Part 1

Intake:

AUXILIARY PARTS
1. Remove the oil drain plug and drain the engine oil. After draining engine oil, install the oil drain plug.

Tightening torque: 30 - 41 Nm (22 - 30 ft. lbs.)

2. Disassemble in the order shown in the figure, referring to Disassembly Note.
3. Assemble in the reverse order of disassembly, referring to Assembly Note.

Disassembly Note
Oil filter

Remove the oil filter by using the Special Service Tool (SST).

Assembly Note
Oil filter
1. Apply clean engine oil to the rubber seal of the oil filter.
2. Install the filter and tighten it by hand until the rubber seal contacts the oil cooler.
3. Tighten the filter 1 - 1/6 turns by using the SST.

TIMING BELT

1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.

Disassembly Note
Crankshaft pulley

1. Hold the drive plate by using the Special Service Tool (SST).
2. Remove the pulley bolt.

CAUTION: The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily.

3. Remove the crankshaft pulley.

Timing belt

1. Temporarily install the crankshaft pulley bolt.
2. Turn the crankshaft clockwise to align the timing marks of the pulleys.

3. Mark the timing belt rotation for proper reinstallation.

CAUTION: When removing the bolt, hold the tensioner so that the bolt holes are aligned, otherwise the threads can be damaged.

4. Remove the auto tensioner bolts gradually in five or six steps in the order shown.

CAUTION: The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bending it, or allowing oil or grease on it.

5. Remove the timing belt.

Assembly Note
Timing belt auto tensioner

CAUTION: Applying pressure of more than 9,807 N (2,200 lbf) can damage the tensioner.

1. Press in the tensioner rod slowly, using a press.

2. Insert a pin 1.6 mm (0.06 inch) into the second hole in the body to hold tensioner rod.

3. Install the auto tensioner to the cylinder block and hand tighten the upper tensioner bolt so that the tensioner can move.

NOTE: This must be done to reduce the timing belt resistance when the idler pulley is installed.

Timing belt

1. Align the timing marks of the pulleys.

CAUTION: The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, bending it, or allowing oil or grease on it.

2. With the No. 1 idler pulley removed, install the timing belt on the pulleys in the order described below.
1) Timing belt pulley
2) No.2 Idler pulley
3) Camshaft pulley (LH)
4) Tensioner pulley
5) Camshaft pulley (RH)
3. Verify that there is tension between pulleys (3) and (2), and between pulleys (1) and (5).

4. Install the No. 1 idler pulley while applying the pressure on the timing belt.

Tightening torque:
38 - 51 Nm (28 - 38 ft. lbs.)

5. Push the auto tensioner in the direction of the arrow and install the lower bolt.
6. Tighten the upper and lower tensioner bolts to the specified torque.

Tightening torque:
19 - 25 Nm (14 - 18 ft. lbs.)

7. Remove the pin from the auto tensioner, and apply tension to the belt.

8. Turn the crankshaft clockwise two turns, and align the timing marks.
9. Verify that all timing marks are correctly aligned. If not, remove the timing belt and repeat the procedure from Timing belt auto tensioner.

10. Check the timing belt deflection. If it is incorrect, replace the auto tensioner.

Deflection: 6.0 - 8.0 mm (0.24 - 0.31 inch)

Crankshaft pulley

1. Hold the drive plate by using the SST.
2. Remove the crankshaft pulley bolt.

CAUTION: Install the crankshaft pulley carefully. The crankshaft position sensor rotor is on the rear of the pulley, and can be damaged easily.

3. Install the crankshaft pulley onto the crankshaft.
4. Apply clean engine oil to the bolt threads.
5. Tighten the pulley bolt.

Tightening torque:
157 - 166 Nm (116 - 122 ft. lbs.)

CYLINDER HEAD

Upper Engine:

1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.

Disassembly Note
Camshaft pulley

1. Hold the camshaft by using a wrench on the cast hexagon as shown, and loosen the camshaft pulley lock bolt.
2. Remove the camshaft pulley lock bolt.
3. Remove the camshaft pulley.

Camshaft

CAUTION: When the camshaft lobe is pressing on the HLA, removing the camshaft caps can damage the cylinder head thrust journal support.

1. Loosen the front camshaft cap bolts in five or six steps in the order shown.
2. Remove the front camshaft caps.

3. Loosen the camshaft cap bolts in five or six steps in the order shown.

CAUTION: Remove the thrust caps only after removing all camshaft caps. Otherwise, the thrust caps can be damaged.

4. Remove the camshaft caps.
5. Remove the distributor cap. (LH)
6. Inspect the following when removing the camshaft.
1) Camshaft end play.
2) Camshaft journal oil clearance.

HLA

CAUTION: The HLA must be reinstalled in the same positions from which they were removed. If they are not, it can cause premature and uneven wear.

1. Remove the HLA from the cylinder head.
2. Store the HLA upside down in an oil-filled container.

Cylinder head

1. Loosen the cylinder head bolts in two or three steps in the order shown.
2. Remove the cylinder head bolts.
3. Remove the cylinder heads.

Valve keeper

1. Set the Special Service Tool (SST) against the upper valve spring seat as shown.
2. Compress the spring and remove the valve keepers.

Valve seal

Remove the valve seal by using the SST.

Assembly Note
Valve seal

NOTE: The intake and exhaust valve seals are different as shown. The exhaust valve seal has ridges on the top for identification.

1. Assemble the SST so that depth L is as specified.

Depth L
IN: 16.3 mm (0.642 inch)
EX: 13.8 mm (0.543 inch)

2. Slide the valve seal onto the valve guide with the SST.

3. Set the SST against the valve seal.

CAUTION: Using a hammer will damage the valve seal.

4. Using the SST, press the valve seal on by hand until the SST touches the cylinder head.

Valve spring

Install the valve spring with the closer pitch toward the cylinder head.

Valve keeper

1. Compress the valve spring with the SST, and install the valve keepers.
2. Remove the SST.
3. Tap the end of the valve stem lightly two or three times with a plastic hammer to verify that the keepers are fully seated.

Cylinder head gasket
1. Measure the amount of the oil control plug projection from the deck of the cylinder block.

Projection (A): 13.0 - 14.0 mm (0.52 - 0.55 inch)

2. Apply clean engine oil to new O-rings and install them to the oil control plugs.

3. Turn the crankshaft clockwise and apply clean engine oil to the cylinder walls.
4. Place a new cylinder head gasket on the left bank with the L mark.
5. Place a new cylinder head gasket on the right bank with the R mark.

Cylinder head
1. Install the cylinder heads to the cylinder block.

2. Tighten the cylinder head bolts as described below.
1) Before installation, measure the length of each bolt. Replace any that exceed the maximum length.

Length: 133.7 - 134.3 mm (5.264 - 5.287 inch)
Maximum: 135.0 mm (5.315 inch)

2) Apply clean engine oil to the threads and the seat face of each bolt and install them.

Head Torque Sequence:

3) Tighten the bolts in two or three steps in the order shown.

Tightening torque:
23.1 - 25.9 Nm (17.0 - 19.1 ft. lbs.)

4) Put a paint mark on each bolt head.
5) Using the marks as a reference, tighten the bolts by turning each 85° - 95° in the sequence shown.
6) Further tighten each bolt by turning another 85° - 95°.

Camshaft

CAUTION: Camshafts must be assembled in the following procedure. Otherwise, camshaft can be broken or damaged because there is little camshaft thrust clearance.

1. Apply clean engine oil to the camshaft journals and the supports.

2. Install the camshafts so that the intake camshaft gear mark and exhaust camshaft gear mark align.
3. Remove the oil, dirt from the mating surfaces between the front camshaft cap and the cylinder head, and degrease.

CAUTION: Excessive silicone sealant will get into the cylinder head and cause the piston seizure.

4. Apply silicone sealant to the shaded areas as shown.

Thickness: 1.5 - 2.5 mm (0.06 - 0.09 inch)

CAUTION: Install the thrust caps (RH is [4] mark, LH is [A] mark) first. Otherwise, camshaft can be broken or damaged.

5. Install the thrust caps onto the cylinder heads. Hand tighten the bolts in five or six steps in the order shown, until the thrust caps fully seated on the cylinder heads.

6. install the camshaft caps onto the cylinder heads. Hand tighten the bolts in five or six steps in the order shown, until the camshaft caps fully seated on the cylinder heads.
7. Tighten the bolts in the order shown.

Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)

8. Retighten the bolts in the order shown.

Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)

9. Install the distributor cap onto the cylinder head. (LH)
10. Tighten the distributor cap bolts.

Tightening torque:
11.3 - 14.2 Nm (99.9 - 125 inch lbs.)

11. Apply clean engine oil to the new oil seal.
12. Push the oil seal slightly in by hand.

13. Tap the oil seal into the cylinder head by using the SST and a hammer.

Protrusion: 0 - 0.5 mm (0 - 0.02 inch)

14. Tap in the new blind cap by using a plastic hammer.

Camshaft pulley

1. Install the RH camshaft pulley so that the "R" mark can be seen and the groove aligns with the camshaft knock pin.
2. Install the LH camshaft pulley so that the "L" mark can be seen and the groove aligns with the camshaft knock pin.

3. Apply clean engine oil to the camshaft pulley lock bolt threads.
4. Hold the camshaft by using a wrench on the cast hexagon as shown, and tighten the camshaft puny lock bolt.

Tightening torque:
123 - 140 Nm (90.5 - 103 ft. lbs.)

Cylinder head cover

CAUTION: Silicone sealant hardens and causes oil leakage when it is left for an extended period. Therefore, install parts within five minutes of applying sealant.

1. Apply silicone sealant to the cylinder head cover as shown.
2. Install the new cylinder head cover gasket into the cylinder head cover.
3. Apply silicone sealant to the shaded areas as shown.

Thickness: 1.5 - 2.5 mm (0.06 - 0.09 inch)

4. Install the cylinder head cover and tighten the bolts in five or six steps in the order shown.

Tightening torque:
5.0 - 8.8 Nm (44 - 78 inch lbs.)

5. Retighten RH (5) (6) and LH (6) (7) cylinder head cover bolts.

Tightening torque:
5.0 - 8.8 Nm (44 - 78 inch lbs.)

CYLINDER BLOCK (EXTERNAL PARTS)

1. Disassemble in the order shown in the figure, referring to Disassembly Note.
2. Assemble in the reverse order of assembly, referring to Assembly Note.

Disassembly Note
Backing plate, drive plate, adapter

1. Hold the drive plate by using the Special Service Tool (SST).
2. Remove the drive plate lock bolts in two or three steps in the order shown.
3. Remove the backing plate, drive plate, and adapter.

Knock sensor

Remove the knock sensor by using the SST.

Oil pan

1. Remove the oil pan mounting bolts.
2. Turn a bolt into the special bolt hole as shown to make a small gap between the oil pan and the lower cylinder block.

3. Insert a screwdriver or a seal cutter between the cylinder block and the oil pan to separate them.
4. Remove the oil pan.