ENGINE UNIT > REASSEMBLY

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1. INSTALL STUD BOLT



A107604E01



2. INSTALL STRAIGHT PIN



A053947E01



3. INSTALL RING PIN



A107618E01



4. INSTALL PISTON SUB-ASSEMBLY WITH PIN


    A054370

  1. Using a small screwdriver, install a new snap ring on one side of the piston pin hole.



    A054371E02

  1. Gradually heat the piston to about 60°C (140°F).



    A107616E01

  1. Coat the piston pin with engine oil.

  1. The piston's front mark and the connecting rod's outside mark should face the same direction, as shown in the illustration.

    NOTICE:
    The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with "3L" and the RH piston is marked with "3R".

  1. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.



    A054360

  1. Check the fit between the piston and piston pin.

    1. Try to move the piston back and forth on the piston pin.



    A054362

  1. Using a small screwdriver, install a new snap ring on the other side of the piston pin hole.



    A107617E02

  1. Install the oil ring expander and 2 side rails by hand.



  1. Using a piston ring expander, install the No. 1 and No. 2 piston rings with the code mark facing upward.

    Code mark:
    Piston Ring
    		Code Mark
    No. 1
    		1R
    No. 2
    		2R



    A107619E01

  1. Position the piston rings so that the ring ends are as shown in the illustration.

    NOTICE:
    Do not align the ring ends.



5. INSTALL CONNECTING ROD BEARING


    A054736

  1. Align the bearing claw with the groove of the connecting rod or connecting cap.

  1. Install the bearings in the connecting rod and connecting rod cap.



6. INSTALL CRANKSHAFT BEARING


A054737E01

HINT:
  1. Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
  2. Upper bearings have an oil groove and oil holes; lower bearings do not.



    A054343

  1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.



    A054738E01

  1. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

    HINT:
    A number is marked on each bearing cap to indicate the installation position.



7. INSTALL CRANKSHAFT THRUST WASHER SET


    A054344E01

  1. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.



    A054739E01

  1. Install the 2 thrust washers on the No. 3 bearing cap with the grooves facing outward.



8. INSTALL CRANKSHAFT


    A054740

  1. Place the crankshaft on the cylinder block.



    A054741

  1. Install the 5 crankshaft bearing caps in their proper locations.

    HINT:
    Place the bearing caps level and let them return to their original positions by their own weight.

    NOTICE:
    Do not install the bearing cap by tapping it.



    A054720E02

  1. Install the crankshaft bearing cap bolts.

    HINT:
    If any one of the bearing cap bolts is broken or deformed, replace it.


    1. Apply a light coat of engine oil on the threads and under the crankshaft bearing cap bolts.

    2. Install and uniformly tighten the 20 crankshaft bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque:
      27 N*m{ 275 kgf*cm , 20 ft.*lbf }

      If any of the bearing cap bolts cannot meet the torque specification, replace the bearing cap bolt.



      3. A054742E01

    3. Mark the front of the crankshaft bearing cap bolt's head with paint.

    4. Tighten the crankshaft bearing cap bolts another 90° as shown in the illustration.

    5. Check that the painted mark is now at a 90° angle to the front.



      6. A054719

    6. Install a new seal washer to the crankshaft bearing cap bolt.

    7. Install and uniformly tighten the 10 crankshaft bearing cap bolts.

      Torque:
      49 N*m{ 500 kgf*cm , 36 ft.*lbf }

  1. Check that the crankshaft turns smoothly.

  1. Check the crankshaft thrust clearance.



9. INSTALL PISTON AND CONNECTING ROD


    A107613E01

  1. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

    NOTICE:
    The shape of the piston varies for the LH and RH banks. The LH piston is marked with "3L" and the RH piston is marked with "3R".



    A054743

  1. Place the connecting rod cap on the connecting rod.

    1. Match the numbered connecting rod cap with the connecting rod.

    2. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.



      3. A107614E01

    3. Check that the outside mark of the connecting rod cap is facing in the correct direction.



    A054714

  1. Install the connecting rod cap bolts.

    HINT:
    If any one of the connecting rod cap bolts is broken or deformed, replace it.


    1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.

    2. Install and alternately tighten the 2 connecting rod cap bolts in several passes.

      Torque:
      24.5 N*m{ 250 kgf*cm , 18 ft.*lbf }

      If any of the connecting rod cap bolts cannot meet the torque specification, replace the connecting rod cap bolts.



      3. A054745E01

    3. Mark the front of the connecting cap bolt with paint.

    4. Tighten the cap bolts another 90° as shown in the illustration.

    5. Check that the painted mark is now at a 90° angle to the front.

  1. Check that the crankshaft turns smoothly.

  1. Check the connecting rod thrust clearance.



10. INSTALL WATER SEAL PLATE

  1. Remove any old packing (FIPG) material.



    A054746E02

  1. Apply seal packing to the seal plate as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2 to 3 mm (0.08 to 0.12 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the seal plate within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing the seal plate.

  1. Install the seal plate with the 2 nuts. Alternately tighten the nuts in several passes.

    Torque:
    14 N*m{ 142 kgf*cm , 10 ft.*lbf }



11. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


    A054747E01

  1. Apply seal packing to 2 or 3 threads.

    Seal packing:
    Part No. 08826-00100 or equivalent



    A054748E01

  1. Install the RH and LH drain cocks.

    Torque:
    49 N*m{ 500 kgf*cm , 36 ft.*lbf }

    HINT:
    After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.



12. INSTALL CAMSHAFT SETTING OIL SEAL


    A054032E01

  1. Place a new oil seal into the timing tube.

    NOTICE:
    Be careful of the installation direction.



13. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY


    A054029E01

  1. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.

  1. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.

    SST
    09960-10010   (09962-01000, 09963-00500)

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

    NOTICE:
    Be careful not to damage the timing tube.



    A003173

  1. Mount the hexagon wrench head portion of the camshaft in a vise.

    NOTICE:
    Be careful not to damage the camshaft.



    A054031E01

  1. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.

  1. Using a 10 mm hexagon wrench, install the bolt.

    Torque:
    78 N*m{ 795 kgf*cm , 58 ft.*lbf }

  1. Install the seal washer and screw plug.

    Torque:
    15 N*m{ 152 kgf*cm , 11 ft.*lbf }



14. INSTALL CAMSHAFT SUB GEAR


    A091488E01

  1. Install the bolt washer (1), sub gear (2) and wave washer (3).

    HINT:
    Attach the pins on the gears to the gear bolt washer ends.



    A002861

  1. Using snap ring pliers, install the snap ring.



    A002859

  1. Mount the hexagon wrench head portion of the camshaft in a vise.

    NOTICE:
    Be careful not to damage the camshaft.



    A002889E01

  1. Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.

    SST
    09960-10010   (09962-01000, 09963-00500)

  1. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.



15. INSTALL ENGINE REAR OIL SEAL RETAINER

  1. Remove any oil packing (FIPG) material.



    A054347E02

  1. Apply seal packing to the oil seal retainer as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3 to 4 mm (0.12 to 0.16 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the oil seal within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing the oil seal retainer.



    A054973E01

  1. Install a new O-ring to the cylinder block.

  1. Install the oil seal retainer with the 7 bolts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }



16. INSTALL OIL PUMP ASSEMBLY


    B002620E01

  1. Apply seal packing to the oil pump as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2 to 3 mm (0.08 to 0.12 in.)

    NOTICE:
    1. Wipe off any oil from the contact surface.
    2. Install the oil pump within 3 minutes after applying seal packing.
    3. Do not expose the seal to engine oil for at least 2 hours after installing it.



    B002621E01

  1. Apply engine oil to a new O-ring.

  1. Install the O-ring to the cylinder block.

  1. Align the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump onto the crankshaft.



    B013038E01

  1. Install the oil pump with a new stud bolt and the 7 bolts. Uniformly tighten the bolts in several passes.

    Torque:
    15.5 N*m{ 153 kgf*cm , 11 ft.*lbf } for bolt A, B, C and E
    30.5 N*m{ 311 kgf*cm , 22 ft.*lbf } for bolt D

    HINT:
    1. Use a 6 mm hexagon wrench for the hexagon head bolt.
    2. Each bolt length is as shown in the table.

      Bolt length:
      Bolt
      		Bolt Head Size
      		Length
      A
      		12 mm bolt
      		50 mm (1.97 in.)
      B
      		12 mm stud bolt
      		106 mm (4.17 in.)
      C
      		12 mm
      		30 mm (1.18 in.)
      D
      		14 mm
      		44 mm (1.73 in.)
      E
      		6 mm hexagon bolt
      		28 mm (1.10 in.)

    NOTICE:
    Do not reuse the stud bolt B.



17. INSTALL OIL STRAINER SUB-ASSEMBLY


    A091810

  1. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }

    HINT:
    The bolt length is 12 mm (0.47 in.).



18. INSTALL OIL PAN STUD BOLT



A110464E01



19. INSTALL OIL PAN SUB-ASSEMBLY


    A109862E01

  1. Apply the seal packing as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2 to 3 mm (0.08 to 0.12 in.)

    NOTICE:
    1. Wipe off any oil from the contact surface.
    2. Install the oil pump within 3 minutes after applying seal packing.
    3. Do not expose the seal to engine oil for at least 2 hours after installing it.



    A108774E01

  1. Temporarily install the oil pan with the 18 bolts, stud bolt and 2 nuts.

    HINT:
    Each bolt length is as shown in the table.

    Bolt length:
    Bolt
    		Bolt Head Size
    		Length
    A
    		10 mm
    		22 mm (0.87 in.)
    B
    		12 mm
    		25 mm (0.99 in.)
    C
    		12 mm
    		60 mm (2.38 in.)
    D
    		10 mm
    		35 mm (1.38 in.)

  1. Set the oil pan as shown in the illustration.

    NOTICE:
    Make sure the clearance between the rear end of the oil pan and cylinder block is 0.2 mm (0.008 in.) or less. If the clearance is more than 0.2 mm (0.008 in.), the oil pan will deform when tightening the bolts and nuts.

  1. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf } for bolt A, D
    28 N*m{ 286 kgf*cm , 21 ft.*lbf } for bolt B, C
    28 N*m{ 286 kgf*cm , 21 ft.*lbf } for nut E



20. INSTALL OIL PAN BAFFLE PLATE


    A108773E01

  1. Install the baffle plate with the 4 bolts and 2 nuts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



21. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    A109863E02

  1. Apply seal packing as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3 to 4 mm (0.12 to 0.16 in)

    NOTICE:
    1. Wipe off any oil from the contact surface.
    2. Install the oil pan within 3 minutes after applying seal packing.
    3. Do not expose the seal to engine oil for at least 2 hours after installing it.

  1. Install the oil pan with the 15 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    6.9 N*m{ 70 kgf*cm , 61 in.*lbf }

    HINT:
    The bolt length is 14 mm (0.55 in.).



22. INSTALL WATER PUMP ASSEMBLY


    A054358

  1. Install a new gasket and the water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolt
    18 N*m{ 184 kgf*cm , 13 ft.*lbf } for stud bolts and nut

    HINT:
    Use bolts that are 30 mm (1.18 in.) in length.



23. INSTALL CYLINDER HEAD SUB-ASSEMBLY


    A053968E01

  1. Place a new cylinder head gasket on the cylinder block.

    HINT:
    The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.

    NOTICE:
    Be careful of the installation direction.

  1. Place the cylinder head on the cylinder head gasket.



    A053970E02

  1. Install the cylinder head bolts.

    HINT:
    If any cylinder head bolt is broken or deformed, replace it.


    1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

    2. Install the plate washer to the cylinder head bolt.



      3. A053972E01

    3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.

      Torque:
      59 N*m{ 602 kgf*cm , 44 ft.*lbf }

      If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

      NOTICE:
      Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.



      4. A053975E01

    4. Mark the front of the cylinder head bolt's head with paint.

    5. Tighten the cylinder head bolts another 90° in the sequence shown in the illustration.

    6. Check that the painted mark is now at a 90° angle to the front.



24. INSTALL CYLINDER HEAD LH


    A053969E01

  1. Place a new cylinder head gasket on the cylinder block.

    HINT:
    The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.

    NOTICE:
    Be careful of the installation direction.

  1. Place the cylinder head on the cylinder head gasket.



    A053971E02

  1. Install the cylinder head bolts.

    HINT:
    If any cylinder head bolt is broken or deformed, replace it.


    1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

    2. Install the plate washer to the cylinder head bolt.



      3. A053973E01

    3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown.

      Torque:
      59 N*m{ 602 kgf*cm , 44 ft.*lbf }

      If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

      NOTICE:
      Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.



      4. A053974E01

    4. Mark the front of the cylinder head bolt's head with paint.

    5. Tighten the cylinder head bolts another 90° in the sequence shown in the illustration.

    6. Check that the painted mark is now at a 90° angle to the front.



25. INSTALL CAMSHAFT (for Bank 2)

NOTICE:
Since 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 receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.



    G038669E01

  1. Set the crankshaft position.

    1. Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft to 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.

      NOTICE:
      The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.

  1. Apply MP grease to the thrust portion of the camshafts.



    A054030E01

  1. Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the 2 camshafts.

  1. Set the timing marks (1 dot mark each) of the camshaft drive and driven main gears at an approximately 10° angle.



    A054033E01

  1. Apply seal packing to the camshaft housing plug.

    1. Remove the old packing (FIPG) material.

    2. Apply seal packing to the housing plug as shown in the illustration.

      Seal packing:
      Part No. 08826-00080 or equivalent



    A054976

  1. Install the camshaft housing plug to the cylinder head as shown in the illustration.

  1. Install the oil control valve filter to the cylinder head.

    NOTICE:
    Be careful of the installation direction.



    A054356E02

  1. Apply seal packing to the front bearing cap.

    1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.

    2. Apply seal packing to the bearing cap as shown in the illustration.

      Seal packing:
      Part No. 08826-00080 or equivalent

      Seal diameter:
      1.5 to 2.0 mm (0.059 to 0.079 in.)

      NOTICE:
      Do not apply seal packing to the front bearing cap grooves.



    A054977

  1. Install the front bearing cap.

    HINT:
    Installing the front bearing cap will determine the thrust portion of the camshaft.

  1. Install the other bearing caps in the sequence shown, with the arrow mark facing forward.



    A053981E01

  1. Push in the camshaft setting oil seal.



    A054151E03

  1. Install new seal washers to the bearing cap bolts A and B.

  1. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts D and E.

    NOTICE:
    Do not apply engine oil under the heads of the bearing cap bolts A, B and C.

    Bolt length:
    94 mm (3.70 in.) for A with seal washer
    72 mm (2.83 in.) for B with seal washer
    25 mm (0.98 in.) for C
    52 mm (2.05 in.) for D
    38 mm (1.50 in.) for E

  1. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.



    A054151E02

  1. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 ft.*lbf } for bolts 21 and 22

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf } for other bolts



    A054025E01

  1. Remove the service bolt.



26. INSTALL NO. 3 CAMSHAFT SUB-ASSEMBLY (for Bank 1)

NOTICE:
Since 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 receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.



    A054064E01

  1. Check that the set key of the crankshaft is at a position 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.

    NOTICE:
    The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.

  1. Apply MP grease to the thrust portion of the camshafts.



    A054979E01

  1. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the 2 camshafts.



    A054033E01

  1. Apply seal packing to the camshaft housing plug.

    1. Remove the old packing (FIPG) material.

    2. Apply seal packing to the housing plug as shown in the illustration.

      Seal packing:
      Part No. 08826-00080 or equivalent



    A054980

  1. Install the camshaft housing plug to the cylinder head as shown in the illustration.

  1. Install the oil control valve filter to the cylinder head.

    NOTICE:
    Be careful of the installation direction.



    A054357E02

  1. Apply seal packing to the front bearing cap.

    1. Remove any old packing (FIPG) material.

    2. Apply seal packing to the bearing cap as shown in the illustration.

      Seal packing:
      Part No. 08826-00080 or equivalent

      Seal diameter:
      1.5 to 2.0 mm (0.059 to 0.079 in.)

      NOTICE:
      Do not apply seal packing to the front bearing cap grooves.



    A054981

  1. Install the front bearing cap.

    HINT:
    Installing the front bearing cap will determine the thrust portion of the camshaft.

  1. Install the other bearing caps in the sequence shown, with the arrow mark facing forward.



    A054040E01

  1. Push in the camshaft setting oil seal.



    A054154E03

  1. Install new seal washers to the bearing cap bolts A and B.

  1. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts D and E.

    NOTICE:
    Do not apply engine oil under the heads of the bearing cap bolts A, B and C.

    Bolt length:
    94 mm (3.70 in.) for A with seal washer
    72 mm (2.83 in.) for B with seal washer
    25 mm (0.98 in.) for C
    52 mm (2.05 in.) for D
    38 mm (1.50 in.) for E

  1. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.



    A054154E02

  1. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 ft.*lbf } for bolts 21 and 22

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf } for other bolts



    A054037E01

  1. Remove the service bolt.



27. INSTALL REAR TIMING BELT PLATE RH

  1. Install the timing belt plate with the bolt and stud bolt.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



28. INSTALL REAR NO. 2 TIMING BELT PLATE RH

  1. Install the timing belt plate with the 2 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



29. INSTALL REAR TIMING BELT PLATE LH

  1. Install the timing belt plate with the bolt.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



30. INSTALL REAR NO. 2 TIMING BELT PLATE LH

  1. Install the timing belt plate with the 2 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



31. INSTALL CAMSHAFT TIMING PULLEY


    A054475

  1. Align the knock pin of the camshaft timing tube with the knock pin groove of the timing pulley.

  1. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.

  1. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



32. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH


    A054477

  1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.

  1. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward.

  1. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



33. INSTALL CRANKSHAFT TIMING PULLEY


    A054473E01

  1. Align the timing pulley set key with the key groove of the pulley.

  1. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.

    SST
    09223-46011  



34. INSTALL NO. 2 TIMING BELT IDLER SUB-ASSEMBLY

  1. Install the idler with the bolt.

    Torque:
    34.5 N*m{ 351 kgf*cm , 25 ft.*lbf }

  1. Check that the idler moves smoothly.



35. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


    A054472E01

  1. Apply adhesive to 2 or 3 threads of the pivot bolt.

    Adhesive:
    Part No. 08833-00080, THREE BOND 1344, LOCATE 242 or equivalent

  1. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.

    Torque:
    34.5 N*m{ 351 kgf*cm , 25 ft.*lbf }

  1. Check that the idler bracket moves smoothly.



36. INSTALL TIMING BELT


A054008

NOTICE:
The engine should be cold.



  1. Set the No. 1 cylinder to TDC/compression.



      A054464E01

    1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.

      HINT:
      Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.
      Camshaft timing pulley of LH bank: 1/2 of a tooth
      Camshaft timing pulley of RH bank: 1 tooth



      2. A054465E01

    2. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.



    A054463

  1. Install the timing belt.

    1. Remove any oil or water on each pulley, and keep them clean.

      NOTICE:
      Only wipe the pulleys. Do not use cleaning agents on the pulleys.

    2. Face the front mark (arrow) on the belt forward.

    3. Connect the belt to the crankshaft timing pulley. Align the installation mark of the crankshaft timing pulley.

    4. Connect the belt to the No. 2 idler.

    5. Connect the timing belt to the camshaft timing pulley LH. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.

    6. Connect the timing belt to the water pump pulley.

    7. Connect the timing belt to the camshaft timing pulley RH. Align the installation mark on the belt with the timing mark of the camshaft timing pulley.

    8. Connect the timing belt to the No. 1 idler.



    A054983E01

  1. Set the belt tensioner.

    1. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.

    2. Align the holes of the push rod and housing. Pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    3. Release the press.

    4. Install the dust boot to the belt tensioner.



    A054462E01

  1. Install the belt tensioner.

    1. Temporarily install the belt tensioner with the 2 bolts.

    2. Alternately tighten the 2 bolts.

      Torque:
      26 N*m{ 265 kgf*cm , 19 ft.*lbf }

    3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.



    A054456E01

  1. Check the valve timing.

    1. Using the crankshaft damper bolt, slowly turn the crankshaft timing pulley 2 revolutions from TDC to TDC.

      NOTICE:
      Always turn the crankshaft pulley clockwise.



      2. A054458

    2. Check that each pulley aligns with the timing marks as shown in the illustration.
      If the timing marks do not align, remove the belt and reinstall it.



37. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE


    A053994E01

  1. Install the crankshaft position sensor plate as shown in the illustration.

    NOTICE:
    Be careful of the installation direction.



38. INSTALL TIMING GEAR COVER SPACER

  1. Install the gasket to the cover spacer.

  1. Install the cover spacer.



39. INSTALL NO. 1 TIMING BELT COVER

  1. Install the timing belt cover with the 4 bolts.

    Torque:
    7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



40. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY


    A054471E01

  1. Align the damper set key with the key groove of the crankshaft damper.

  1. Using SST and a hammer, tap in the crankshaft damper.

    SST
    09223-46011  



    A054469E01

  1. Using SST, install the damper bolt.

    SST
    09213-70011  
    09330-00021  

    Torque:
    245 N*m{ 2,498 kgf*cm , 181 ft.*lbf }



41. ADJUST VALVE CLEARANCE


    A033624E01

  1. Using a powerful magnet, remove the valve lifter and adjusting shim.

    NOTICE:
    1. Since shims might drop inside the cylinder head, the operation should be performed slowly.
    2. Shims should be classified by the installation.



    A091480

  1. Determine the replacement adjusting shim size according to these formulas and charts.

    1. Using a micrometer, measure the thickness of the removed shim.

    2. Calculate the thickness of a new shim so that a valve clearance is within the specified value.
      T = Thickness of removed shim
      A = Measured valve clearance

      Valve clearance:
      Valve
      		Standard Thickness
      Intake
      		T + (A 0.20 mm (0.008 in.))
      Exhaust
      		T + (A 0.30 mm (0.012 in.))

  1. Select a new shim with a thickness as close as possible to the calculated value.

    HINT:
    Shims are available in 41 increments of 0.020 mm (0.0008 in.), from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102).

  1. Install a new adjusting shim to the spring retainer.



  1. Install the valve lifter.


    A107620E01



    A107621E01

    Intake valve clearance (Cold):
    0.15 to 0.25 mm (0.006 to 0.010 in.)
    EXAMPLE:
    The 2.300 mm (0.0906 in.) shim is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 2.300 mm (0.0906 in.) shim with a No. 54 shim.


    New Shim Thickness:

    Shim No.
    		Thickness
    		Shim No.
    		Thickness
    		Shim No.
    		Thickness
    00
    		2.000 mm (0.0787 in.)
    		28
    		2.280 mm (0.0898 in.)
    		56
    		2.560 mm (0.1008 in.)
    02
    		2.020 mm (0.0795 in.)
    		30
    		2.300 mm (0.0906 in.)
    		58
    		2.580 mm (0.1016 in.)
    04
    		2.040 mm (0.0803 in.)
    		32
    		2.320 mm (0.0913 in.)
    		60
    		2.600 mm (0.1024 in.)
    06
    		2.060 mm (0.0811 in.)
    		34
    		2.340 mm (0.0921 in.)
    		62
    		2.620 mm (0.1031 in.)
    08
    		2.080 mm (0.0819 in.)
    		36
    		2.360 mm (0.0929 in.)
    		64
    		2.640 mm (0.1039 in.)
    10
    		2.100 mm (0.0827 in.)
    		38
    		2.380 mm (0.0937 in.)
    		66
    		2.660 mm (0.1047 in.)
    12
    		2.120 mm (0.0835 in.)
    		40
    		2.400 mm (0.0945 in.)
    		68
    		2.680 mm (0.1055 in.)
    14
    		2.140 mm (0.0843 in.)
    		42
    		2.420 mm (0.0953 in.)
    		70
    		2.700 mm (0.1063 in.)
    16
    		2.160 mm (0.0850 in.)
    		44
    		2.440 mm (0.0961 in.)
    		72
    		2.720 mm (0.1071 in.)
    18
    		2.180 mm (0.0858 in.)
    		46
    		2.460 mm (0.0969 in.)
    		74
    		2.740 mm (0.1079 in.)
    20
    		2.200 mm (0.0866 in.)
    		48
    		2.480 mm (0.0976 in.)
    		76
    		2.760 mm (0.1087 in.)
    22
    		2.220 mm (0.0874 in.)
    		50
    		2.500 mm (0.0984 in.)
    		78
    		2.780 mm (0.1094 in.)
    24
    		2.240 mm (0.0882 in.)
    		52
    		2.520 mm (0.0992 in.)
    		80
    		2.800 mm (0.1102 in.)
    26
    		2.260 mm (0.0890 in.)
    		54
    		2.540 mm (0.1000) in.



    A107622E01



    A107623E01

    Exhaust valve clearance (Cold):
    0.25 to 0.35 mm (0.010 to 0.014 in.)
    EXAMPLE:
    The 2.300 mm (0.0906 in.) shim is installed, and the measured clearance is 0.440 mm (0.0173 in.). Replace the 2.300 mm (0.0906 in.) shim with a No. 44 shim.


    New Shim Thickness:

    Shim No.
    		Thickness
    		Shim No.
    		Thickness
    		Shim No.
    		Thickness
    00
    		2.000 mm (0.0787 in.)
    		28
    		2.280 mm (0.0898 in.)
    		56
    		2.560 mm (0.1008 in.)
    02
    		2.020 mm (0.0795 in.)
    		30
    		2.300 mm (0.0906 in.)
    		58
    		2.580 mm (0.1016 in.)
    04
    		2.040 mm (0.0803 in.)
    		32
    		2.320 mm (0.0913 in.)
    		60
    		2.600 mm (0.1024 in.)
    06
    		2.060 mm (0.0811 in.)
    		34
    		2.340 mm (0.0921 in.)
    		62
    		2.620 mm (0.1031 in.)
    08
    		2.080 mm (0.0819 in.)
    		36
    		2.360 mm (0.0929 in.)
    		64
    		2.640 mm (0.1039 in.)
    10
    		2.100 mm (0.0827 in.)
    		38
    		2.380 mm (0.0937 in.)
    		66
    		2.660 mm (0.1047 in.)
    12
    		2.120 mm (0.0835 in.)
    		40
    		2.400 mm (0.0945 in.)
    		68
    		2.680 mm (0.1055 in.)
    14
    		2.140 mm (0.0843 in.)
    		42
    		2.420 mm (0.0953 in.)
    		70
    		2.700 mm (0.1063 in.)
    16
    		2.160 mm (0.0850 in.)
    		44
    		2.440 mm (0.0961 in.)
    		72
    		2.720 mm (0.1071 in.)
    18
    		2.180 mm (0.0858 in.)
    		46
    		2.460 mm (0.0969 in.)
    		74
    		2.740 mm (0.1079 in.)
    20
    		2.200 mm (0.0866 in.)
    		48
    		2.480 mm (0.0976 in.)
    		76
    		2.760 mm (0.1087 in.)
    22
    		2.220 mm (0.0874 in.)
    		50
    		2.500 mm (0.0984 in.)
    		78
    		2.780 mm (0.1094 in.)
    24
    		2.240 mm (0.0882 in.)
    		52
    		2.520 mm (0.0992 in.)
    		80
    		2.800 mm (0.1102 in.)
    26
    		2.260 mm (0.0890 in.)
    		54
    		2.540 mm (0.1000) in.



42. INSTALL IDLER PULLEY ASSEMBLY


    A054466E01

  1. Install the idler with the 2 bolts and 2 nuts.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf } for 12 mm head

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for 14 mm head

    Bolt length:
    106 mm (4.17 in.) for 12 mm head bolt A
    114 mm (4.49 in.) for 14 mm head bolt B



43. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    A110457

  1. Install the belt tensioner with the bolt and 2 nuts.

    Torque:
    15.5 N*m{ 158 kgf*cm , 11 ft.*lbf }

    HINT:
    Use a bolt that is 106 mm (4.17 in.) in length.



44. INSTALL NO. 2 TIMING BELT COVER SUB-ASSEMBLY


    A110458

  1. Set the No. 2 cover by matching the claws and pin with each part.

  1. Install the timing belt cover with the 2 bolts.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }

    HINT:
    Use bolts that are 106 mm (4.17 in.) in length.



45. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    A110456

  1. Install the idler pulley and cover plate with the bolt.

    Torque:
    39 N*m{ 398 kgf*cm , 29 in.*lbf }



46. INSTALL SEMICIRCULAR PLUG


    A054984E01

  1. Remove any old packing (FIPG) material.

  1. Apply seal packing to the semicircular plug grooves.

    Seal packing:
    Part No. 08826-00080 or equivalent



    A054985E01

  1. Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.



47. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    A054067E01

  1. Remove any old packing (FIPG) material.

  1. Apply seal packing to the cylinder heads as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

  1. Install the gasket to the cylinder head cover.

  1. Install the seal washer to the bolt.

  1. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }



48. INSTALL OIL FILLER CAP HOUSING

Torque:
7.5 N*m{ 76 kgf*cm , 66 in.*lbf }



49. INSTALL SPARK PLUG