Part 3

RH Bank:

LH Bank:

PARTIAL ENGINE ASSY
OVERHAUL
70. INSTALL CYLINDER HEAD GASKET NO.2

a) Place a new cylinder head gasket on the cylinder block with the L mark as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Make sure the cylinder head gasket is facing in the correct direction.

71. INSTALL CYLINDER HEAD LH

NOTICE:
^ To prevent damage to the block, place the the gasket carefully.
^ The cylinder head bolts are tightened in 2 successive steps.

a) Apply a light coat of engine oil on the threads of the cylinder head bolts.
b) Install the plate washers to the cylinder head bolts.
c) Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e) Retighten the cylinder head bolts by 90° in the same sequence as step
f) Check that each painted mark is now at a 90° angle to the front.

g) Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
72. INSTALL OIL CONTROL VALVE FILTER

a) Check that no foreign matter is on the mesh part of the filter.
b) Assemble the valve filter and the plug.
c) Install a new gasket and the plug.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
73. INSTALL CYLINDER HEAD COVER REAR
a) Install a new gasket and the rear cover with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
74. INSTALL CAMSHAFT SUB GEAR

a) Clamp the camshaft's hexagonal lobe in a vise

NOTICE: Be careful not to damage the camshaft.

b) Install the camshaft gear bolt washer and the camshaft sub gear.

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

c) Install the wave washer.

d) Using snap ring pliers, install the snap ring.

e) Using SST, align the holes of the camshaft main gear and sub gear by turning the camshaft sub gear counterclockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
f) Align the gear teeth of the main gear and sub gear, and tighten the service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: Be careful not to damage the camshaft journals.

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

75. INSTALL CAMSHAFT TIMING GEAR ASSY

a) Align the pin with the pin groove and install the VVT-i on the camshaft.

NOTICE: Install the VVT-i with the lock-pin engaged and locked at the extreme retarded angle position.

b) Apply engine oil on a new nut, the mounting surface of the VVT-i and the screw threads.

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

c) Using a 46 mm socket wrench, install and tighten an oily lock nut by turning it counterclockwise.
Torque: 150 Nm (1,530 kgf-cm, 111 ft. lbs.)

NOTICE:
^ The lock nut has LH threads.
^ Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.

76. INSTALL NO.2 CAMSHAFT

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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out.

a) Apply new engine oil to the thrust portion and journal of the camshaft.
b) Place the No. 2 camshaft at a 90° angle of the timing mark (2 dot marks) on the cylinder head.
c) Apply MP grease to a new oil seal lip.

d) Install the oil seal to the camshaft.

NOTICE:
^ Make sure the oil seal is installed facing the correct direction, as shown in the illustration.
^ Insert the oil seal until it cannot be pushed any further.

e) Remove any old packing material from the contact surface.

f) Apply seal packing to the No. 1 bearing cap as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Install the No. 1 bearing cap within 5 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

g) Install the 5 bearing caps in their proper locations.
h) Apply a light coat of engine oil on the threads of the bearing cap bolts.

i) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
77. INSTALL CAMSHAFT

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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out.

a) Apply new engine oil to the thrust portion and journal of the camshaft.
b) Align the camshaft drive and driven gear's timing marks (2 dot marks each).
c) Place the camshaft on the cylinder head.

d) Install the 5 bearing caps in their proper locations.
e) Apply a light coat of engine oil on the threads of the bearing cap bolts.

f) Uniformly tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g) Remove the service bolt.
78. INSTALL NO.4 CAMSHAFT SUB-ASSY

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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out.

a) Apply new engine oil to the thrust portion and journal of the camshaft.
b) Place the No. 4 camshaft at a 90° angle of the timing mark (1 dot mark) on the cylinder head.
c) Apply MP grease to a new oil seal lip.

e) Remove any old packing material from the contact surface.
f) Apply seal packing to the No. 1 bearing cap as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Install the No. 1 bearing cap within 5 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

g) Install the 5 bearing caps in their proper locations.
h) Apply a light coat of engine oil on the threads of the bearing cap bolts.

i) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
79. INSTALL NO.3 CAMSHAFT SUB-ASSY

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, damage to the cylinder head or to the camshaft may result. To avoid this, the following steps must be carried out.

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

b) Align the camshaft drive and driven gear's timing marks (1 dot mark each).
c) Place the camshaft on the cylinder head.

d) Install the 5 bearing caps in their proper locations.
e) Apply a light coat of engine oil on the threads of the bearing cap bolts.

f) Uniformly tighten the 10 bearing cap bolts in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g) Remove the service bolt.
80. INSTALL CRANKSHAFT TIMING PULLEY

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

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

b) Install the timing belt plate with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
81. INSTALL WATER PUMP ASSY

a) Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
82. INSTALL OIL LEVEL GAGE GUIDE
a) Apply a light coat of engine oil to a new O-ring and install it to the level gage guide.
b) Install the level gage guide.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
83. INSTALL OIL FILTER SUB-ASSY
a) Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
b) Check and clean the oil filter installation surface.
c) Apply clean engine oil to the gasket of a new oil filter.
d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.

e) Using SST, tighten it an additional 3/4 turn.
SST 09228-07501
84. INSTALL TIMING BELT IDLER BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
85. INSTALL TIMING BELT NO.3 COVER
a) Visually check for cracks and breaks on the gasket of the timing belt cover.

HINT: If water is entering through cracks or breaks in the gasket, repair according to these guidelines: 1) if the crack length is within 2 to 3 cm (0.79 to 1.18 inch), repair with seal packing; or 2) if the crack length is over 3 cm (1.18 inch). replace the casket.

b) If the timing belt cover gasket needs to be repaired, follow the procedure.
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 the gasket.

c) If the timing belt cover gasket needs to be replaced, follow the procedure.
1) Using a screwdriver and gasket scraper, remove the remaining gasket.

NOTICE: Be careful not to 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:
^ Affix the gasket in the center of the groove.
^ At the corners, try to keep the gasket thickness uniform.

Length

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 the gasket.

d) Install the timing belt cover with the 6 bolts.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)
86. INSTALL CAMSHAFT TIMING PULLEY

a) Install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporarily.

HINT:
^ Face the belt guide of the RH timing pulley towards the front of the engine.
^ Face the belt guide of the LH timing pulley towards the rear of the engine.

b) Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)

c) Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)
87. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
88. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
a) Using a 10 mm socket hexagon wrench, install the plate washer and timing belt idler No. 1 with the pivot bolt.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
89. INSTALL TIMING BELT
a) Remove any oil or water on the pulleys and keep them clean.

NOTICE:
^ If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
^ Only wipe the pulleys. Do not use cleaning agents on the pulleys.

b) Inspect the idler pulleys.
1) Check that the idler pulley turns smoothly.
2) Visually check the sealed portion of the idler pulley for oil leakage.
c) Inspect the water pump.
1) Turn the pulley, and check that the water pump bearing moves smoothly without any noise.
2) Visually check the drain hole for coolant leakage.
d) Temporarily install the crankshaft pulley bolt and washer to the crankshaft.

e) Turn the crankshaft counterclockwise by approximately 60°.

NOTICE: To prevent the piston head and the valve head from colliding, set the crankshaft pulley at approximately 60° BTDC/compression position.

f) Using SST, turn the crankshaft pulley, and align the timing marks of the timing pulleys with the No. 3 timing belt cover.
SST 09960-10010 (09962-01000, 09963-01000)

g) Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.

h) Face the front mark on the timing belt forward.
i) Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
j) Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.

k) Install the timing in this order.
90. INSTALL TIMING BELT TENSIONER ASSY
a) Set the timing belt tensioner uprightly on the press.

b) Slowly press in the push rod.

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

c) 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.
d) Release the press.
e) Temporarily install the tensioner with the 2 bolts.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)

NOTICE: Install the tensioner's bolts uniformly and evenly. Installing the tensioner at an angle may cause it to malfunction. Remove the 1.5 mm hexagon wrench from the tensioner.

g) Turn the crankshaft 2 revolutions slowly, and align the timing mark of the crankshaft timing pulley with the oil pump body.

NOTICE: Always turn the crankshaft clockwise.

h) Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
i) Remove the crankshaft pulley bolt.
91. INSTALL TIMING BELT GUIDE NO.2

a) Install the timing belt guide, facing the cup side toward the engine front.
92. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
93. INSTALL TIMING BELT NO.2 COVER
a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace that water is entering at the visual check, replace the timing belt cover.
b) Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
94. INSTALL TIMING BELT NO.1 COVER
a) Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace that water is entering at the visual check, replace the timing belt cover.
b) Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
95. INSTALL CRANKSHAFT PULLEY

a) Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
b) Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 Nm (2,250 kgf-cm, 162 ft. lbs.)
96. INSTALL VVT SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
97. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
98. INSTALL ENGINE HANGER NO.2
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
99. INSPECT VALVE CLEARANCE
100. INSTALL CYLINDER HEAD COVER SUB-ASSY

a) Install the gasket to the cylinder head cover.
b) Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

c) Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
102. INSTALL VENTILATION VALVE SUB-ASSY
a) Apply adhesive to 2 or 3 threads.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b) Install the ventilation valve.
Torque: 19 Nm (193 kgf-cm, 14 ft. lbs.)
103. INSTALL OIL FILLER CAP GASKET
104. INSTALL OIL FILLER CAP SUB-ASSY
105. INSTALL SPARK PLUG
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)