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OVERHAUL
42. INSPECT CAMSHAFTS
a. Inspect camshaft for runout
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.08 mm (0.0031 inch)
If the circle runout is greater than maximum, replace the camshaft.
b. Inspect cam lobes.
1. Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
intake 41.94 - 42.04 mm (1.6512 - 16.551 inch)
Exhaust 41.96 - 42.06 mm (1.6520 - 1.6559 inch)
Minimum cam lobe height:
intake 41.79 mm (1.6453 inch)
Exhaust 41.81 mm (1.6461 inch)
If the cam lobe height is less than minimum, replace the camshaft.
c. Inspect camshaft journals.
1. Using a micrometer, measure the journal diameter.
Journal diameter: 26.954 - 26.970 mm (1.0612 - 1.0618 inch)
If the journal diameter is not as specified, check the oil clearance.
43. INSPECT CAMSHAFT TIMING GEAR BOLT WASHER
a. Using vernier calipers, measure the free distance between the washer ends.
Free distance: 18.2 - 18.8 mm (0.717 - 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 09960-10010 (09962-01000, 09963-00500)
e. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.
Recommended 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 (09316-00011)
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 09223-56010
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 (82 kgf-cm, 71 inch lbs.)
50. INSTALL OIL PUMP ASSY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pump and cylinder block.
1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
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 pump as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: Avoid applying an excessive amount to the surface. Be particularly careful near oil passage.
1. Install a nozzle that has been cut to a 2 - 3 mm (0.08 - 0.12 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. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.
e. Install the oil pump with a new stud bolt and the 7 bolts. Uniformly tighten the bolts diagonally.
NOTICE: Do not reuse the stud bolt.
HINT: Use a 6 mm hexagon wrench for the hexagon head bolt. The following chart is the reference to the oil pump bolt length.
Torque:
16 Nm (158 kgf-cm, 11 ft. lbs.) for bolt A, B. C and E
31 Nm (311 kgf-cm, 23 ft. lbs.) for bolt D
51. INSTALL OIL STRAINER SUB-ASSY
a. Install a new gasket and the oil strainer with the 2 bolts and 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
HINT: Use bolts 12 mm (0.47 inch) in length.
52. INSTALL STUD BOLT
53. 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 No.1 oil pan, cylinder block, oil pump and rear oil seal retainer.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the No.1 oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 3 - 5 mm (0.12 - 0.20 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.
c. Temporarily install the oil pan with the 18 bolts and 2 nuts.
HINT: The provided chart is the reference to the oil pump bolt length.
d. Set the oil pan as shown in the illustration.
NOTICE: Make sure the clearance between the rear end of the oil pan and cylinder block is 0.2 mm (0.008 inch) or less.
If the clearance is more than 0.2 mm (0.008 inch), the oil pan will be stretched.
e. Uniformly tighten the bolts and nuts diagonally.
Torque:
7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolt A and D
28 Nm (286 kgf-cm, 21 ft. lbs.) for bolt B. C and nut
54. INSTALL OIL PAN BAFFLE PLATE
a. Install the baffle plate with the 2 bolts and 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
HINT: Use bolts 12 mm (0.47 inch) in length.
55. INSTALL OIL PAN SUB-ASSY No.2
a. Remove any oil packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No.1 and No.2 oil pans.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
NOTICE: Do not use a solvent which will affect the painted surfaces.
b. Apply seal packing to the No.2 oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
- Install a nozzle that has been cut to a 3 - 5 mm (0.12 - 0.20 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.
c. Install the No.2 oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
HINT: Use bolts 14 mm (0.55 inch) in length.
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:
Bolt 21 Nm (214 kgf-cm, 15 ft. lbs.)
Stud bolt and nut 18 Nm (184 kgf-cm, 13 ft. lbs.)
HINT: Use bolts 35 mm (1.38 inch) in length.
57. INSTALL CYLINDER HEAD SUB-ASSY
a. Place 2 new cylinder head gaskets in position on the cylinder block.
HINT: On the rear side of the cylinder head gasket are marks to distinguish the LH and RH banks, a "2UR" mark for the RH bank and a "2UL" mark for the LH bank.
NOTICE: Be careful of the installation direction.
b. Place the 2 cylinder heads in position on the cylinder head gaskets.
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, then do the other side as shown.
Torque: 32 Nm (326 kgf-cm, 24 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.
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. Retighten the cylinder head bolts by an additional 90°.
7. Check that the painted mark is now at a 180° angle to front.
58. INSTALL CAMSHAFTS
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 intake and exhaust 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.
NOTICE: Be careful of the installation direction.
6. 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 - 0.079 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 caps in the sequence shown with the arrow mark facing forward.
9. Push in a new 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
55 mm (2.17 inch) for D
40 mm (1.57 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.
Torque:
7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolt C
16 Nm (163 kgf-cm, 12 ft. lbs.) for others
14. Boring the service bolt installed in the driven subgear upward by turning the hexagon wrench head portion of the camshaft with a wrench.
15. Remove the service bolt.
c. 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.
NOTICE: Be careful of the installation direction.
5. 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 - 0.079 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.
6. Install the front bearing cap.
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.
7. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
8. Push in a new camshaft setting oil seal.
9. Install a new seal washer to the bearing cap bolt (A and B).
10. 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
55 mm (2.17 inch) for D
40 mm (1.57 inch) for E
11. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
12. Uniformly tighten the 22 bearing cap bolts in several passes, in the sequence shown.
Torque:
7.5 Nm (76 kgf-cm, 66 inch lbs.) for bolt C
16 Nm (163 kgf-cm, 12 ft. lbs.) for others
13. Boring the service bolt installed in the driven subgear upward by turning the hexagon wrench head portion of the camshaft with a wrench.
14. Remove the service bolt.