REASSEMBLY

HINT:

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

Coat the piston pin with engine oil.

HINT:

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

Install the oil ring expander by hand.

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

HINT:

The compression ring No.2 is installed with code mark "2R" facing upward as shown in the illustration.

NOTICE:

Do not align the ring ends.

NOTICE:

Clean the backside of the bearing and the bearing surface of the connecting rod. The surface should be free of dust and oils.

HINT:

Main bearings come in widths of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No.1 and No.2 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.3 and No.4 positions.

NOTICE:

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

NOTICE:

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

HINT:

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

Apply engine oil to upper bearing and install the crankshaft on the cylinder block.

Apply a light coat of engine oil to the threads of the bearing cap bolts.

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

Apply a light coat of engine oil to the threads of the main bearing cap bolts.

Torque:

22 N*m{ 224 kgf*cm , 16 ft.*lbf }

Retighten the bearing cap bolts by 90° in the same sequence as step (h).

Check that the crankshaft turns smoothly.

Torque:

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

HINT:

Use the short bolt for the marked position (arrow).

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

NOTICE:

Match the numbered connecting rod cap with the connecting rod.

Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

Torque:

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

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

Torque:

50 N*m{ 510 kgf*cm , 37 ft.*lbf }

Torque:

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

Torque:

50 N*m{ 510 kgf*cm , 37 ft.*lbf }

Remove any old seal packing from the contact surface.

Seal packing:

Part No.08826-00100 or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the seal plate within 3 minutes after applying seal packing.
   
3. Do not expose the seal to engine oil within 2 hours after installing.
   

Install the seal plate with the 2 nuts.

Torque:

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

Apply adhesive to 2 or 3 threads of the drain cock end.

Adhesive:

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

Torque:

39 N*m{ 398 kgf*cm , 29 ft.*lbf }

NOTICE:

1. Install the drain cock within 3 minutes after applying adhesive.
   
2. Do not expose the seal to coolant within 1 hour after installing.
   
3. Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock to the specified torque.
   
4. Do not loosen the drain cock after setting it correctly.
   

Protrusion height:

3 mm (0.12 in.)

Protrusion height:

3 mm (0.12 in.)

Torque:

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

Install the stud bolts on the exhaust side.

Torque:

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

Install the valve spring seat.

NOTICE:

Pay much attention when assembling the oil seal for intake and exhaust. Assembling the wrong one may cause an improper installation.

HINT:

The intake valve oil seal is light brown and the exhaust valve oil seal is gray.

SST

09201-41020  

NOTICE:

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

NOTICE:

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

SST

09202-70020   (09202-00010)

NOTICE:

Do not damage the installed valve stem tip.

NOTICE:

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

SST

09202-70020   (09202-00010)

NOTICE:

Do not damage the installed valve stem tip.

Apply a light coat of engine oil to the valve lifter.

NOTICE:

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

Install the valve lifter.

Check that the valve lifter rotates smoothly by hand.

Remove any old seal packing (FIPG) material.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Install the plugs so that it is flush with the top of the cylinder head.
   
2. Install the semi-circular plugs within 3 minutes after applying seal packing.
   
3. Do not expose the seal to engine oil within 2 hours after installing.
   

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

Torque:

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

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

Torque:

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

SST

09950-60010   (09951-00430)
09950-70010   (09951-07100)

Return the ventilation plate tab to its original position.

Apply a light coat of MP grease to the gasket lip.

SST

09223-15030  
09950-70010   (09951-07100)

NOTICE:

1. Do not tap the oil seal at an angle.
   
2. Keep the lip free of foreign objects.
   

Apply MP grease to the oil seal lip.

Remove any old packing material from the contact surface.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the oil seal retainer within 3 minutes after applying seal packing.
   
3. Do not expose the seal to engine oil within 2 hours after installing.
   

Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.

Torque:

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

SST

09223-00010  

NOTICE:

1. Do not tap the oil seal at an angle.
   
2. Keep the lip free of foreign objects.
   

Apply MP grease to the oil seal lip.

Remove any old packing material from the contact surface.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Remove any oil from contact surface.
   
2. Apply seal packing to the inner side of the bolt holes.
   
3. Install the oil pump within 3 minutes after applying seal packing.
   
4. Do not expose the seal to engine oil within 2 hours after installing.
   

Torque:

Bolt A:

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

Bolt B:

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

Bolt C:

43 N*m{ 438 kgf*cm , 32 ft.*lbf }

Remove any old seal packing from the contact surface.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Apply seal packing to the outer side of the bolt holes in the region "X".
   
3. Apply seal packing to the inner side of the bolt holes in the region "Y".
   
4. Install the oil pan within 3 minutes after applying seal packing.
   
5. Do not expose the seal to engine oil within 2 hours after installing.
   

Torque:

10 mm Bolt A:

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

12 mm Bolt B:

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

Torque:

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

Remove any old seal packing from the contact surface.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Apply seal packing to the inner side of the bolt holes.
   
3. Install the oil pan within 3 minutes after applying seal packing.
   
4. Do not expose the seal to engine oil within 2 hours after installing.
   

Torque:

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

Install the drain plug with a new gasket.

Torque:

45 N*m{ 459 kgf*cm , 33 ft.*lbf }

Using a socket hexagon wrench 12 mm, install the oil filter union.

Torque:

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

Check and clean the oil filter installation surface.

Apply clean engine oil to the gasket of a new oil filter.

Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

SST

09228-07501  

Remove any old packing material from the contact surface.

Seal packing:

Part No.08826-00100 or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the water inlet housing within 3 minutes after applying seal packing.
   
3. Do not expose the seal to coolant within 2 hours after installing.
   

Torque:

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

NOTICE:

1. Remove any oil from the contact surface.
   
2. Be careful to install the gasket in the correct direction.
   
3. Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
   

Apply a light coat of engine oil to the threads of the cylinder head bolts.

Install the plate washers to the cylinder head bolts.

Torque:

54 N*m{ 550 kgf*cm , 40 ft.*lbf }

NOTICE:

The cylinder head bolts are tightened in 2 successive steps.

Retighten the cylinder head bolts by 90° in the same sequence as step (c).

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

Torque:

19 N*m{ 194 kgf*cm , 14 ft.*lbf }

NOTICE:

1. Remove any oil from the contact surface.
   
2. Be careful to install the gasket in the correct direction.
   
3. Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
   

Apply a light coat of engine oil to the threads of the cylinder head bolts.

Install the plate washers to the cylinder head bolts.

Torque:

54 N*m{ 551 kgf*cm , 40 ft.*lbf }

NOTICE:

The cylinder head bolts are tightened in 2 successive steps.

Retighten the cylinder head bolts by 90° in the same sequence as step (c).

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

Torque:

19 N*m{ 189 kgf*cm , 14 ft.*lbf }

Check that no foreign object is on the mesh part of the filter.

Assemble the valve filter and the plug.

Torque:

45 N*m{ 459 kgf*cm , 33 ft.*lbf }

Torque:

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

Install the 2 bolts and engine hanger No.2.

Torque:

20 N*m{ 214 kgf*cm , 15 ft.*lbf }

NOTICE:

Do not damage the camshaft.

HINT:

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

Install the wave washer.

SST

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

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

Torque:

5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

NOTICE:

Do not damage the camshaft journals.

HINT:

When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

NOTICE:

Install it with the lock-pin engaged and locked at the most retard angle position.

Apply engine oil to the nut, the mounting surface of VVT-i and the screw threads.

NOTICE:

1. Be sure to apply the oil, otherwise the specified torque cannot be obtained.
   
2. New nuts must be used when replacing the VVT-i unit.
   

Torque:

150 N*m{ 1,530 kgf*cm , 111 ft.*lbf }

NOTICE:

1. The lock nut has left-hand threads.
   
2. Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.
   

Apply new engine oil to the thrust portion and journal of the camshaft.

Apply MP grease to a new oil seal lip.

NOTICE:

1. Do not turn over the oil seal lip.
   
2. Insert the oil seal until it stops.
   

Remove any old packing material from the contact surface.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Install the No.1 bearing cap within 5 minutes after applying seal packing.
   
2. Do not expose the seal to engine oil within 2 hours after installing.
   

Apply a light coat of engine oil to the threads of the bearing cap bolts.

Torque:

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

Apply new engine oil to the thrust portion and journal of the camshaft.

Place the camshaft on the cylinder head.

Apply a light coat of engine oil to the threads of the bearing cap bolts.

Torque:

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

Remove the service bolt.

Apply new engine oil to the thrust portion and journal of the camshaft.

Apply MP grease to a new oil seal lip.

NOTICE:

1. Do not turn over the oil seal lip.
   
2. Insert the oil seal until it stops.
   

Remove any old packing material from the contact surface.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Install the No.1 bearing cap within 5 minutes after applying seal packing.
   
2. Do not expose the seal to engine oil within 2 hours after installing.
   

Apply a light coat of engine oil to the threads of the bearing cap bolts.

Torque:

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

Apply new engine oil to the thrust portion and journal of the camshaft.

Place the camshaft on the cylinder head.

Apply a light coat of engine oil to the threads of the bearing cap bolts.

Torque:

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

Remove the service bolt.

Torque:

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

NOTICE:

Do not scratch the sensor area of the crankshaft timing pulley.

Install the timing belt plate with the bolt.

Torque:

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

Apply a light coat of engine oil to a new O-ring and install it to the level gage guide.

Install the level gage guide.

Torque:

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

Install the oil level gage sub-assembly.

Visually check for cracks and breaks on the gasket of the timing belt cover.

HINT:

If a trace of water is found in the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 in.). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 in.) and more.

1. Repair the cracks and breaks by applying the seal packing to the damaged area.
   

   Seal packing:

   Part No.08826-00080 or equivalent
   

   NOTICE:

   When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.

If the timing belt cover gasket is needed to replace, follow the procedure below.

1. Using a screwdriver and gasket scraper, remove the remaining gasket.
   

   NOTICE:

   Do not damage the timing belt cover.

2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.
   

   NOTICE:

   1. Affix the gasket in the center of the groove.
      
   2. At the corners, try to keep the gasket thickness uniform.
      

   Gasket	D	E	F	G
   Length	335 mm (13.19 in.)	180 mm (7.09 in.)	133 mm (5.24 in.)	72 mm (2.83 in.)

3. If there is a gap on the joint of the gasket, apply seal packing to close the gap.
   

   Seal packing:

   Part No.08826-00080 or equivalent
   

   NOTICE:

   When applying the seal packing, apply it as wide and high as possible to fill the surface area of the gasket.

Torque:

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

HINT:

1. Face the belt guide of the RH timing pulley toward front of the engine.
   
2. Face the belt guide of the LH timing pulley toward rear of the engine.
   

SST

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

Torque:

125 N*m{ 1,275 kgf*cm , 92 ft.*lbf }

SST

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

Torque:

125 N*m{ 1,275 kgf*cm , 92 ft.*lbf }

Torque:

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

Using a socket hexagon wrench 10 mm, install the plate washer and timing belt idler No.1 with the pivot bolt.

Torque:

34 N*m{ 347 kgf*cm , 25 ft.*lbf }

Remove any oil or water on the pulleys, and keep them clean.

NOTICE:

1. If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
   
2. Wipe only the pulleys; do not use any cleaning agent.
   

Inspect the idler pulleys.

1. Check that the idler pulley turns smoothly.
   

2. Visually check the seal portion of the idler pulley for oil leakage.
   

Inspect the water pump.

1. Turn the pulley, and check that the water pump bearing moves smoothly and does not make any noise.
   

2. Visually check the drain hole for coolant leakage.
   

Temporarily install the crankshaft pulley bolt and washer to the crankshaft.

NOTICE:

To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.

SST

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

Face the front mark on the timing belt forward.

Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.

Set the timing belt tensioner upright on the press.

NOTICE:

Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbf) to the rod.

Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.

Release the press.

Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.

Torque:

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

NOTICE:

Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause improper operation.

Remove the 1.5 mm hexagon wrench from the tensioner.

NOTICE:

Always turn the crankshaft clockwise.

HINT:

If the marks do not align, remove the timing belt and reinstall it.

Remove the crankshaft pulley bolt.

Torque:

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

Visually check for cracks and breaks on the gasket of the timing belt cover.
If a trace of water is found in the visual check, replace the timing belt cover.

Torque:

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

Visually check for cracks and breaks on the gasket of the timing belt cover.
If a trace of water is found in the visual check, replace the timing belt cover.

Torque:

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

Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.

SST

09213-54015   (91651-60855)
09330-00021  

Torque:

220 N*m{ 2,243 kgf*cm , 162 ft.*lbf }

Install the engine oil level sensor and a new gasket with the 4 bolts.

Torque:

8.5 N*m{ 87 kgf*cm , 75 in.*lbf }

Torque:

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

Torque:

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

Check that the valve lifters on the No.1 cylinder (IN and EX) are both loose.
If not, turn the crankshaft 1 revolution (360°) and align the mark as above.

1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
   

   Valve clearance (Cold):

   Intake:

   0.15 to 0.25 mm (0.0059 to 0.0098 in.)
   

   Exhaust:

   0.25 to 0.35 mm (0.0098 to 0.0138 in.)
   

2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
   

1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
   

   Valve clearance (Cold):

   Intake:

   0.15 to 0.25 mm (0.0059 to 0.0098 in.)
   

   Exhaust:

   0.25 to 0.35 mm (0.0098 to 0.0138 in.)
   

2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
   

1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
   

   Valve clearance (Cold):

   Intake:

   0.15 to 0.25 mm (0.0059 to 0.0098 in.)
   

   Exhaust:

   0.25 to 0.35 mm (0.0098 to 0.0138 in.)
   

2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
   

Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.

SST

09248-55040   (09248-05410, 09248-05420)

HINT:

1. Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
   
2. When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side at a slight angle.
   

Calculate the thickness of a new shim so the valve clearance comes within the specified value.

Specified value (Cold):

Intake A = B + (C - 0.20 mm (0.0079 in.))

Exhaust A = B + (C - 0.30 mm (0.0118 in.))

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

HINT:

1. Shims are available in 17 sizes in increments of 0.05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.).
   
2. Refer to new shim thickness table below.
   

Intake valve clearance (Cold):

0.15 to 0.25 mm (0.0059 to 0.0098 in.)

HINT:

New shims have the thickness in millimeters imprinted on the face.

Exhaust valve clearance (Cold):

0.25 to 0.35 mm (0.0098 to 0.0138 in.)

HINT:

New shims have the thickness in millimeters imprinted on the face.

Press down the valve lifter with SST (A), and remove SST (B).

SST

09248-55040   (09248-05410, 09248-05420)

Recheck the valve clearance.

Install the cylinder head cover gasket No.2 to the cylinder head cover sub-assembly LH.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes after applying seal packing.
   
3. Do not start the engine within 2 hours after installing.
   

Torque:

12 N*m{ 122 kgf*cm , 9 ft.*lbf }

Install the cylinder head cover gasket to the cylinder head cover sub-assembly.

Seal packing:

Part No.08826-00080 or equivalent

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head cover within 3 minutes after applying seal packing.
   
3. Do not start the engine within 2 hours after installing.
   

Torque:

12 N*m{ 122 kgf*cm , 9 ft.*lbf }

Install the oil filler cap gasket to the oil filler cap sub-assembly.

Torque:

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

Install the spark plug.

Torque:

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