Part 3

OVERHAUL (CONTINUED)
51. INSTALL OIL STRAINER SUB-ASSEMBLY

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

56. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and the water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt
18 Nm (184 kgf-cm, 13 ft. lbs.) for stud bolt and nut

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

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

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A 3R mark is on the RH bank's gasket.

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 (602 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.

58. INSTALL CYLINDER HEAD LH
a. Place a new cylinder head gasket on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A 3L mark is on the LH bank's gasket.

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 (602 kgf-cm, 44 ft. lbs.)
If any of the cylinder head bolts cannot meet the torque specification, replace the cylinder head bolt.

4. Mark the front of the cylinder head bolt's head with paint.
5. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
6. Check that the painted mark is now at a 90° angle to the 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 to 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.

NOTICE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.

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 each) of the camshaft drive and driven main gears, and place the 2 camshafts.
3. Set the timing marks (1 dot mark each) 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 as shown in the illustration.
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.
^ Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Seal width: 1.5 to 2.0 mm (0.059 to 0.079 inch)

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 new seal washers to the bearing cap bolts (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).

Bolt length

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 in the illustration.
Torque:
7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolt C
16 Nm (163 kgf-cm, 12 ft. lbs.) for other bolts
15. Remove the service bolt.

60. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY

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 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.

NOTICE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.

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 each) 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 as shown in the illustration.
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.
^ Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Seal width: 1.5 to 2.0 mm (0.059 to 0.079 inch)

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 new seal washers to the bearing cap bolts (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).

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 oil 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 in the illustration.
Torque:
7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolt C
16 Nm (163 kgf-cm, 12 ft. lbs.) for other bolts

14. Remove the service bolt.
61. INSTALL REAR TIMING BELT PLATE RH
a. Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
62. INSTALL REAR TIMING BELT PLATE RH NO. 2
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
63. INSTALL REAR TIMING BELT PLATE LH
a. Install the timing belt plate with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
64. INSTALL REAR TIMING BELT PLATE LH NO. 2
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (76 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. Face the timing pulley's R mark forward.
c. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

66. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY 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. Face the timing pulley's L mark forward.
c. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.
Torque: 7.5 Nm (76 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 09223-46011
68. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
a. Install the idler with the bolt.
Torque: 34.5 Nm (351 kgf-cm, 25 ft. lbs.)
b. Check that the idler moves smoothly.

69. 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: 34.5 Nm (351 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: Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.

Camshaft timing pulley of LH bank: 1/2 of a tooth
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 agents on the pulleys.

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, and 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 (265 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 rein stall 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.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

74. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
a. Align the pulley set key with the key groove of the crank shaft 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, 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)
75. ADJUST VALVE CLEARANCE

76. INSTALL IDLER PULLEY ASSEMBLY
a. Install the idler pulley with the 2 bolts and 2 nuts.
Torque:
16 Nm (163 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 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)

77. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 15.5 Nm (158 kgf-cm, 11 ft. lbs.)

HINT: Use the bolt 106 mm (4.18 inch) in length

78. INSTALL TIMING BELT COVER SUB-ASSEMBLY 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 (163 kgf-cm, 12 ft. lbs.)

HINT: Use the bolts 106 mm (4.17 inch) in length.

79. 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.)

80. 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.

81. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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 passes.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
82. INSTALL OIL FILLER CAP SUB-ASSEMBLY
83. INSTALL SPARK PLUG