Part 4
OVERHAUL (CONTINUED)67. INSTALL REAR TIMING BELT PLATE LH NO. 2
a. Install the rear timing belt plate with the 2 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
68. INSTALL CRANKSHAFT TIMING PULLEY
a. Fit the timing pulley set key to the key groove of the pulley.
b. Using SST and a hammer, tap in the timing pulley with the flange side facing inward.
SST 09223-46011
69. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
a. Install the idler with the bolt.
Torque: 35 Nm (352 kgf-cm, 25 ft. lbs.)
b. Check that the idler moves smoothly.
70. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1
a. Apply adhesive to 2 or 3 threads of the pivot bolt.
Adhesive:
Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.
Torque: 35 Nm (352 kgf-cm, 25 ft. lbs.)
c. Check that the idler bracket moves smoothly.
71. INSTALL CAMSHAFT TIMING PULLEYS
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's R and L marks forward.
c. Hold the hexagonal portion of the camshaft.
d. Using a 5 mm hexagon wrench, install the 8 bolts.
Torque: 8.1 Nm (83 kgf-cm, 72 inch lbs.)
72. INSTALL TIMING BELT
NOTICE: The engine should be cold.
a. Set the No. 1 cylinder to TDC/compression.
1 Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.
HINT: By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy:
1/2 teeth turn for the left bank camshaft timing pulley
1 tooth turn for the right bank camshaft timing pulley
2 Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
b. Install the timing belt.
1 Remove any oil or water on each pulley. Keep them clean after removal.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
2 Face the front mark (arrow) on the timing belt forward.
3 Connect the timing belt to the crankshaft timing pulley.
^ Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
4 Connect the timing belt to the idler No.2.
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 bank).
^ Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
8 Connect the timing belt to the idler No.(1)
c. 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 lbs.) 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.
d. Install the belt tensioner.
1 Temporarily install the belt tensioner with the 2 bolts.
2 Alternately tighten the 2 bolts.
Torque: 26 Nm (270 kgf-cm, 19 ft. lbs.)
3 Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.
e. Check the valve timing.
1 Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.
NOTICE: Always turn the crankshaft pulley clockwise.
2 Check that each pulley aligns with the timing marks as shown in the illustration. If the timing marks are not aligned, remove the timing belt and reinstall it.
73. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the sensor plate as shown in the illustration.
NOTICE: Take care not to install it in a wrong direction.
74. INSTALL TIMING GEAR COVER SPACER
a. Install the gasket to the cover spacer.
b. Install the cover spacer.
75. INSTALL TIMING BELT NO.1 COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
76. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
a. Align the pulley set key with the key groove of the crankshaft damper.
b. Using SST and a hammer, tap in the crankshaft damper.
SST 09223-46011
c. Using SST, install the damper bolt.
SST 09213-70011 (90105-08076), 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)
77. INSPECT VALVE CLEARANCE
78. ADJUST VALVE CLEARANCE
79. INSTALL FAN BRACKET SUB-ASSEMBLY
a. Install the idler pulley with the 2 bolts and 2 nuts.
Torque:
16 Nm (160 kgf-cm, 12 ft. lbs.) for 12 mm head
32 Nm (326 kgf-cm, 24 ft. lbs.) for 14 mm head
HINT: Each bolt length is as follows:
106 mm (4.17 inch) for 12 mm head (A)
114 mm (4.49 inch) for 14 mm head (B)
80. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (160 kgf-cm, 11 ft. lbs.)
HINT: Use a bolt 106 mm (4.17 inch) in length.
81. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Install the timing belt cover and fit the claws and pins into each part.
b. Install the timing belt cover with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
HINT: Use bolts 106 mm (4.17 inch) in length.
82. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
83. INSTALL SEMICIRCULAR PLUG
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the semicircular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.
84. INSTALL CYLINDER HEAD COVER
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the gasket to the cylinder head cover.
d. Install the seal washer to the bolt.
e. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.
Torque: 6.0 Nm (60 kgf-cm, 53 inch lbs.)
85. INSTALL OIL FILLER CAP HOUSING
a. Install a new gasket and the oil filler cap housing with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
86. INSTALL OIL FILLER CAP SUB-ASSEMBLY
87. INSTALL SPARK PLUG
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)
88. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent
b. Install the 2 drain cocks.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
HINT: After tightening to the specified torque, rotate the drain union clockwise until its drain port is facing forward.
89. INSTALL ENGINE HANGER NO.1
a. Install the 2 engine hangers with the 4 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)