REPLACEMENT N0. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE ). REMOVE ENGINE WIRE 3. REMOVE FRONT FRAME ASSY (SEE PAGE ). REMOVE STARTER ASSY (SEE PAGE 99). REMOVE AUTOMATIC TRANSAXLE ASSY (SEE PAGE 0) 6. REMOVE OIL LEVEL GAUGE GUIDE SUBASSY (SEE PAGE ). REMOVE EXHAUST MANIFOLD SUBASSY RH (SEE PAGE ). REMOVE EXHAUST MANIFOLD SUBASSY LH (SEE PAGE ) 9. REMOVE DRIVE PLATE & RING GEAR SUBASSY (SEE PAGE 0) SST 09300 (093000), 09330000 0. FIX ENGINE ASSY. REMOVE IDLER PULLEY SUBASSY NO.. REMOVE ENGINE MOUNTING BRACKET RH (SEE PAGE ) 3. REMOVE VRIBBED BELT TENSIONER ASSY (SEE PAGE ). REMOVE WATER PUMP PULLEY (SEE PAGE 60) SST 09960000 (09960000, 099630000). REMOVE TIMING GEAR COVER NO. 6. REMOVE ENGINE MOUNTING STAY NO. RH (SEE PAGE ). REMOVE ENGINE MOUNTING BRACKET FRONT NO. LH (SEE PAGE ). REMOVE WATER INLET HOUSING (SEE PAGE 60) 9. REMOVE CRANKSHAFT PULLEY (SEE PAGE ) SST 09300 (093000), 09330000, 0990003 (099000, 099000, 0993000, 09900) 0. REMOVE OIL PAN SUBASSY NO. (SEE PAGE ) SST 09030000. REMOVE OIL STRAINER SUBASSY (SEE PAGE ). REMOVE OIL PAN SUBASSY (SEE PAGE ) 3. REMOVE INTAKE AIR SURGE TANK (SEE PAGE ). REMOVE IGNITION COIL ASSY. REMOVE OIL PIPE NO. (SEE PAGE ) 6. REMOVE OIL PIPE NO. (SEE PAGE ). REMOVE CYLINDER HEAD COVER SUBASSY RH (SEE PAGE ). REMOVE CYLINDER HEAD COVER SUBASSY LH (SEE PAGE ) 9. REMOVE TIMING CHAIN COVER SUBASSY (SEE PAGE ) 30. REMOVE TIMING CHAIN COVER OIL SEAL (SEE PAGE ) 3. SET NO. CYLINDER TO TDC/COMPRESSION (SEE PAGE ) 3. REMOVE CHAIN TENSIONER ASSY NO. (SEE PAGE ) 33. REMOVE CHAIN SUBASSY (SEE PAGE ) 30
6 ENGINE MECHANICAL 3. REMOVE CAMSHAFT TIMING GEARS AND NO. CHAIN (LH BANK) must be kept level while it is being removed. If the Push (a) While pushing down the chain tensioner No.3, insert a pin of φ.0 mm (0.039 in.) into the hole to fix it. A966 A96 Turn Hold G090 A963 (b) Hold each hexagonal portion of the No.3 camshaft and No. 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. chain subassy. 3. REMOVE CHAIN TENSIONER ASSY NO.3 (a) Remove the bolt and chain tensioner No.3. 36. REMOVE CAMSHAFTS must be kept level while it is being removed. If the (a) Remove the 3 gaskets. G03 30
(b) Make sure that the knock pin of the camshaft is positioned as shown in the illustration. Front View G00 G09 Knock Pin G3 (c) Using several steps, loosen and remove the bearing cap bolts in the sequence shown in the illustration. 6 3 G09 9 0 3 6 3 G09 (d) Using several steps, loosen and remove the bearing cap bolts in the sequence 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. HINT: Make sure the removed parts are returned to the same places they were removed from. 306
ENGINE MECHANICAL 3. REMOVE CAMSHAFT HOUSING SUBASSY LH (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. HINT: Tape the screwdriver tip before use. Protective Tape Protective Tape G093 3. INSTALL CAMSHAFT TIMING GEAR (SEE PAGE ) 39. INSPECT CAMSHAFT TIMING GEAR ASSY (SEE PAGE ) 0. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSY LH (SEE PAGE ). REMOVE CAMSHAFT TIMING GEAR (SEE PAGE ). INSTALL CAMSHAFTS must be kept level while it is being installed. If the Stem End Cap Rocker Arm (a) Install the camshaft and No. camshaft to the camshaft housing subassy. Before and after setting the camshaft and No. camshaft, check that the rocker arm is firmly set to the lash adjuster. CORRECT INCORRECT Lash Adjuster G3 (b) (c) (d) Apply engine oil to the camshaft journal, camshaft housing and bearing cap. Install the No.3 camshaft and No. camshaft to the camshaft housing LH. Confirm the marks and numbers on the camshaft bearing caps and place them in each proper position and direction. A969 30
9 3 (e) Using several steps, install and temporarily tighten the bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 0 N m (0 kgf cm, ft lbf) 6 G9 3. to. (0.3 to 0.) : Seal Packing mm (in.) G0 3. INSTALL CAMSHAFT HOUSING SUBASSY LH (a) Apply seal packing in a continuous bead as shown in the illustration. Seal packing: Part No. 060000 or equivalent Seal diameter: 3. to. mm (0.3 to 0. in.) Remove any oil from the contact surface. Install the camshaft housing subassy LH within 3 minutes and tighten the bolts within minutes after applying seal packing. Do not start the engine for at least hours after installation. 9 3 6 0 3 (b) Install the camshaft housing LH, and tighten the 3 bolts in the order shown in the illustration. Torque: N m ( kgf cm, ft lbf) Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing LH. Front View G09 Knock Pin G0 3 6 (c) Using several steps, tighten the 9 bearing cap bolts uniformly in the sequence as shown in the illustration. Torque: 6 N m (63 kgf cm, ft lbf) Remove all excess seal packing after installing the bearing cap bolts. G09 30
0 ENGINE MECHANICAL (d) Install 3 new gaskets. G03 A96. INSTALL CHAIN TENSIONER ASSY NO.3 (a) Install the chain tensioner No.3 with the bolt. Torque: N m ( kgf cm, ft lbf) (b) While pushing in the tensioner, insert a pin of φ.0 mm (0.039 in.) into the hole to fix it.. INSTALL CAMSHAFT TIMING GEARS AND NO. CHAIN (LH BANK) must be kept level while it is being installed. If the 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 LH with the No. chain installed. Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it. G093 Turn Hold (d) (e) Hold the hexagonal portion of the camshaft with a wrench, and tighten the bolts. Torque: 00 N m (,00 kgf cm, ft lbf) Remove the pin from the tensioner. G090 309
6. INSTALL CHAIN TENSIONER ASSY NO. (SEE PAGE ). INSTALL TIMING CHAIN COVER OIL SEAL (SEE PAGE ) SST 0936600 (0936000). INSTALL TIMING CHAIN COVER SUBASSY (SEE PAGE ) 9. INSTALL WATER INLET HOUSING (SEE PAGE 60) 0. INSTALL ENGINE MOUNTING BRACKET FRONT NO. LH (SEE PAGE ) Install engine mounting bracket front No. LH within minutes after apply FIPG to timing chain cover.. INSTALL CYLINDER HEAD COVER SUBASSY LH (SEE PAGE ). INSTALL CYLINDER HEAD COVER SUBASSY RH (SEE PAGE ) 3. INSTALL OIL PIPE NO. (SEE PAGE ). INSTALL OIL PIPE NO. (SEE PAGE ). INSTALL IGNITION COIL ASSY Torque: 0 N m (0 kgf cm, ft lbf) 6. INSTALL INTAKE AIR SURGE TANK (SEE PAGE ). INSTALL OIL PAN SUBASSY (SEE PAGE ). INSTALL OIL STRAINER SUBASSY (SEE PAGE ) 9. INSTALL OIL PAN SUBASSY NO. (SEE PAGE ) 60. INSTALL CRANKSHAFT PULLEY (SEE PAGE ) SST 09300 (093000), 09330000 6. INSTALL ENGINE MOUNTING STAY NO. RH (SEE PAGE ) 6. INSTALL TIMING GEAR COVER NO. 63. INSTALL WATER PUMP PULLEY (SEE PAGE 60) SST 09960000 (09960000, 099630000) 6. INSTALL VRIBBED BELT TENSIONER ASSY (SEE PAGE ) 6. INSTALL ENGINE MOUNTING BRACKET RH (SEE PAGE ) 66. INSTALL IDLER PULLEY SUBASSY NO. 6. REMOVE ENGINE ASSY 6. INSTALL DRIVE PLATE & RING GEAR SUBASSY (SEE PAGE 0) SST 09300 (093000), 09330000 69. INSTALL EXHAUST MANIFOLD SUBASSY LH (SEE PAGE ) 0. INSTALL EXHAUST MANIFOLD SUBASSY RH (SEE PAGE ). INSTALL OIL LEVEL GAUGE GUIDE SUBASSY (SEE PAGE ). INSTALL AUTOMATIC TRANSAXLE ASSY (SEE PAGE 0) 3. INSTALL STARTER ASSY (SEE PAGE 99). INSTALL FRONT FRAME ASSY (SEE PAGE ). INSTALL ENGINE WIRE 6. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (SEE PAGE ) 300