14142 REPLACEMENT HINT: ENGINE MECHANICAL Refer to CAMSHAFT (RH BANK) or CAMSHAFT (LH BANK) for the replacement procedure of the No.2 chain (see page 14157 or 14175). 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) 5. REMOVE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 408) 1424J01 6. REMOVE OIL LEVEL GAUGE GUIDE SUBASSY (a) Remove the oil level gauge. (b) Remove the bolt and pull out the oil level gauge guides No.1 and No.2. (c) Remove the 2 Orings from the oil level gauge guide. G42162 7. REMOVE DRIVE PLATE & RING GEAR SUBASSY (SEE PAGE 14208) SST 0921370011 (0921370020), 0933000021 8. FIX ENGINE ASSY (a) Fix the engine onto the engine stand. 9. REMOVE IDLER PULLEY SUBASSY NO.2 (a) Remove the bolt and idler pulley. 10. REMOVE ENGINE MOUNTING BRACKET RH (SEE PAGE 1421) 11. REMOVE VRIBBED BELT TENSIONER ASSY (a) Remove the 5 bolts and Vribbed belt tensioner. G42367 12. REMOVE WATER PUMP PULLEY (SEE PAGE 1610) SST 0996010010 (0996201000, 0996300700) 13. REMOVE TIMING GEAR COVER NO.2 14. REMOVE ENGINE MOUNTING STAY NO.2 RH (SEE PAGE 1421) 15. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH (SEE PAGE 1421) 16. REMOVE WATER INLET HOUSING (SEE PAGE 1610) 3011
ENGINE MECHANICAL 14143 17. REMOVE CRANKSHAFT PULLEY (a) Using SST, hold the crankshaft pulley and loosen the pulley set bolt. SST 0921370011 (0921370020), 0933000021 SST SST G42372 (b) Using the pulley set bolt and SST, remove the crankshaft pulley. SST 0995050013 (0995105010, 0995205010, 0995305020, 0995405021) SST G42373 18. REMOVE OIL PAN SUBASSY NO.2 (a) Remove the 16 bolts and 2 nuts. G41576 (b) Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the oil pan subassy No.2. SST 0903200100 Be careful not to damage the contact surfaces of the oil pans. A53930 3012
14144 ENGINE MECHANICAL 19. REMOVE OIL STRAINER SUBASSY (a) Remove the bolt, 2 nuts and oil strainer and gasket. G41580 20. REMOVE OIL PAN SUBASSY (a) Remove the 16 bolts and 2 nuts. HINT: Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage. G41577 Protective Tape (b) Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver. Be careful not to damage the contact surfaces of the cylinder block and oil pan. HINT: Tape the screwdriver tip before use. Protective Tape G41578 (c) Remove the Orings from the oil pump. G41579 21. REMOVE INTAKE AIR SURGE TANK (SEE PAGE 1115) 22. REMOVE IGNITION COIL ASSY 23. REMOVE OIL PIPE NO.1 (SEE PAGE 14157) 24. REMOVE OIL PIPE NO.2 (SEE PAGE 14157) 25. REMOVE CYLINDER HEAD COVER SUBASSY RH (SEE PAGE 14157) 3013
ENGINE MECHANICAL 14145 26. REMOVE CYLINDER HEAD COVER SUBASSY LH (SEE PAGE 14157) 27. REMOVE TIMING CHAIN COVER SUBASSY (SEE PAGE 177) 28. REMOVE TIMING CHAIN COVER OIL SEAL (SEE PAGE 177) Center Line 29. SET NO. 1 CYLINDER TO TDC/COMPRESSION (a) Temporarily tighten the pulley set bolt. (b) Set the timing mark on the crank angle sensor plate to the RH block bore center line. (TDC/compression) Sensor Plate G41585 (c) Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration. If not, turn the crankshaft 1 complete revolution (360 ) and align the timing marks as above. G41586 Push 30. REMOVE CHAIN TENSIONER ASSY NO.1 (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate s hole. (c) Remove the 2 bolts and chain tensioner. Stopper Plate Stopper Plate A72958 31. REMOVE CHAIN TENSIONER SLIPPER 3014
14146 ENGINE MECHANICAL 10 Center Line 32. REMOVE CHAIN SUBASSY (a) Turn the crankshaft 10 counterclockwise to loosen the chain of the crankshaft timing gear. (b) Remove the chain from the crank timing gear and place it on the crankshaft. Sensor Plate G41587 RH Side: (c) (d) Turn the camshaft timing gear assy on the RH bank clockwise (approximately 60 ) and set it as shown in the illustration. Be sure to loosen the chain between the center banks. Remove the chain subassy. A94657 G40486 Mark Plate Timing Mark Mark Plate Timing Mark 33. INSTALL CHAIN SUBASSY (a) Align the mark plate and timing mark as shown in the illustration and install the chain. Do not pass the chain over the crankshaft, just put it on it. HINT: The chain mark plate is orange. G41597 RH Side: (b) Turn the camshaft timing gear assy on the RH bank counterclockwise to tighten the chain between banks. A94657 G40486 3015
ENGINE MECHANICAL 14147 Mark Plate (c) Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing gear. HINT: The chain mark plate is yellow. (d) Temporarily tighten the pulley set bolt. G41598 34. INSTALL CHAIN TENSIONER SLIPPER Stopper Plate 35. INSTALL CHAIN TENSIONER ASSY NO.1 (a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner. (b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate. A95595 Plunger G40516 (c) Install the chain tensioner No.1 with the 2 bolts. Torque: 10 N m (102 kgf cm, 7 ft lbf) A95165 3016
14148 ENGINE MECHANICAL (d) (e) Remove the lock pin of chain tensioner assy No.1. Check that each timing mark is aligned with the crankshaft at the TDC/compression. Remove the pulley set bolt. Center Line G42594 36. INSTALL TIMING CHAIN COVER OIL SEAL (SEE PAGE 177) SST 0931660011 (0931600011) 37. INSTALL TIMING CHAIN COVER SUBASSY (SEE PAGE 177) 38. INSTALL WATER INLET HOUSING (SEE PAGE 1610) 39. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH (SEE PAGE 1421) Install engine mounting bracket front No.1 LH within 15 minutes after apply FIPG to timing chain cover. 40. INSTALL CYLINDER HEAD COVER SUBASSY LH (SEE PAGE 14157) 41. INSTALL CYLINDER HEAD COVER SUBASSY RH (SEE PAGE 14157) 42. INSTALL OIL PIPE NO.2 (SEE PAGE 14157) 43. INSTALL OIL PIPE NO.1 (SEE PAGE 14157) 44. INSTALL IGNITION COIL ASSY Torque: 10 N m (102 kgf cm, 7 ft lbf) 45. INSTALL INTAKE AIR SURGE TANK (SEE PAGE 1115) 46. INSTALL OIL PAN SUBASSY (a) Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan. 3017
ENGINE MECHANICAL 14149 (b) Install 2 new Orings to the oil pump. G41579 3.0 to 4.0 mm (0.118 to 0.156 in.) : Seal Packing Nut G41604 A A (c) Apply seal packing in a continuous bead as shown in the illustration. Seal packing: Part No. 0882600080 or equivalent Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) 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. (d) Install the oil pan with the 16 bolts and 2 nuts. Torque: 10 N m (102 kgf cm, 7 ft lbf) for bolt A 21 N m (214 kgf cm, 15 ft lbf) for bolts except A Nut G41577 47. INSTALL OIL STRAINER SUBASSY (a) Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 10 N m (102 kgf cm, 7 ft lbf) 48. INSTALL OIL PAN SUBASSY NO.2 (a) Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No.2. G41580 3.0 to 4.0 mm (0.118 to 0.156 in.) G41605 : Seal Packing G43210 (b) Apply seal packing in a continuous bead as shown in the illustration. Seal packing: Part No. 0882600080 or equivalent Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 in.) 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. 3018
14150 ENGINE MECHANICAL Nut (c) (d) Install the oil pan No.2 with the 16 bolts and 2 nuts. Torque: 10 N m (102 kgf cm, 7 ft lbf) Install a new gasket and the drain plug. Torque: 40 N m (408 kgf cm, 30 ft lbf) Nut G41576 SST 49. INSTALL CRANKSHAFT PULLEY (a) Using SST, install the pulley set bolt. SST 0921370011 (0921370020), 0933000021 Torque: 250 N m (2,549 kgf cm, 184 ft lbf) SST G40910 50. INSTALL ENGINE MOUNTING STAY NO.2 RH (SEE PAGE 1421) 51. INSTALL TIMING GEAR COVER NO.2 52. INSTALL WATER PUMP PULLEY (SEE PAGE 1610) SST 0996010010 (0996201000, 0996300700) 53. INSTALL VRIBBED BELT TENSIONER ASSY A (a) Temporarily install the Vribbed belt tensioner with the 5 bolts. 1 (b) Install the Vribbed belt tensioner by tightening the bolt 1 B and bolt 2 in the order shown in the illustration. B B Torque: 43 N m (438 kgf cm, 32 ft lbf) B 2 (c) Tighten the other bolts. Torque: 43 N m (438 kgf cm, 32 ft lbf) G42367 HINT: Each bolt length is as follows: A: 70 mm (2.76 in.) B: 35 mm (1.38 in.) 54. INSTALL ENGINE MOUNTING BRACKET RH (SEE PAGE 1421) 55. INSTALL IDLER PULLEY SUBASSY NO.2 (a) Install the idler pulley with the bolt. Torque: 43 N m (438 kgf cm, 32 ft lbf) 56. REMOVE ENGINE ASSY (a) Remove the engine from the engine stand. 57. INSTALL DRIVE PLATE & RING GEAR SUBASSY (SEE PAGE 14208) SST 0921370011 (0921370020), 0933000021 3019
ENGINE MECHANICAL 14151 No.1 No.2 G42162 58. INSTALL OIL LEVEL GAUGE GUIDE SUBASSY (a) Install 2 new Orings to the oil level gauge guide. (b) Apply a light coat of engine oil to the 2 Orings. (c) Push in the oil level gauge guide end into the guide hole. (d) Install the oil level gauge guide No.1 with the bolt. Torque: 10 N m (102 kgf cm, 7 ft lbf) (e) Install the oil level gauge guide No.2 with the bolt. Torque: 21 N m (214 kgf cm, 15 ft lbf) (f) Install the oil level gauge. 59. INSTALL AUTOMATIC TRANSAXLE ASSY (SEE PAGE 408) 60. INSTALL STARTER ASSY (SEE PAGE 199) 61. INSTALL FRONT FRAME ASSY (SEE PAGE 1421) 62. INSTALL ENGINE WIRE 63. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE 1421) 3020