Part 2

ENGINE UNIT

COMPONENTS:

REASSEMBLY (STEPS 28-54)

28. INSTALL NO. 2 CAMSHAFT
a. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 Nm (306 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
^ Tighten the bolts after deciding the position for the thrust direction of the camshaft by the bearing cap No. 2.
^ Install the camshaft with its timing mark of the camshaft timing gear on top.

29. INSTALL OIL PUMP ASSEMBLY
a. Install a new gasket and oil pump with the 3 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

30. INSTALL NO. 2 CHAIN SUB-ASSEMBLY
a. Set the crankshaft key into the left horizontal position.
b. Turn the cutout of the drive shaft to the top.

c. Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration.
d. Insert the sprocket with chain to the crankshaft and oil pump shaft.
e. Temporarily tighten the oil pump driven sprocket with the nut.

f. Insert the damper spring into the adjusting hole, and install the chain tensioner plate by the bolt.
Torque: 12 Nm (122 kgf-cm, 9.0 ft. lbs.)

g. Align the adjusting hole of the sprocket with the groove of the oil pump.
h. Put a bar (4 mm (0.16 inch)) into the adjusting hole of the sprocket to temporarily lock the sprocket in position. Install the nut.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

i. Rotate the crankshaft clockwise 90°, and align the crankshaft key with the top.
31. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
32. INSTALL CHAIN VIBRATION DAMPER NO. 1
a. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

33. INSTALL CHAIN SUB-ASSEMBLY
a. Set the No. 1 cylinder to TDC/compression.
(1) Align the timing marks of the camshaft timing gear/sprocket and bearing caps (No. 1 and No. 2).

(2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.

b. Align the mark link (blue or orange colored link) with the timing mark of the crankshaft timing sprocket.

c. Using SST, tap in the sprocket.
SST 09309-37010

d. Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Then install the chain.
34. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
35. INSTALL TIMING CHAIN GUIDE
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

36. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
a. Install the sensor plate with the F mark facing forward.

37. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a. Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010
b. Apply a light coat of MP grease to the lip of the oil seal.

NOTICE: Keep the gap between the timing chain cover edge and the oil seal free of foreign matter.

38. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

NOTICE:
^ Remove any oil from the contact surface.
^ Install the chain cover within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

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. Apply seal packing in a continuous bead (seal width: 2.0 mm (0.079 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

c. Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

d. Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 Nm (92 kgf-cm, 80 inch lbs.)
Bolt B 21 Nm (214 kgf-cm, 15 ft. lbs.)
Bolt C 43 Nm (438 kgf-cm, 32 ft. lbs.)
Nut 9.0 Nm (92 kgf-cm, 80 inch lbs.)
e. Install the stud bolt to the drive belt tensioner.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
39. INSTALL OIL PAN SUB-ASSEMBLY

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
b. Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 inch)) as shown in the illustration, and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent

c. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
40. INSTALL OIL PAN DRAIN PLUG
a. Install a new gasket and the drain plug.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

41. INSTALL WATER PUMP ASSEMBLY
a. Clean the contact surface of the cylinder block.
b. Apply seal packing in a continuous bead (seal width: 2.2 to 2.5 mm (0.087 to 0.098 inch)) to the outside edge of the water pump.
Seal packing: Part No. 08826-00100 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the water pump within 5 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

c. Install the water pump with the 4 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: Tighten the outside bolts and nuts with the clamp.

42. INSTALL WATER PUMP PULLEY
a. Using SST, install the water pump pulley with the 4 bolts.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)

43. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the sensor with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Confirm that the wire harness of the sensor is placed as shown in the illustration.

44. INSTALL CRANKSHAFT PULLEY
a. Install the pulley.
b. Using SST, tighten the bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 180 Nm (1,835 kgf-cm, 133 ft. lbs.)

HINT: Apply a light coat of engine oil to the bolt threads and the area beneath the bolt head that come in contact with the washer.

45. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
a. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.

b. Install a new gasket and the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: If the hook is released while inserting, apply the hook again, and insert the chain tensioner.

c. Turn the crankshaft counterclockwise and check that the plunger knock pin is disconnected from the hook.

d. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger.
46. INSPECT VALVE CLEARANCE
47. ADJUST VALVE CLEARANCE
48. INSTALL CYLINDER HEAD COVER GASKET
a. Install the gasket to the cylinder head cover.
49. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove any old packing (FIPG) material.

b. Apply seal packing to the 2 locations shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 5 minutes after applying seal packing.
^ Do not apply engine oil for at least 2 hours after installing.

c. Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
Nut 11 Nm (112 kgf-cm, 8 ft. lbs.)
Bolt A 11 Nm (112 kgf-cm, 8 ft. lbs.)
Bolt B 14 Nm (143 kgf-cm, 10 ft. lbs.)
50. INSTALL SPARK PLUG
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
51. INSTALL VENTILATION VALVE SUB-ASSEMBLY
a. Apply adhesive on the threads of the ventilation valve.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
52. INSTALL OIL FILLER CAP SUB-ASSEMBLY
53. INSTALL OIL FILTER UNION
a. Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

54. INSTALL OIL FILTER SUB-ASSEMBLY
a. Check and clean the oil filter installation surface.
b. Apply clean engine oil to the gasket of a new oil filter.
c. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
d. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501