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OVERHAUL
67. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)
a) Align the mark links (yellow) with the timing marks (1 dot mark and 2 dot marks) of camshaft timing gears as shown in the illustration.
b) Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts.
c) Temporarily install the 2 camshaft timing gear bolts.
NOTICE: Do not push camshaft timing gear assembly to the camshaft forcibly when installing it.
d) Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
e) Remove the pin from the chain tensioner No. 3.
68. INSTALL CHAIN VIBRATION DAMPER NO.1
a) Install the chain vibration damper No. 1 with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
69. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
a) Align the timing gear set key with the key groove of the timing gear.
b) Install the timing gear onto the crankshaft with the gear side facing inward.
70. INSTALL CHAIN TENSIONER SLIPPER
71. INSTALL CHAIN TENSIONER ASSY NO.1
a) While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
b) While turning the stopper plate of the tensioner counterclockwise, insert a bar of 3.5 mm (0.138 inch) into the holes in the stopper plate and tensioner to fix the stopper plate.
c) Install the chain tensioner with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
72. INSTALL CHAIN SUB-ASSY
a) Set the No. 1 cylinder to TDC compression.
1) Align the timing marks of the camshaft timing gears and bearing caps.
2) Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.
b) Align the mark link (yellow) with the timing mark of the crankshaft timing gear.
c) Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
73. INSTALL CHAIN VIBRATION DAMPER NO.2
74. INSTALL IDLE GEAR NO.1
a) Apply a light coat of engine oil to rotating surface of the idle gear shaft No. 1.
b) Temporarily install the idle gear shaft No. 1 and idle gear No. 1 with the idle gear shaft No. 2 while aligning the knock pin of the idle gear shaft No. 1 with the knock pin groove of the cylinder block.
NOTICE: Be careful of the idle gear direction.
c) Using a 10 mm hexagon wrench, tighten the idle gear shaft No. 2.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
d) Remove the bar from the chain tensioner.
75. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09226-10010
b) Apply MP grease to the oil seal lip.
76. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
b) Install a new O-Ring to the LH cylinder head as shown in the illustration.
c) Apply a continuous bead of the seal packing (diameter 3 - 4 mm (0.12 - 0.16 inch)) to 4 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
d) Apply a continuous bead of the seal packing (diameter 3 - 4 mm (0.12 - 0.16 inch)) to the timing chain cover as shown in the illustration.
Seal packing:
Water pump part: Part No. 08826-00100 or equivalent
Other part: Part No. 08826-00080 or equivalent
NOTICE:
- Install the timing chain cover within 3 minutes after applying seal packing. After installing it, timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
- Do not apply seal packing to the "A" as shown in the illustration.
e) Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.
f) Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
NOTICE:
- Pay attention not to wrap the chain and slipper over the timing chain cover seal line.
- After installing the timing chain cover, must install the water pump within 15 minutes.
HINT:
Each bolt length as follows:
A 25 mm (0.98 inch)
B 55 mm (2.17 inch)
77. INSTALL WATER PUMP ASSY
a) Install a new gasket and the water pump with the 17 bolts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
23 Nm (235 kgf-cm, 17 ft. lbs.) for 12 mm (0.47 inch) head
78. INSTALL OIL PAN SUB-ASSY
a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.
b) Install the 4 stud bolts.
Torque: 4.0 Nm (41 kgf-cm, 35 inch lbs.)
c) Install a new O-ring to the oil pump.
d) Apply a continuous bead of the seal packing (diameter 3 - 4 mm (0.12 - 0.16 inch)) to the oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: Install the oil pan within 3 minutes after applying seal packing. After installing it, oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
e) Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
19 Nm (194 kgf-cm, 14 ft. lbs.) for 12 mm (0.47 inch) head
HINT:
Each bolt length as follows:
A 25 mm (0.98 inch)
B 40 mm (1.57 inch)
C 14 mm (0.55 inch)
79. INSTALL OIL STRAINER SUB-ASSY
a) Install a new gasket and the oil strainer with the 2 nuts
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
80. INSTALL OIL PAN SUB-ASSY NO.2
a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No 2.
b) Apply a continuous bead of the seal packing (diameter 3 - 4 mm (0.12 - 0.16 inch)) as shown in the illustration
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: Install the oil pan No.2 within 3 minutes after applying seal packing. After installing it, oil pan No.2 bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
c) Install the oil pan No.2 with the 10 bolts and 2 nuts. tighten the bolts and nuts uniformly in several steps.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
81. INSTALL OIL PAN DRAIN PLUG
a) Install the drain plug with a new gasket
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
82. INSTALL CRANKSHAFT PULLEY
a) Using SST, install the pulley set bolt
SST 09213-54015 (91651-60855), 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft. lbs.)
83. SET NO. 1 CYLINDER TO TDC/COMPRESSION
84. INSPECT VALVE CLEARANCE
85. ADJUST VALVE CLEARANCE
86. INSTALL CYLINDER HEAD COVER SUB-ASSY
a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
b) Install the gasket to the cylinder head cover.
c) Apply a continuous bead of the seal packing (diameter 2 - 3 mm (0.08 - 0.12 inch)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
d) Install the seal washers to the bolts.
e) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
87. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
b) Apply adhesive on the threads of the ventilation valve.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
c) Install the ventilation valve to the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
d) Install the gasket to the cylinder head cover.
e) Apply a continuous bead of the seal packing (diameter 2 - 3 mm (0.08 - 0.12 inch)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing: Part No. 0882-00080 or equivalent
NOTICE: Install the cylinder head cover within 3 minutes after applying seal packing. After installing it, cylinder head cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
f) Install the seal washers to the bolts.
g) Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
88. INSTALL OIL CONTROL VALVE FILTER
a) Check that no foreign objects on the mesh part of the 2 filters.
b) Install 2 new gaskets to each new plug.
c) Insert the filters to the plugs.
d) Apply adhesive to 2 or 3 threads of the plugs
Adhesive: Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent
e) Install the plugs to each cylinder head.
Torque: 62 Nm (632 kgf-cm, 46 ft. lbs.)
89. INSTALL CRANKSHAFT POSITION SENSOR
a) Install the crankshaft position sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
90. INSTALL VVT SENSOR
a) Apply a light coat of engine oil to the O-ring of each VVT sensor.
b) Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
91. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a) Apply adhesive to 2 or 3 threads of the drain cocks end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b) After reached the specified torque, rotate the drain cocks clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
NOTICE:
- Do not rotate the drain cocks more than 1 complete revolution (360°) after tightening the drain cocks with the specified torque.
- Do not loosen the drain cocks after setting it correctly.
92. INSTALL OIL LEVEL GAUGE GUIDE
a) Install a new O-ring to the oil level gauge guide.
b) Apply a light coat of engine oil to the O-ring.
c) Push in the oil level gauge guide end into the guide hole of the oil pan.
d) Install the oil level gauge guide with the bolt
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
93. INSTALL ENGINE HANGER NO.2
a) Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
94. INSTALL ENGINE HANGER NO.1
a) Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)