ENGINE UNIT > REASSEMBLY

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1. INSTALL TIGHT PLUG


A058129E01

NOTICE:
If water leaks from the tight plug or the plug corrodes, replace it.

  1. Apply adhesive around the tight plugs.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent.



  1. Using SST, tap in the tight plugs.

    SST
    09950-60010   (09951-00340)
    09950-70010   (09951-07100)


    A107559E02



2. INSTALL STRAIGHT PIN


  1. Using a plastic-faced hammer, tap in new straight pins to the cylinder block.
    Standard protrusion: 
    Pin A
    		23 mm (0.906 in.)
    Pin B
    		6 mm (0.236 in.)
    Pin C
    		11 mm (0.433 in.)
    Pin D
    		9 mm (0.354 in.)


    A106225E02



3. INSTALL STUD BOLT


  1. Using an E8 "torx" socket, install the stud bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



    A106226E03



4. INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY


A109730

  1. Using a 5 mm hexagon wrench and socket wrench, install the oil nozzles.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



5. INSTALL PISTON SUB-ASSEMBLY WITH PIN


A095548E01

  1. Using a screwdriver, install a new snap ring at one end of the piston pin hole.

    HINT:
    Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.



    P012417E04

  1. Gradually heat the piston to approximately 80 to 90°C (176 to 194°F).



    A106228E01

  1. Coat the piston pin with engine oil.

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

    HINT:
    The piston and pin are a matched set.



    A107551

  1. Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.



    A094947E01

  1. Using a screwdriver, install a new snap ring at the other end of the piston pin hole.

    HINT:
    Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.



6. INSTALL PISTON RING SET


A106229E01

  1. Install the oil ring expander by hand.

  1. Using a piston ring expander, install the oil ring rail.

  1. Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

    NOTICE:
    Do not align the ring ends.



    A106230E01

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

    NOTICE:
    Do not align the ring ends.



7. INSTALL CRANKSHAFT BEARING


A076063E03

NOTICE:
Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

  1. Clean the main journal and the both surfaces of the bearing.



    A094746E01

  1. Install the upper bearing.

    1. Install the upper bearing to the cylinder block as shown in the illustration.

      NOTICE:
      Do not apply engine oil to the bearing and its contact surface.



    A106222E01

  1. Install the lower bearing.

    1. Install the lower bearing to the bearing cap.

    2. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.

      Dimension (A - B):
      0.7 mm (0.0276 in.) or less.

      NOTICE:
      Do not apply engine oil to the bearing's contact area and backside.



8. INSTALL CRANKSHAFT


A106233E01

  1. Install the crankshaft thrust washer to the cylinder block.

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

  1. Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.



    A109789

  1. Confirm the front marks and numbers of the main bearing caps and install the bearing caps on the cylinder block.

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

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

  1. Temporarily install the 8 main bearing cap bolts to the inside positions.



    A095547E02

  1. Insert the main bearing cap with your hand until the clearance between the main bearing cap and the cylinder block is less than 6 mm (0.23 in.) by marking the 2 internal bearing cap bolts as a guide.

    Bolt length:
    98.50 to 100.50 mm (3.87 to 3.95 in.)



    A109696

  1. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

  1. Apply a light coat of engine oil on the threads and under the heads of the 8 main bearing cap bolts.



    A096431E01

  1. Install the 8 main bearing cap bolts to the outside positions.

    Bolt length:
    Item
    		Length
    Bolt A
    		98.50 to 100.50 mm (3.87 to 3.95 in.)
    Except bolt A
    		104.0 to 106.0 mm (4.09 to 4.17 in.)



    A094942E02

  1. Install the crankshaft bearing cap bolts.

    HINT:
    The main bearing cap bolts are tightened in 2 progressive steps.

  1. Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.

    Torque:
    61 N*m{ 622 kgf*cm , 45 ft.*lbf }

    If any of the main bearing cap bolts does not meet the torque specified, replace it.



    A094943E01

  1. Mark the front of the bearing cap bolts with paint.

  1. Retighten the bearing cap bolts by 90° in the order above.

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

  1. Check that the crankshaft turns smoothly.

  1. Check the crankshaft thrust clearance (see page).



    A096902E02

  1. Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.

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

    Bolt length:
    45 mm (1.77 in.)

  1. Check that the crankshaft turns smoothly.

  1. Check the crankshaft thrust clearance (see apge).



9. INSTALL CONNECTING ROD BEARING


A094752E01

  1. Install the connecting rod bearing to the connecting rod and bearing cap.

  1. Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edge and the connecting rod bearing's edge.

    Dimension (A - B):
    0.7 mm (0.0276 in.) or less

    NOTICE:
    Do not apply engine oil to the bearing's contact area and backside.



10. INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

  1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of the connecting rod bearings.



    A106230E01

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

    NOTICE:
    Do not align the ring ends.



    A094756E01

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

    NOTICE:
    Match the numbered connecting rod cap with the connecting rod.



    A094938E01

  1. Check that the front mark of the connecting rod cap is facing forward.

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

  1. Install the connecting cap bolts.

    HINT:
    The connecting cap bolts are tightened in 2 progressive steps.



    A107552

  1. Install and alternately tighten the bolts of the connecting rod cap in several steps.

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }



    A094943E01

  1. Mark the front side of each connecting cap bolt with paint.

  1. Retighten the cap bolts by 90° as shown in the illustration.

  1. Check 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.



11. INSTALL RING PIN


A094733E01

  1. Using a plastic hammer, tap in new ring pins to the specified protrusion height.

    Specified protrusion height:
    2.5 to 3.8 mm (0.098 to 0.150 in.)



12. INSTALL NO. 1 STRAIGHT SCREW PLUG


A094723E01

  1. Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.

    Torque:
    44 N*m{ 449 kgf*cm , 32 ft.*lbf }



13. INSTALL NO.2 STRAIGHT SCREW PLUG


A094724E01

  1. Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.

    Torque:
    80 N*m{ 816 kgf*cm , 59 ft.*lbf }



14. INSTALL UNION


A075631E01

  1. Apply adhesive to the union of the cylinder head.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent.



  1. Install the union to the cylinder head as shown in the illustration.

    Torque:
    15 N*m{ 153 kgf*cm , 11 ft.*lbf }



    A094738E01



15. INSTALL STUD BOLT



A094737E01

NOTICE:
If the stud bolt is deformed or the threads are damaged, replace it.

  1. Using E6 and E8 "torx" sockets, install the stud bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf } for bolts A, B and D
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf } for bolt C



16. INSTALL STRAIGHT PIN



A094739E01

  1. Using a plastic-faced hammer, tap in a new straight pin as shown in the illustration.

    Protrusion height:
    17.5 to 19.5 mm (0.689 to 0.768 in.)



17. INSTALL VALVE SPRING SEAT

  1. Install the valve spring seats to the cylinder head.



18. INSTALL VALVE STEM OIL SEAL


A094934E02

  1. Apply a light coat of engine oil to new oil seals.

    NOTICE:
    Pay attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust side or installing the exhaust oil seal to the intake side can cause installation problems later.

    HINT:
    The intake valve oil seals are white and the exhaust valve oil seals are black.



    A094740E01

  1. Using SST, push in the oil seals.

    SST
    09201-41020  

    NOTICE:
    Failure to use SST will cause the seal to be damaged or improperly seated.



19. INSTALL INTAKE VALVE


A094935E01

  1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

  1. Install the valve, compression spring and spring retainer to the cylinder head.

    NOTICE:
    Install the same parts in the same combination to the original locations.



    A094721E01

  1. Using SST, compress the spring and install the 2 retainer locks.

    SST
    09202-70020   (09202-00010)



    A109790

  1. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

    NOTICE:
    Be careful not to damage the retainer.



20. INSTALL EXHAUST VALVE


A094936E01

  1. Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

  1. Install the valve, compression spring and spring retainer to the cylinder head.

    NOTICE:
    Install the same parts in the same combination to the original locations.



    A094722E01

  1. Using SST, compress the spring and install the 2 retainer locks.

    SST
    09202-70020   (09202-00010)



    A109791

  1. Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

    NOTICE:
    Be careful not to damage the retainer.



21. INSTALL VALVE STEM CAP

  1. Apply a light coat of engine oil to the valve stem caps.

  1. Install the valve stem caps to the cylinder head.



22. INSTALL REAR ENGINE OIL SEAL RETAINER


A095164E02

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2.0 to 3.0 mm (0.079 to 0.118 in.)

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



    A109718

  1. Install the oil seal retainer with the 6 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

    NOTICE:
    Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent



23. INSTALL WATER OUTLET PIPE SUB-ASSEMBLY


A109723

  1. Install the water outlet pipe with the 2 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



24. INSTALL CYLINDER BLOCK WATER JACKET SPACER LH


A096388E02

  1. Install the water jacket spacer as shown in the illustration.

    HINT:
    Be sure to face the slope to front of the engine.



25. INSTALL CYLINDER BLOCK WATER JACKET SPACER RH

  1. Install the water jacket spacer as shown in the illustration.

    HINT:
    Be sure to face the slope to front of the engine.



26. INSTALL CYLINDER HEAD SUB-ASSEMBLY RH


A096908E02

  1. Apply a continuous line of seal packing to a new cylinder head gasket as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2.5 to 3.0 mm (0.098 to 0.118 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head gasket within 3 minutes after applying the seal packing.
    3. Install the cylinder head bolt within 15 minutes after applying the seal packing.
    4. Do not apply engine oil within 2 hours of installation.



    A094683E01

  1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

    NOTICE:
    1. Be careful of the installation direction.
    2. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

  1. Place the cylinder head on the cylinder block.

    NOTICE:
    Be careful not to allow oil to adhere to the bottom part of the cylinder head.

    HINT:
    The cylinder head bolts are tightened in 3 progressive steps.

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



    A095241E01

  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.

    Torque:
    36 N*m{ 367 kgf*cm , 27 ft.*lbf }



    A035289E01

  1. Mark the cylinder head bolt head with paint as shown in the illustration.

  1. Tighten the cylinder head bolts another 90°.

  1. Tighten the cylinder head bolts by an additional 90°.

  1. Check that the painted mark is now facing rearward.



    A090989E01

  1. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.



27. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH


A096909E02

  1. Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2.5 to 3.0 mm (0.098 to 0.118 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the cylinder head gasket within 3 minutes after applying the seal packing.
    3. Install the cylinder head bolt within 15 minutes after applying the seal packing.
    4. Do not apply engine oil within 2 hours of installation.



    A094684E01

  1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

    NOTICE:
    1. Be careful of the installation direction.
    2. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

  1. Place the cylinder head on the cylinder block.

    NOTICE:
    Be careful not to allow oil to adhere to the bottom part of the cylinder head.

    HINT:
    The cylinder head bolts are tightened in 3 progressive steps.

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



    A096389E01

  1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

    Torque:
    36 N*m{ 367 kgf*cm , 27 ft.*lbf }



    A035289E01

  1. Mark the cylinder head bolt head with paint as shown in the illustration.

  1. Tighten the cylinder head bolts by 90°.

  1. Tighten the cylinder head bolts by an additional 90°.

  1. Check that the painted mark is now facing rearward.



    A096390E01

  1. Tighten the 2 bolts in the order shown in the illustration.

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }



    A090989E01

  1. Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.



28. INSTALL VALVE LASH ADJUSTER ASSEMBLY


A109630E01

NOTICE:
  1. Keep the lash adjuster free from dirt and foreign objects.
  2. Only use clean engine oil.

  1. Place the lash adjuster into a container full of engine oil.

  1. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

    SST
    09276-75010  

  1. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.

  1. Check the movement of the plunger and bleed the air.

    OK:
    Plunger moves up and down.

    NOTICE:
    When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

  1. After bleeding the air, remove SST. Then, try to quickly and firmly press the plunger with a finger.

    OK:
    Plunger is very difficult to move.

    If the result is not as specified, replace the lash adjuster.

  1. Install the lash adjusters.

    NOTICE:
    Install the lash adjuster to the same place it was removed from.



29. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


A096392E01

  1. Apply engine oil to the lash adjuster tip and valve stem cap end.

  1. Make sure that the valve rocker arm is installed as shown in the illustration.



30. INSTALL CAMSHAFT BEARING CAP RH


A094680E01

  1. Apply engine oil to the camshaft journal, camshaft housing and bearing cap.

  1. Install the camshaft and camshaft No. 2 to the camshaft housing RH.

  1. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.



    A094645E01

  1. Temporarily tighten the 9 bolts in the order shown in the illustration.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH


A095049E04

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3.5 to 4.0 mm (0.138 to 0.158 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.



    A095051E01

  1. Tighten the 14 bolts in the order shown in the illustration.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

    NOTICE:
    Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing RH.



    A095686E01

  1. Tighten the 9 bolts in the order shown in the illustration.

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

    NOTICE:
    Thoroughly wipe clean any seal packing.

  1. Install 3 new gaskets.



32. INSTALL CAMSHAFT BEARING CAP LH


A094679E01

  1. Apply engine oil to the camshaft journal, camshaft housing and bearing cap.

  1. Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.

  1. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.



    A094665E01

  1. Temporarily tighten the 8 bolts in the order shown in the illustration.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH


A095048E04

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3.5 to 4.0 mm (0.138 to 0.158 in.)

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.



    A095050E01

  1. Tighten the 12 bolts in the order shown in the illustration.

    Torque:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }

    NOTICE:
    Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing LH.



    A095687E01

  1. Tighten the 8 bolts in the order shown in the illustration.

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

    NOTICE:
    Thoroughly wipe clean any seal packing.

  1. Install 3 new gaskets.



34. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY


A109792

  1. Install the chain tensioner with the bolt.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to fix it.



35. INSTALL NO. 2 CAMSHAFT TIMING GEARS AND CHAIN (for Bank 1)


A094669E02

  1. Align the mark plate (yellow) with the timing marks (1 dot mark) of the camshaft timing gears as shown in the illustration.

  1. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

  1. 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 No. 2 chain installed.



    A094473E01

  1. 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 }

  1. Remove the pin from the chain tensioner.



36. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY


A109793

  1. Install the chain tensioner with the bolt.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. While pushing in the tensioner, insert a pin of φ 1.0 mm (0.039 in.) into the hole to hold it.



37. INSTALL NO. 2 CAMSHAFT TIMING GEARS AND CHAIN (for Bank 2)


A095603E03

  1. Align the mark plate (yellow) with the timing marks (2 dot mark) of the camshaft timing gears as shown in the illustration.

  1. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

  1. 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 No. 2 chain installed.



    A094663E01

  1. 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 }

  1. Remove the pin from the chain tensioner.



38. INSTALL NO. 1 CHAIN VIBRATION DAMPER


A109719

  1. Install the chain vibration damper with the 2 bolts.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }



39. INSTALL NO. 2 CHAIN VIBRATION DAMPER

  1. Install the 2 chain vibration dampers.



40. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET


A109720

  1. Install the timing gear set keys and timing gear as shown in the illustration.



41. INSTALL IDLE SPROCKET ASSEMBLY


A095557E01

  1. Apply a light coat of engine oil to rotating surface of the No.1 idle gear shaft.

  1. Temporarily install the No. 1 idle gear shaft and No. 1 idle sprocket with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear with the knock pin groove of the cylinder block.

    NOTICE:
    Be careful of the idle gear direction.

  1. Using a 10 mm hexagon wrench, tighten the No. 1 idle gear shaft.

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }



42. INSTALL CHAIN SUB-ASSEMBLY


A095061E02

  1. Align the mark plate and timing mark as shown in the illustration and install the chain.

    NOTICE:
    Do not pass the chain over the crankshaft, just put it on it.

    HINT:
    The camshaft mark plate is orange.

  1. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between the center banks.



    A094661E02

  1. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing gear.

    HINT:
    The crankshaft mark plate is yellow.

  1. Temporarily tighten the pulley set bolt.



    A096635E01

  1. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC / compression).



43. INSTALL CHAIN TENSIONER SLIPPER

  1. Install the chain tensioner slipper.



44. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


A096895E01

  1. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

  1. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

  1. Install the chain tensioner with the 2 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



    A096455E02

  1. Remove the lock pin of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression.

  1. Remove the pulley set bolt.



45. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

  1. Install a new gasket and the chain cover plate with the 4 bolts.

    Torque:
    9.1 N*m{ 93 kgf*cm , 81 in.*lbf }



  1. Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    5.0 to 5.5 mm (0.197 to 0.217 in.)


    NOTICE:
    1. Be sure to clean and degrease the contact surfaces, especially 7 areas indicated by C in the illustration.
    2. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
    3. Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    4. Do not start the engine for at least 2 hours after installing.

    A106259E03



  1. Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

    Seal packing:
    08826-00080 or equivalent
    08826-00100 or equivalent

    NOTICE:
    1. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
    2. Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing.


    Apply seal packing as follows:

    Area
    		Seal Packing Diameter
    		Application Position from Inside Seal Line
    Continuous Line Area
    		3.5 to 4.0 mm (0.138 to 0.158 in.)
    		3.0 to 4.0 mm (0.118 to 0.158 in.)
    Alternate Long and Dashed Line Area
    		3.5 to 4.0 mm (0.138 to 0.158 in.)
    		2.0 to 3.0 mm (0.079 to 0.118 in.)
    Dashed Line Area
    		4.0 to 5.0 mm (0.158 to 0.197 in.)
    		1.0 to 2.0 mm (0.039 to 0.079 in.)



    A106260E02



    A094903E02

  1. Install a new O-ring.



    A094904E01

  1. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.



    A106153E02

  1. Install the timing chain cover with the 16 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf } for bolt A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for except bolt A
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for nut

    Bolt length:
    Item
    		Length
    Bolt A
    		50 mm (1.97 in.)
    Bolt B
    		25 mm (0.98 in.)
    Bolt C
    		55 mm (2.17 in.)

    NOTICE:
    Make sure that there is no oil on the bolt threads.

  1. Install a new gasket.

  1. Install the timing chain cover plate to the timing chain cover with the 4 bolts.

    Torque:
    9.1 N*m{ 93 kgf*cm , 81 in.*lbf }



46. INSTALL WATER PUMP ASSEMBLY


A106154E03

  1. Install a new gasket and the water pump with the 16 bolts.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolt A
    9.1 N*m{ 93 kgf*cm , 81 in.*lbf } for except bolt A

    NOTICE:
    1. Be sure to replace the bolts indicated by B with new ones or reuse them after applying adhesive 1344.
    2. Make sure that there is no oil on the bolt A threads.



47. INSTALL OIL PAN BAFFLE PLATE


A109717

  1. Install the baffle plate with the 8 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



48. INSTALL OIL STRAINER SUB-ASSEMBLY


  1. Using an E6 "torx" socket, install the stud bolts as shown in the illustration.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }



    A095995E03



    A094463E02

  1. Install a new gasket and the oil strainer with the 3 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. Install 2 new O-rings.



49. INSTALL OIL PAN SUB-ASSEMBLY


A109786E02

  1. When replacing a stud bolt, install it by using an E6 "torx" socket wrench.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }



    A109751E04

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3.0 to 4.0 mm (0.118 to 0.156 in.)

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



    A109706E03

  1. 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
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for nut



50. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


A109753E04

  1. Apply seal packing in a continuous line as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3.0 to 4.0 mm (0.118 to 0.156 in.)

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



    A095044E03

  1. Install the oil pan with the 15 bolts and 2 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. Install a new gasket and the drain plug.

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }



51. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH


A094646E02

  1. Apply seal packing as shown in the illustration.

    Seal packing:
    08826-00080 or equivalent

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

  1. Install the gasket to the head cover.



    A095596E02

  1. Install the head cover with the 14 bolts.

    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



52. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH


A094647E02

  1. Apply seal packing as shown in the illustration.

    Seal packing:
    08826-00080 or equivalent

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

  1. Install the gasket to the head cover.



    A094649E02

  1. Install the head cover with the 14 bolts.

    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



53. INSTALL WATER BY-PASS JOINT RR


A109713

  1. Install 2 new gaskets and a new O-ring.

  1. Apply soapy water to the O-ring.

  1. Install the water by-pass joint RR with the 2 bolts and 4 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



54. INSTALL WATER INLET WITH THERMOSTAT


A109712

  1. Install a new gasket and water inlet with thermostat with the 3 nuts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



55. INSTALL WATER INLET SUB-ASSEMBLY


A109711

  1. Install 2 new O-rings.

  1. Apply soapy water to the O-ring.

  1. Install the water inlet with the 4 bolts and nut.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }

  1. Install the 3 water by-pass hose.



56. INSTALL CRANKSHAFT PULLEY


A094448E01

  1. Align the pulley set key with the key groove of the pulley, and slide on the pulley.

  1. Using SST, install the pulley bolt.

    SST
    09213-70011   (09213-70020)
    09330-00021  

    Torque:
    250 N*m{ 2,550 kgf*cm , 184 ft.*lbf }



57. INSTALL OIL FILTER ELEMENT


A106167E01

  1. Clean the inside of the oil filter cap, the threads and O-ring groove.

  1. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

  1. Set a new oil filter element to the oil filter cap.

  1. Remove dirt or foreign matter from the installation surface and inside of the engine.

  1. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.

    NOTICE:
    Be careful that the O-ring does not get caught between the parts.



    A106166E01

  1. Using SST, tighten the oil filter cap.

    SST
    09228-06501  

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }

    NOTICE:
    Make sure that the oil filter is installed securely as shown in the illustration.



58. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY


A076531E01

  1. Apply adhesive around the drain cock.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent



    A095990E01

  1. Install the water drain cock as shown in the illustration.

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }

    NOTICE:
    1. Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
    2. Do not loosen the drain cock plug of the water drain cock.

  1. Install the water drain cock plug to the water drain cock.

    Torque:
    13 N*m{ 130 kgf*cm , ft.*lbf }



59. INSTALL NO. 1 OIL PIPE


A109708

  1. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

  1. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install oil pipe (on the head cover side).

  1. Install a new gasket and temporarily install oil pipe (on the cylinder head side) with the oil check valve bolt.

  1. Tighten the oil pipe union (on the head cover side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }

  1. Tighten the oil check valve bolt (on the cylinder head side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }



60. INSTALL NO. 2 OIL PIPE


A109709

  1. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

  1. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install oil pipe (on the head cover side).

  1. Install a new gasket and temporarily install oil pipe (on the cylinder head side) with the oil check valve bolt.

  1. Tighten the oil pipe union (on the head cover side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }

  1. Tighten the oil check valve bolt (on the cylinder head side).

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }



61. INSTALL CRANKSHAFT POSITION SENSOR


A106266

  1. Install the sensor with the bolt.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



62. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY LH


A106267

  1. Install the 4 oil control valves with the 4 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



63. INSTALL CAMSHAFT POSITION SENSOR


A106268

  1. Install the 4 sensors with the 4 bolts.

    Torque:
    10 N*m{ 102 kgf*cm , 7 ft.*lbf }



64. INSTALL VENTILATION VALVE SUB-ASSEMBLY

  1. Apply adhesive around the ventilation valve.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent

  1. Install the ventilation valve.

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



65. INSTALL SPARK PLUG

  1. Install the spark plugs.

    Torque:
    18 N*m{ 184 kgf*cm , 13 ft.*lbf }



66. INSTALL NO. 2 ENGINE HANGER

  1. Install the engine hanger with the 2 bolts.

    Torque:
    33 N*m{ 337 kgf*cm , 24 ft.*lbf }



67. INSTALL NO. 1 ENGINE HANGER

  1. Install the engine hanger with the 2 bolts.

    Torque:
    33 N*m{ 337 kgf*cm , 24 ft.*lbf }



68. INSTALL RADIATOR CAP SUB-ASSEMBLY


69. INSTALL OIL FILLER CAP SUB-ASSEMBLY