Part 2

OVERHAUL
30. REMOVE WATER PUMP ASSY
a. Remove the 5 bolts, 2 stud bolts and nut, water pump and gasket.
31. REMOVE OIL PAN SUB-ASSY NO.2
32. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 3 bolts, 2 nuts and baffle plate.
33. REMOVE OIL PAN SUE-ASSY
34. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt, 2 nuts, oil strainer and gasket.
35. REMOVE OIL PUMP ASSY

36. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 7 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
c. Remove the O-ring.

37. REMOVE SPARK PLUG TUBE GASKET
a. Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more.
b. Using a screwdriver, pry out the gasket.

NOTICE: Be careful not to damage the cylinder head cover. Tape the screwdriver tip.

38. INSTALL SPARK PLUG TUBE GASKET
a. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09551-00240, 09951-00440, 09952-06010), 0995-70010 (09951-07100)

NOTICE: Be careful of the installation direction.

b. Apply a light coat of MP grease to the gasket lip.
c. Return the 4 ventilation case claws to its original position.
39. REMOVE CAMSHAFT TIMING TUBE ASSY

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

NOTICE: Be careful not to damage the camshaft. The 4 bolts shown in the illustration determine the backlash of the gear in the timing tube, so do not remove them. H any of the 4 bolts are removed, install a new timing tube assy.

b. Remove the screw plug and seal washer.
c. Using a 10 mm hexagon wrench, and remove the bolt.
d. Pull out the timing tube and drive gear assembly from the camshaft.

e. Using SST and a 5 mm hexagon wrench, and remove the 4 bolts, drive gear and oil seal.
SST 0996-10010 (09962-01000, 09963-00500)

NOTICE: Be careful not to damage the timing tube.

40. INSTALL CAMSHAFT SETTING OIL SEAL
a. Place a new oil seal to the timing tube.

NOTICE: Be careful of the installation direction.

41. INSTALL CAMSHAFT TIMING TUBE ASSY
a. 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.

b. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several passes.
SST 0996-10010 (09962-01000, 09963-00500)
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)

NOTICE: Be careful not to damage the timing tube.

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

NOTICE: Be careful not to damage the camshaft.

d. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until you feel it touch the bottom.
e. Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (790 kgf-cm, 58 ft. lbs.)
f. Install the seal washer and screw plug.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
42. REMOVE CAMSHAFT SUB GEAR

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

NOTICE: Be careful not to damage the camshaft.

b. Using SST, turn the sub gear clockwise, and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)

c. Using snap ring pliers, remove the snap ring.
d. Remove the wave washer, sub gear and gear bolt washer.

HINT: Arrange the driven sub gears and gear bolt washers (RH and LH sides).

43. INSPECT CAMSHAFT TIMING GEAR BOLT WASHER
Using vernier calipers, measure the free distance between the washer ends.
Free distance: 18.2 - 18.8 mm (0.712 - 0.740 inch)
If the free distance is not as specified, replace the washer.
44. INSTALL CAMSHAFT SUB GEAR

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

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

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

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

NOTICE: Be careful not to damage the camshaft.

d. 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 0996-10010 (09962-10000, 09963-00500)
e. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.

45. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the oil pump body. Tape the screwdriver tip.

46. INSTALL OIL PUMP SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09316-60011 (0931-00011)
b. Apply MP grease to the oil seal lip.

47. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and hammer, tap out the oil seal.

48. INSTALL ENGINE REAR OIL SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 0922-56010
b. Apply MP grease to the oil seal lip.
49. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
1. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
2. Thoroughly clean all components to remove all the loose material.
3. Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

1. Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.
2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
3. Immediately remove nozzle from the tube and reinstall cap.

c. Install a new O-ring to the cylinder block.
d. Install the oil seal retainer with the 7 bolts.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
50. INSTALL OIL PUMP ASSY
51. INSTALL OIL STRAINER SUB-ASSY

52. INSTALL OIL PAN STUD BOLT
53. INSTALL OIL PAN SUB-ASSY
54. INSTALL OIL PAN BAFFLE PLATE
55. INSTALL OIL PAN SUB-ASSY NO.2

56. INSTALL WATER PUMP ASSY
a. Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

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

57. INSTALL CYLINDER HEAD SUB-ASSY
a. Place a new cylinder head gasket on the cylinder block.

HINT: On the rear side of the cylinder head gasket are marks to distinguish the RH and LH banks, a "3R" mark for the RH bank

NOTICE: Be careful of the installation direction.

b. Place the cylinder head on the cylinder head gasket.

c. Install the cylinder head bolts.

HINT: The cylinder head bolts are tightened in 2 progressive steps (steps (3) and (5)). 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. 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 Nm (600 kgf-cm, 44 ft. lbs.)
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 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.

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

HINT: On the rear side of the cylinder head gasket are marks to distinguish the RH and LH banks, a "3L" mark for the LH bank

NOTICE: Be careful of the installation direction.

b. Place the cylinder head on the cylinder head gasket.

c. Install the cylinder head bolts.

HINT: The cylinder head bolts are tightened in 2 progressive steps (steps (3) and (5)). 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. 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 Nm (600 kgf-cm, 44 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

4. Mark the front of the cylinder head bolt head with paint.
5. Retighten the cylinder head bolts by 90° in the numerical order shown.
6. Check that the painted mark is now at a 90° angle to front.
59. 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, 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.

a. Set the crankshaft position.
1. Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft at the position of 90° counterclockwise from the timing mark (dot) of the oil pump body.

NOTICE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

b. Install the camshafts of the RH bank.
1. Apply MP grease to the thrust portion of the camshafts.
2. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts.

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

4. Apply seal packing to the camshaft housing plug.
- Remove the old packing (FIPG) material.
- Apply seal packing to the housing plug.
Seal packing: Part No. 08826-00080 or equivalent

5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
6. Install the oil control valve filter to the cylinder head.

NOTICE: Be careful of the installation direction.

7. Apply seal packing to the front bearing cap.
- 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.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
- Apply seal packing to the bearing cap as shown in the illustration.
- Install a nozzle that has been cut to a 1.5 - 2.0 mm (0.059 - 0.79 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
Seal packing: Part No. 08826-00080 or equivalent

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

8. Install the front bearing cap.

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

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

10. Push in the camshaft setting oil seal.

11. Install a new seal washer to the bearing cap bolt (A and B).
12. 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 bolt (A), (B) and (C).

HINT: Each bolt length is indicated in the illustration.

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

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

14. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown.
Torque:
7.5 Nm (80 kgf-cm, 66 inch lbs.) for bolt C
16 Nm (160 kgf-cm, 12 ft. lbs.) for others

15. Remove the service bolt.