 cylinder
• L: No. 5 cylinder
• M: No. 7 cylinder
11. If out of specifications, adjust as necessary.
ADJUSTMENT
NOTE:
• Perform adjustment depending on the selected head thickness of the valve lifter.
• The specified valve lifter thickness is the dimension at normal temperatures. Ignore dimensional differences
caused by temperature. Us e the specifications for hot engine condition to adjust.
1. Remove the camshaft. Refer to EM-53, "
Removal and Installation".
2. Remove the valve lifters at the locations that are out of specification.
3. Measure the center thickness of the removed valve lifters using suitable tool.
4. Use the equation below to calculate the valve lifter thickness for replacement.
• Valve lifter thickness calculation:Thickness of replacement valve lifter = t1+ (C1 - C2)
t1 = Thickness of removed valve lifter
C1 = Measured valve clearance
C2= Standard valve clearance:
• Thickness of a new valve lifter can be identified by stamp marks on the reverse side (inside the cylinder).
Stamp mark N788 indicates 7.88 mm (0.3102 in) in thickness.
• Available thickness of valve lifter: 25 sizes with range 7.88 to 8.36 mm (0.3102 to 0.3291 in) in steps of 0.02 mm (0.0008 in)
(when manufactured at factory). Refer to EM-108, "
Standard
and Limit".
5. Install the selected valve lifter.
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EM-34
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OIL PAN AND OIL STRAINER
a. Remove the oil pan (lower) bolts in the reverse order as shownusing power tool.
• : Engine front
b. Insert Tool between the lower oil pan and the upper oil pan. CAUTION:
• Be careful not to damage the mating surface.
• Do not insert a screwdriver, this will damage the matingsurfaces.
c. Slide (2) the Tool by tapping (1) its side with a hammer to remove the lower oil pan from the upper oil pan.
4. Remove the oil strainer from the oil pan (upper).
5. Remove the oil cooler, if necessary. Refer to LU-12, "
Removal and Installation".
6. Remove the oil pan (upper) using the following steps.
a. Remove the oil pan (upper) bolts in the reverse order as shown. • : Engine front
b. Remove the oil pan (upper) from the cylinder block by prying it at the points shown, using suitable tool.
CAUTION:
Do not damage mating surface.
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Tool number : KV10111100 (J-37228)
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EM-46
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TIMING CHAIN
7. Obtain compression TDC of No. 1 cylinder as follows:
a. Turn the crankshaft pulley clockwise to align the TDC identifica-tion notch (without paint mark) with the timing indicator on the
front cover.
b. At this time, make sure both intake and exhaust cam lobes of No. 1 cylinder (top front on LH bank) point outside.
• If they do not point outside, turn crankshaft pulley once more.
8. Remove the crankshaft pulley.
a. Loosen the crankshaft pulley bolts using a hammer handle to secure the crankshaft.
b. Remove the crankshaft pulley from the crankshaft using tool. • Remove the crankshaft pulley using suitable tool. Set the boltsin the two bolt holes [M6 x 1.0 mm (0.04 in)] on the front sur-
face.
NOTE:
The dimension between the centers of the two bolt holes is 61
mm (2.40 in).
9. Remove the front cover.
a. Loosen and remove the bolts in the reverse of order shown.
b. Cut the liquid gasket and remove the covers using Tool. CAUTION:
Do not damage mating surfaces.
10. Remove the front oil seal using suitable tool. CAUTION:
Do not damage front cover.
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Tool number : KV10111100 (J-37228)
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TIMING CHAINEM-49
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1. Make sure the crankshaft key and camshaft dowel pin RH bank
and camshaft dowel pin LH bank are facing in the direction
shown.
2. Install the camshaft sprockets. • Install the camshaft sprocket INT (VTC) (A) and camshaftsprockets EXH (B) by selectively using the groove of the
dowel pin according to the bank. (Common part used for both
exhaust banks.)
NOTE:
Use the groove marked "R" for RH bank and "L" for LH bank.
• Lock the hexagonal part of the camshaft in the same way as for removal, and tighten the bolts.
3. Install the crankshaft sprockets for both banks. • Install LH bank crankshaft sprocket (B) and RH bank crank-shaft sprocket (C) so that their flange side (A) (the larger diam-
eter side without teeth) faces in the direction shown.
NOTE:
The same parts are used but facing directions are different.
4. Install the timing chains and associated parts. • Align the alignment mark on each sprocket and the timing chain for installation.CAUTION:
• Before installing timing chain tensioner, it is possible to change the position of alignment mark
on timing chain and each sprocket . After the alignment marks are aligned, keep them aligned
by holding them by hand.
• Install the slack guides and tension guides onto the correct side by checking the identification mark on
the surface.
• Install the chain tensioner with t he plunger locked in with the stopper pin.
CAUTION:
• Before and after the installation of the timing chain tensioner, make sure that the alignment
mark on the timing chain is not out of alignment.
• After installing the timing chain tensioner, remove the stopp er pin to release the tensioner.
Make sure the tensioner is released.
• To avoid chain-link skipping of the timing chain, do not move crankshaft or camshafts until the
front cover is installed.
5. In the same way as for the RH bank, install the timing chain and associated parts on the LH bank.
6. Install the oil pump.
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EM-50
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TIMING CHAIN
7. Install the oil pump drive spacer as follows:• Install so that the front mark on the front edge of the oil pumpdrive spacer faces the front of the engine.
• Insert the oil pump drive spacer according to the directions of the crankshaft key and the two flat surfaces of the oil pump
inner rotor.
• If the positional relationship does not allow the insertion, rotate the oil pump inner rotor to allow the oil pump drive spacer to
be inserted.
8. Install the front oil seal using suitable tool. CAUTION:
Do not scratch or make burrs on the circumference of the
oil seal.
9. Install the chain tensioner cover. • Apply liquid gasket as shown.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-15, "
Recommended Chemical Products and Sealants".
10. Install the front cover as follows:
a. Install a new O-ring on the cylinder block.
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TIMING CHAINEM-51
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b. Apply liquid gasket as shown.
Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-15, "
Recommended Chemical Products and Sealants".
c. Check again that the timing alignment marks on the timing chain and on each sprocket are aligned. Then install the front cover.
d. Install the bolts in the numerical order shown.
e. After tightening, re-tighten to the specified torque. CAUTION:
Be sure to wipe off any excessive liquid gasket leaking onto
surface mating with oil pan.
11. Install the Intake valve timing control solenoid valve cover (RH) (A) and Intake valve timing control solenoid valve cover (LH) (B)
as follows:
• Cross mark that can not be seen after assembly (C)
a. Apply liquid gasket (D) as shown. Use Genuine RTV Silicone Seal ant or equivalent. Refer to
GI-15, "
Recommended Chemical Products and Sealants".
CAUTION:
The start and end of the appl ication of the liquid gasket
should be crossed at a position (C) that cannot be seen
after attaching the chain case cover.
b. Install the bolts and tighten them to specification in the numeri- cal order shown.
• A: Intake valve timing control solenoid valve cover (RH)
• B: Intake valve timing control solenoid valve cover (LH)
12. Install the crankshaft pulley. • Install the key of the crankshaft.
• Insert the pulley by lightly tapping it.
CAUTION:
Do not tap pulley on the side surface where th e belt is installed (outer circumference).
13. Tighten the crankshaft pulley bolt. • Lock the crankshaft using suitable tool, then tighten the bolt.
• Perform the following steps for angular tightening:
a. Apply engine oil onto the threaded parts of the bolt and seating area.
KBIA2517E
M6 × 50 mm (1.97 in) : No. 1, 20, 25, 26, 27
M6 × 80 mm (3.15 in) : No. 4, 5, 7
M6 × 20 mm (0.79 in) : Except the above
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D : 2.6 - 3.6 mm (0.102 - 0.142 in) dia.
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EM-52
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TIMING CHAIN
b. Select the one most visible notch of the four on the bolt flange.Corresponding to the selected notch, put a alignment mark
(such as paint) on the crankshaft pulley.
14. Rotate the crankshaft pulley in normal direction (clockwise when viewed from engine front) to check for parts interference.
15. Installation of the remaining components is in the reverse of order of removal.
INSPECTION AFTER INSTALLATION
• Before starting the engine, check oil/fluid levels in cluding engine coolant and engine oil. If the levels are
lower than required quantity, fill to the specified level. Refer to MA-13, "
Fluids and Lubricants".
• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the connection points.
• Start engine. With engine speed increased, che ck again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration. NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide
may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop
after hydraulic pressure rises.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to
specified level if necessary.
• Summary of the inspection items:
*Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.
Crankshaft pulley bolt torque
Step 1 : 93.1 N·m (9.5 kg-m, 69 ft-lb)
Step 2 : additional 90 ° (angle tightening)
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Item Before starting engine Engine runningAfter engine stopped
Engine coolant LevelLeakage Level
Engine oil LevelLeakage Level
Other oils and fluids* LevelLeakage Level
Fuel LeakageLeakageLeakage
Exhaust gas —Leakage —
Revision: April 20092010 QX56