Part 3
OVERHAUL60. 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, 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. Check the set key of the crankshaft is 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 LH bank.
1. Apply MP grease to the thrust portion of the camshafts.
2. Align the timing marks (2 dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts.
3. 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
4. Install the camshaft housing plug to the cylinder head as shown in the illustration.
5. Install the oil control valve filter to the cylinder head.
NOTICE: Be careful of the installation direction.
6. Apply seal packing to the front bearing cap.
- Remove any old packing (FIPG) material and be care 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.
7. Install the front bearing cap.
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.
8. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
9. Push in the camshaft setting oil seal.
10. Install a new seal washer to the bearing cap bolt (A and B).
11. 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
12. Install the lock feed pipe and the 22 bearing cap bolts as shown in the illustration.
13. 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
14. Remove the service bolt.
61. INSTALL TIMING BELT PLATE FIR RH
a. Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
62. INSTALL TIMING BELT PLATE RR RH NO.2
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
63. INSTALL TIMING BELT PLATE RR LH
a. Install the timing belt plate with the bolt.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
64. INSTALL TIMING BELT PLATE RR LH NO.2
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
65. INSTALL CAMSHAFT TIMING PULLEY
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, facing the "R" mark forward.
c. Hold the hexagon wrench head portion of the camshaft, install the 4 pulley bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
66. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSY LH
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, facing the "L" mark forward.
c. Hold the hexagon wrench head portion of the camshaft, install the 4 pulley bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
67. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the timing pulley set key with the key groove of the pulley.
b. Using SST and a hammer, tap in the timing pulley, facing the flange side inward.
SST 09223-06011
68. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
a. Install the idler with the bolt.
Torque: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
69. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
a. Apply adhesive 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: 34.5 Nm (350 kgf-cm, 25 ft. lbs.)
c. Check that the idler bracket moves smoothly.
70. INSTALL TIMING BELT
NOTICE: The engine should be cold.
a. Set the No. 1 cylinder to TDC/compression.
1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates aligned.
HINT: Setting positions of the camshaft timing pulleys by turning them slightly clockwise makes it easy to install the timing belt:
Camshaft timing pulley of LH bank: 1/2 teeth
Camshaft timing pulley of RH bank: 1 tooth
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 the each pulley, and keep them clean.
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 - 9,807 N (100 - 1,000 kgf, 220 - 2,205 lbs.) of pressure. 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 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 do not align, remove the timing belt and reinstall it.
71. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the sensor plate, facing the cup side outward.
72. INSTALL TIMING GEAR COVER SPACER
a. Install the gasket to the cover spacer.
b. Install the cover spacer.
73. INSTALL TIMING BELT NO.1 COVER
a. Install the timing belt cover with the 4 bolts.
74. INSTALL CRANKSHAFT DAMPER SUB-ASSY
a. Using SST and a hammer tap in the crankshaft damper.
SST 09223-06011
b. Using SST, install the damper bolt.
SST 09213-70010, 09330-00021
Torque: 245 Nm (2,500 kgf-cm, 181 ft. lbs.)
c. Align the pulley set key with the key groove of the crankshaft damper.
75. INSPECT VALVE CLEARANCE
76. ADJUST VALVE CLEARANCE
77. INSTALL IDLER PULLEY ASSY
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 (330 kgf-cm, 24 ft. lbs.) for 14 mm head
HINT: Each bolt length is indicated in the illustration.
Bolt Length:
106 mm (4.17 inch) for 12 mm head (A)
114 mm (4.49 inch) for 14 mm head (B)
78. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 15.5 Nm (160 kgf-cm, 11 ft. lbs.)
HINT: Use a bolt 106 mm (4.18 inch) in length.
79. INSTALL TIMING BELT COVER SUB-ASSY NO.2
a. Fit the timing belt cover, matching the claws and pin with 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
80. INSTALL IDLER PULLEY SUB-ASSY NO.2
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
81. 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 a shown in the illustration.
82. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder heads as shown in the illustration. Seal packing: Part No. 0882-00080 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 passes.
Torque: 6.0 Nm (60 kgf-cm, 53 inch lbs.)
83. INSTALL OIL FILLER CAP SUB-ASSY
84. INSTALL SPARK PLUG