Part 2

ENGINE UNIT

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

REASSEMBLY(continued)

25. INSTALL CRANKSHAFT TIMING GEAR KEY
(a) Install the timing gear key.

HINT: The other timing gear key will be installed at a later step.

26. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) While raising up the No. 2 chain tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it in place.

27. INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

28. INSTALL NO. 1 CHAIN VIBRATION DAMPER RH
(a) Install the vibration damper with the 2 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
29. INSTALL NO. 1 CHAIN TENSIONER SLIPPER RH

HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.

30. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

(c) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(d) Remove the hexagon wrench from the chain tensioner.

31. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the chain tensioner with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) While pushing down the No. 2 chain tensioner, insert a pin of [diameter]1.0 mm (0.0394 in.) into the hole to fix it in place.

32. INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.

(c) Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear and camshaft timing exhaust gear, and attach the No. 2 chain to the gears as shown in the illustration.

HINT: The crankshaft timing gear and camshaft exhaust gear will be installed with the No. 1 and No. 2 chains connected to the gears.

(d) Install the crankshaft timing sprocket to the crankshaft.
(e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear.
(f) Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear.

NOTICE: Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

(g) Remove the pin from the No. 2 chain tensioner.
33. INSTALL NO. 1 CHAIN TENSIONER SLIPPER LH

HINT: If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner.

34. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH
(a) Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
(b) Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

35. INSTALL NO. 1 CHAIN VIBRATION DAMPER LH
(a) Install the vibration damper with the 2 bolts.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(b) Remove the hexagon wrench from the No. 1 chain tensioner.

36. TIGHTEN CAMSHAFT TIMING GEAR
(a) LH:
(1) Using a wrench to hold the hexagonal portion of the No. 3 camshaft, tighten the camshaft timing gear with the bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)

(2) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear with the bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)

(b) RH:
(1) Using a wrench to hold the hexagonal portion of the No. 1 camshaft, tighten the camshaft timing gear with the bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)

(2) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear with the bolt.
Torque: 100 N*m (1020 kgf*cm, 74 ft.*lbf)
37. CHECK NO. 1 CYLINDER TO TDC / COMPRESSION
(a) Temporarily install the pulley set bolt.
(b) Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.
(c) Remove the crankshaft pulley bolt.

38. INSTALL WATER INLET PIPE
39. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

40. INSTALL FRONT CRANKSHAFT OIL SEAL
(a) Apply MP grease to the lip of a new oil seal.
(b) Using SST and a hammer, tap in the oil seal to a depth between 0 to 1.0 mm (0 to 0.0394 in.) from the timing chain cover edge.
SST 09223-22010, 09506-35010

NOTICE:
^ Keep the lip free from foreign matter.
^ Do not tap oil seal at an angle.

41. INSTALL CRANKSHAFT TIMING GEAR KEY
(a) Install the crankshaft timing gear key to the crankshaft.

42. INSTALL SPARK PLUG TUBE GASKET
(a) Using a cutter knife, cut off the seal part of the removed gasket.

(b) Using the removed gasket and a hammer, tap in a new gasket until it stops.

HINT: If the removed gasket does not fit on the new one, correct the removed one with pliers.

(c) Apply a light coat of MP grease to the gasket lip.
(d) Return the 4 ventilation baffle plate claws to the original positions.

43. INSTALL OIL CONTROL VALVE FILTER
(a) LH:
(1) Install the valve filter in the cylinder head.
(2) Install a new gasket and the cylinder head cover spacer with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

(b) RH:
(1) Install the valve filter in the cylinder head.
(2) Install a new gasket and the cylinder head cover spacer with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
44. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

46. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY
(a) LH:
(1) Apply a light coat of engine oil to 2 new O-rings.
(2) Install the 2 O-rings to the 2 oil control valves.
(3) Install the 2 oil control valves with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

(b) RH:
(1) Apply a light coat of engine oil to 2 new O-rings.
(2) Install the 2 O-rings to the 2 oil control valves.
(3) Install the 2 oil control valves with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

47. INSTALL CRANKSHAFT POSITION SENSOR
(a) Install the crankshaft position sensor with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

48. INSTALL CRANK POSITION SENSOR PROTECTOR
(a) Install the sensor protector with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

49. INSTALL CAMSHAFT POSITION SENSOR
(a) Install the camshaft position sensor with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

50. INSTALL VVT SENSOR
(a) LH:
(1) Install the 2 VVT sensors with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

(b) RH:
(1) Install the 2 VVT sensors with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
51. INSTALL SPARK PLUG

52. INSTALL OIL FILLER CAP HOUSING
(a) Align the protrusion of a new gasket with the cutout of the oil filler cap housing, and install the gasket to the housing.

(b) Install the cap housing with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
53. INSTALL OIL FILLER CAP SUB-ASSEMBLY
54. INSTALL CRANKSHAFT PULLEY
55. INSTALL OIL FILTER BRACKET (w/o Oil Cooler)
56. INSTALL OIL FILTER BRACKET (w/ Oil Cooler)
57. INSTALL NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)
58. INSTALL OIL FILTER ELEMENT