25. REMOVE OIL PIPE NO.1 (a) Remove the 2 oil pipe unions, and oil pipe No.1. (b) Remove the oil control valve filter LH and gaskets.

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1 CAMSHAFT (RH BANK) (2GRFE) REPLACEMENT 1. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 1421) 2. REMOVE ENGINE WIRE 3. REMOVE FRONT FRAME ASSY (SEE PAGE 1421) 4. REMOVE STARTER ASSY (SEE PAGE 199). REMOVE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 408) 6. REMOVE OIL LEVEL GAUGE GUIDE SUBASSY (SEE PAGE 1421) 7. REMOVE EXHAUST MANIFOLD SUBASSY RH (SEE PAGE 1421) 8. REMOVE EXHAUST MANIFOLD SUBASSY LH (SEE PAGE 1421) 9. REMOVE DRIVE PLATE & RING GEAR SUBASSY (SEE PAGE 14208) 10. FIX ENGINE ASSY 11. REMOVE IDLER PULLEY SUBASSY NO REMOVE ENGINE MOUNTING BRACKET RH (SEE PAGE 1421) 13. REMOVE WATER PUMP PULLEY (SEE PAGE 1610) 14. REMOVE VRIBBED BELT TENSIONER ASSY (SEE PAGE 1421) 1. REMOVE TIMING GEAR COVER NO REMOVE ENGINE MOUNTING STAY NO.2 RH (SEE PAGE 1421) 17. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH (SEE PAGE 1421) 18. REMOVE WATER INLET HOUSING (SEE PAGE 1610) 19. REMOVE CRANKSHAFT PULLEY (SEE PAGE 14142) 20. REMOVE OIL PAN SUBASSY NO.2 (SEE PAGE 14142) 21. REMOVE OIL STRAINER SUBASSY (SEE PAGE 14142) 22. REMOVE OIL PAN SUBASSY (SEE PAGE 14142) 23. REMOVE INTAKE AIR SURGE TANK (SEE PAGE 111) 24. REMOVE IGNITION COIL ASSY L01 2. REMOVE OIL PIPE NO.1 (a) Remove the 2 oil pipe unions, and oil pipe No.1. (b) Remove the oil control valve filter LH and gaskets. G REMOVE OIL PIPE NO.2 (a) Remove the bolt. (b) Remove the 2 oil pipe unions, and oil pipe No.2. (c) Remove the oil control valve filter RH and gaskets. G

2 1418 ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GRFE) 27. REMOVE CYLINDER HEAD COVER SUBASSY (a) Remove the 12 bolts, head cover and gasket. Make sure the removed parts are returned to the same places they were removed from. G REMOVE CYLINDER HEAD COVER SUBASSY LH (a) Remove the 12 bolts, head cover and gasket. Make sure the removed parts are returned to the same places they were removed from. G REMOVE TIMING CHAIN COVER SUBASSY (SEE PAGE 177) 30. REMOVE TIMING CHAIN COVER OIL SEAL (SEE PAGE 177) 31. SET NO. 1 CYLINDER TO TDC/COMPRESSION (SEE PAGE 14142) 32. REMOVE CHAIN TENSIONER ASSY NO.1 (SEE PAGE 14142) 33. REMOVE CHAIN SUBASSY (SEE PAGE 14142) 34. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK) As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to be seized or to be broken. To avoid this, the following steps should be carried out. (a) While raising the chain tensioner No.2, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. Push G

3 CAMSHAFT (RH BANK) (2GRFE) 1419 A91 Hold Turn G40488 A9642 (b) Hold each hexagonal portion of the camshaft and No.2 camshaft with a wrench, and remove the camshaft timing gear set bolt. Be careful not to damage the cylinder head with the wrench. Do not disassemble the camshaft timing gear assembly. (c) Separate the camshaft timing gears with the No.2 chain subassy. 3. REMOVE CHAIN TENSIONER ASSY NO.2 (a) Remove the chain tensioner No.2 and bolt. 36. REMOVE CAMSHAFTS As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to be seized or to be broken. To avoid this, the following steps should be carried out. (a) Remove the 3 gaskets. G40318 (b) Make sure that the knock pin of the camshaft is positioned as shown in the illustration. Front View 4 G42799 G40320 Knock Pin G

4 14160 ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GRFE) (c) Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration G G40320 (d) Using several steps, loosen and remove the 12 bearing cap bolts in the sequence as shown in the illustration. (e) Remove the camshaft bearing caps, then remove the camshafts. Uniformly loosen the bolts while keeping the camshaft level. Do not pry the camshaft with a tool by applying excessive force to it. Do not damage the intake and exhaust parts on the cylinder head side. Make sure the removed parts are returned to the same places they were removed from. 37. REMOVE CAMSHAFT HOUSING SUBASSY RH (a) Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver. Be careful not to damage the contact surfaces of the cylinder head and camshaft housing. Tape the screwdriver tip before use. Protective Tape Protective Tape G40489 Straight Pin Key Groove G INSTALL CAMSHAFT TIMING GEAR (a) Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin. (b) Lightly press the gear against the camshaft, and turn the gear. Push further to the position where the pin enters the groove. CAUTION: Be sure not to turn the camshaft timing gear in the retard direction. 3029

5 CAMSHAFT (RH BANK) (2GRFE) (c) (d) (e) Check that there is no clearance between the gear s fringe and the camshaft. Tighten the fringe bolt with the camshaft timing gear fixed. Torque: 100 N m (1,020 kgf cm, 74 ft lbf) Check that the camshaft timing gear assembly can move in the retard direction and is locked at the most retarded position. Advance Close Open Retard Open Close 39. INSPECT CAMSHAFT TIMING GEAR ASSY (a) Check the lock of the camshaft timing gear. (1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked. Be careful not to damage the camshaft. (b) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece. (2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration. Vinyl Tape Rubber G40914 Advance Retard (3) Apply approximately 200 kpa (2.0 kgf/cm 2, 28 psi) of air pressure to the two broken paths. CAUTION: Cover the paths with a shop rag or piece of cloth when applying pressure to keep oil from splashing. G4091 Advance Hold Pressure Retard Decompress (4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path. OK: Gear rotates in the advance direction. This operation releases the lock pin for the most retarded position. G

6 14162 ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GRFE) () When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in this order. Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. (c) Check for smooth rotation. (1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly. OK: Gear rotates smoothly in the advance direction within its movable range (about 21 ). CAUTION: Do not use air pressure to perform the smooth operation check. (d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear is locked at the most retarded position. Retard Side Path Open Close Rubber Advance Vinyl Tape Close Open 40. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSY LH (a) Check the lock of the camshaft timing gear. (1) Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked. Be careful not to damage the camshaft. (b) Release the lock pin. (1) Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration. 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece. (2) Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration. A94638 G

7 CAMSHAFT (RH BANK) (2GRFE) Advance Retard (3) Apply approximately 200 kpa (2.0 kgf/cm 2, 28 psi) of air pressure to the two broken paths. CAUTION: Cover the paths with a shop rag or piece of cloth when applying pressure to keep oil from splashing. G40918 Advance Decompress Retard Hold Pressure G40919 (4) Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path. OK: Gear rotates in the advance direction. This operation releases the lock pin for the most retarded position. () When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in this order. Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin. (c) Check for smooth rotation. (1) Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly. OK: Gear rotates smoothly in the advance direction within its movable range (about 18. ). CAUTION: Do not use air pressure to perform the smooth operation check. (d) Check the lock in the most retarded position. (1) Confirm that the camshaft timing gear is locked at the most retarded position. 3032

8 14164 ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GRFE) Intake Side: Do not remove Exhaust Side: Do not remove Straight Pin Do not remove Straight Pin 41. REMOVE CAMSHAFT TIMING GEAR (a) Remove the fringe bolt and camshaft timing gear. Be sure not to remove the other bolts. If planning to reuse the gear, be sure to release the straight pin lock before installing the gear. 42. INSTALL CAMSHAFTS As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to be seized or to be broken. To avoid this, the following steps should be carried out. (a) Apply clean engine oil to the camshaft s cam portion and the cylinder head journals. A9160 A9162 Fringe Bolt Do not remove G40921 Stem End Cap Rocker Arm (b) Install the camshaft and No.2 camshaft to the camshaft housing subassy. Before and after setting the camshaft and No.2 camshaft, check that the rocker arm is firmly set to the lash adjuster. CORRECT INCORRECT Lash Adjuster G3211 (c) (d) (e) Apply engine oil to the camshaft journal, camshaft housing and bearing cap. Install the camshaft and No.2 camshaft to the camshaft housing RH. Make sure of the marks and numbers on the camshaft bearing caps an place them in each proper position and direction. G (f) Using several steps, install and temporarily tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 10 N m (102 kgf cm, 7 ft lbf) G

9 CAMSHAFT (RH BANK) (2GRFE) to 4. (0.138 to 0.177) : Seal Packing mm (in.) G INSTALL CAMSHAFT HOUSING SUBASSY RH (a) Apply seal packing in a continuous bead as shown in the illustration. Seal packing: Part No or equivalent Seal diameter: 3. to 4. mm (0.138 to in.) Remove any oil from the contact surface. Install the camshaft housing subassy RH within 3 minutes and tighten the bolts within 1 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation (b) Install the camshaft housing RH, and tighten the 12 bolts in the order shown in the illustration. Torque: 2 N m (2 kgf cm, 18 ft lbf) Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing RH. 8 Front View G40320 Knock Pin G (c) Using several steps, tighten the 8 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 16 N m (163 kgf cm, 12 ft lbf) Remove all excess seal packing after installing the bearing cap bolts G40319 (d) Install the 3 new gaskets to the camshaft bearing cap. G

10 14166 ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GRFE) A INSTALL CHAIN TENSIONER ASSY NO.2 (a) Install the chain tensioner No.2 with the bolt. Torque: 21 N m (214 kgf cm, 1 ft lbf) (b) While compressing the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it. 4. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK) As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to be seized or to be damaged. To avoid this, the following steps should be carried out. Timing Marks Mark Links (a) Align the mark links (yellow) with the timing marks of the camshaft timing gears as shown in the illustration. (b) Apply a small amount of engine oil to the bolt threads and boltseating surface. (c) Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No.2 chain installed. Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it. G40923 Hold Turn (d) (e) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts. Torque: 100 N m (1,020 kgf cm, 74 ft lbf) Remove the pin from the tensioner. G INSTALL CHAIN SUBASSY (SEE PAGE 14142) 47. INSTALL TIMING CHAIN COVER OIL SEAL (SEE PAGE 177) SST ( ) 48. INSTALL TIMING CHAIN COVER SUBASSY (SEE PAGE 177) 49. INSTALL WATER INLET HOUSING (SEE PAGE 1610) 0. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH (SEE PAGE 1421) Install engine mounting bracket front No.1 LH within 1 minutes after apply FIPG to timing chain cover. 303

11 CAMSHAFT (RH BANK) (2GRFE) INSTALL CYLINDER HEAD COVER SUBASSY (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover A 12 : Seal Packing and G G417 (b) Apply a continuous bead of seal packing to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Part No or equivalent Remove any oil from the contact surface. Install the crankcase within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. (c) Install the seal washers to the bolts. (d) Install the head cover with the 12 bolts. Torque: 21 N m (214 kgf cm, 1 ft lbf) for bolt A 10 N m (102 kgf cm, 7 ft lbf) for bolts except A 2. INSTALL CYLINDER HEAD COVER SUBASSY LH (a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover. 6 2 : Seal Packing and 10 G (b) Apply a continuous bead of seal packing to the cylinder head and timing chain cover as shown in the illustration. Seal packing: Part No or equivalent Remove any oil from the contact surface. Install the crankcase within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installation. (c) Install the seal washers to the bolts. (d) Install the head cover with the 12 bolts. Torque: 21 N m (214 kgf cm, 1 ft lbf) for bolt A 10 N m (102 kgf cm, 7 ft lbf) for bolts except A 11 and A G

12 14168 ENGINE MECHANICAL CAMSHAFT (RH BANK) (2GRFE) G INSTALL OIL PIPE NO.2 (a) Make sure that there is no foreign matter on the mesh of the oil control valve filter RH. (b) Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install oil pipe No.2 (on the head cover side). Remove any oil from the contact surface. (c) Install a new gasket and temporarily install oil pipe No.2 (on the cylinder head side) with the oil check valve bolt. Remove any oil from the contact surface. (d) Tighten the oil pipe union (on the head cover side). Torque: 6 N m (662 kgf cm, 48 ft lbf) (e) Tighten the oil pipe union (on the cylinder head side). Torque: 6 N m (662 kgf cm, 48 ft lbf) 4. INSTALL OIL PIPE NO.1 (a) Make sure that there is no foreign matter on the mesh of the oil control valve filter LH. (b) Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install oil pipe No.1 (on the head cover side). (A) Remove any oil from the contact surface. G416 (c) Install a new gasket and temporarily install oil pipe No.1 (on the cylinder head side) with the oil check valve bolt. Remove any oil from the contact surface. (d) Install the bolt (A) to the cylinder head. Torque: 10 N m (102 kgf cm, 7 ft lbf) (e) Tighten the oil pipe union (on the head cover side). Torque: 6 N m (662 kgf cm, 48 ft lbf) (f) Tighten the oil pipe union (on the cylinder head side). Torque: 6 N m (662 kgf cm, 48 ft lbf). INSTALL IGNITION COIL ASSY Torque: 10 N m (102 kgf cm, 7 ft lbf) 6. INSTALL INTAKE AIR SURGE TANK (SEE PAGE 111) 7. INSTALL OIL PAN SUBASSY (SEE PAGE 14142) 8. INSTALL OIL STRAINER SUBASSY (SEE PAGE 14142) 9. INSTALL OIL PAN SUBASSY NO.2 (SEE PAGE 14142) 60. INSTALL CRANKSHAFT PULLEY (SEE PAGE 14142) 61. INSTALL ENGINE MOUNTING STAY NO.2 RH (SEE PAGE 1421) 62. INSTALL TIMING GEAR COVER NO INSTALL WATER PUMP PULLEY (SEE PAGE 1610) 64. INSTALL VRIBBED BELT TENSIONER ASSY (SEE PAGE 1421) 6. INSTALL ENGINE MOUNTING BRACKET RH (SEE PAGE 1421) 3037

13 CAMSHAFT (RH BANK) (2GRFE) INSTALL IDLER PULLEY SUBASSY NO.2 Torque: 43 N m (438 kgf cm, 32 ft lbf) 67. REMOVE ENGINE ASSY 68. INSTALL DRIVE PLATE & RING GEAR SUBASSY (SEE PAGE 14208) 69. INSTALL EXHAUST MANIFOLD SUBASSY LH (SEE PAGE 1421) 70. INSTALL EXHAUST MANIFOLD SUBASSY RH (SEE PAGE 1421) 71. INSTALL OIL LEVEL GAUGE GUIDE SUBASSY (SEE PAGE 1421) 72. INSTALL AUTOMATIC TRANSAXLE ASSY (SEE PAGE 408) 73. INSTALL STARTER ASSY (SEE PAGE 199) 74. INSTALL FRONT FRAME ASSY (SEE PAGE 1421) 7. INSTALL ENGINE WIRE 76. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 1421) 3038

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