Part 3

OVERHAUL (CONTINUED)

76. INSTALL CAMSHAFT BEARING CAP





a. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
b. Install the camshaft No.3 and camshaft No.4 to the camshaft housing LH.
c. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.





d. Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





77. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
a. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 inch)

NOTICE:
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly LH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.





b. Install the camshaft housing LH, and tighten the 13 bolts in the order shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

NOTICE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing LH.





c. Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)

NOTICE: Thoroughly wipe clean any seal packing.





d. Install 3 new gaskets.





78. INSTALL CHAIN TENSIONER ASSEMBLY NO.2
a. Install the chain tensioner No.2 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
b. While pushing in the tensioner, insert a pin of diameter 1.0 mm (0.039 inch) into the hole to fix it.
79. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)





a. Align the mark plate (yellow) with the timing marks (1 - dot mark) of the camshaft timing gears as shown in the illustration.
b. Apply a small amount of engine oil to the bolt threads and bolt-seating surface.
c. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with the No.2 chain installed.





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.2.





80. INSTALL CHAIN TENSIONER ASSEMBLY NO.3
a. Install the chain tensioner No.3 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
b. While pushing in the tensioner, insert a pin of diameter 1.0 mm (0.039 inch) into the hole to fix it.
81. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)





a. Align the mark plate (yellow) with the timing marks (2 - dot mark) of the camshaft timing gears as shown in the illustration.
b. Apply a small amount of engine oil to the bolt threads and bolt-seating surface.
c. Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with the No.2 chain installed.





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.2.





82. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper No.1 with the 2 bolts.
Torque: 23 Nm (230 kgf-cm, 17 ft. lbs.)
83. INSTALL CHAIN VIBRATION DAMPER NO.2
a. Instal the 2 chain vibration dampers.





84. INSTALL CRANKSHAFT TIMING GEAR
a. Install the timing gear set keys and timing gear as shown in the illustration.
85. INSTALL IDLE SPROCKET ASSEMBLY
a. Apply a light coat of engine oil to the rotating surface of the idle gear shaft No.1.





b. Temporarily install the idle gear shaft No.1 and idle sprocket 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.)

86. INSTALL CHAIN SUB-ASSEMBLY





a. Align the mark plate and timing mark as shown in the illustration and temporarily install the chain.

NOTICE: Do not pass the chain over the crankshaft yet.

HINT: The chain mark plate is orange.





b. Turn the camshaft timing gear assembly on the RH bank counterclockwise to tighten the chain between banks.





c. Align the mark plate and timing mark as shown in the illustration and install the chain onto the crankshaft timing gear.

HINT: The chain mark plate is yellow.

d. Temporarily tighten the pulley set bolt.





e. Turn the crankshaft clockwise to set it to the RH block bore center line (TDC/compression).

87. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper.
88. INSTALL CHAIN TENSIONER ASSEMBLY NO.1





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 No.1 with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





d. Remove the lock pin of chain tensioner assembly No.1. Check that each timing mark is aligned with the crankshaft at the TDC/compression.
e. Remove the pulley set bolt.





89. INSTALL TIMING CHAIN COVER OIL SEAL
a. Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.
SST 09316-60011 (09316-00011)

NOTICE:
- Keep the lip free from foreign matter.
- Do not tap on the oil seal at an angle.
- Make sure that the oil seal edge dose not stick out of the timing chain case.





90. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and the water pump with the 8 bolts.
Torque: 9.1 Nm (93 kgf-cm, 81 inch lbs.)

NOTICE: Be sure to replace the bolts indicated by * with new ones or reuse them after applying adhesive 1344.





91. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
a. Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 Nm (93 kgf-cm, 81 inch lbs.)
b. Apply seal packing in a continuous bead to the engine unit as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal width: 3.0 mm or more (0.118 inch)

NOTICE:
- Be sure to clean and degrease the contact surfaces, especially the areas indicated by * in the illustration.
- When the contact surfaces are wet, degrease with cleaning agent and wipe off with an oil-free cloth before applying seal packing.
- Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.








c. Apply seal packing in a continuous bead to the timing chain cover as shown in the illustration.

Seal packing: Part No.08826-00080 or equivalent
Seal packing: Part No.08826-00100 or equivalent

NOTICE:
- When the contact surfaces are wet, degrease with cleaning agent and wipe off with an oil-free cloth before applying seal packing.
- Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.

HINT: Apply seal packing referring to the table and illustration below.





d. Install a new gasket.





e. Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.





f. Loosely install the timing chain cover with the 23 bolts and 2 nuts, but do not tighten the bolts and 2 nuts yet.

NOTICE: Make sure that there is no oil on the bolt threads.

HINT:
Bolt length:
40 mm (1.57 inch) for bolt A
55 mm (2.17 inch) for bolt B
25 mm (0.98 inch) for bolt C

g. Fully tighten the bolts in this order: Area 1 and Area 2. 21 Nm (214 kgf-cm, 15 ft. lbs.)

h. Fully tighten the bolts and nuts in this order: Area 3. 21 Nm (214 kgf-cm, 15 ft. lbs.)
i. Fully tighten the bolts in this order: Area 4.
Torque:
43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolts except A
92. INSTALL WATER INLET HOUSING





a. Install 2 new O-rings.
b. Apply soapy water to the O-ring.





c. Install the water inlet with the 2 bolts and nut.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





d. Apply adhesive around the drain cock.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.
e. Install the water drain cock to the water inlet housing.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
Install the water drain cock plug to the water drain cock.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
g. Install a new gasket to the thermostat.





h. Align the thermostat jiggle valve with the upper stud bolt, and insert the thermostat in the water inlet housing.

HINT: The jiggle valve may be set within 10° of either side of the prescribed position.





i. Install the water inlet with the 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





93. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install the engine mounting bracket front No.1 LH with the 6 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE:
- Install the water inlet and mounting bracket within 15 minutes after installing the chain cover.
- Do not start the engine for at least 2 hours after installation.








94. INSTALL OIL PAN BAFFLE PLATE
a. Install the oil pan baffle plate with the 7 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
95. INSTALL OIL PAN SUB-ASSEMBLY
a. Install the stud bolt.
1. Using an E8 Torx socket wrench, install the stud bolts as shown in the illustration.
Torque: 10 Nm (102 kgf-cm, lbs.)





b. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 inch)

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





c. Install 2 new O-rings.





d. Install the oil pan with the 16 bolts and 2 nuts.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolts except A
96. INSTALL OIL STRAINER SUB-ASSEMBLY





a. Install the stud bolt.
1. Using an E6 Torx socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm, 35 inch lbs.)





b. Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
97. INSTALL OIL PAN SUB-ASSEMBLY NO.2





a. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 3.0 to 4.0 mm (0.118 to 0.156 inch)

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





b. Install the stud bolt.
1. Using an E6 Torx socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm, 35 inch lbs.)





c. Install the oil pan No.2 with the 16 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





98. INSTALL OIL PAN DRAIN PLUG
a. Install a new gasket and the drain plug.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)





99. INSTALL SPARK PLUG TUBE GASKET
a. Using a 32 mm socket wrench, tap in 6 new spark plug tube gaskets to the head covers.

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

b. Return the claw of the ventilation baffle plate to its original position.
100. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY





a. Apply seal packing as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

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





b. Install the gasket to the head cover.
c. Install the head cover with the 12 bolts.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt A
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolts except A

HINT: Make sure the tightening torque of bolts 1.





101. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Apply seal packing as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.
b. Install the gasket to the head cover.





c. Install the head cover with the 12 bolts.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt A
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolts except A

HINT: Make sure the tightening torque of bolts 1 and 10.





102. INSTALL WATER OUTLET
a. Install 2 new gaskets and a new O-ring.
b. Apply soapy water to the O-ring.





c. Install the water outlet with the 2 bolts and 4 nuts.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolts
10 Nm (104 kgf-cm, 8 ft. lbs.) for nuts





103. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 250 Nm (2,550 kgf-cm, 184 ft. lbs.)
104. INSTALL OIL FILTER ELEMENT





a. Clean the inside of the oil filter cap, threads and O-ring groove.
b. Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.
c. Set a new oil filter element to the oil filter cap.
d. Remove dirt or foreign matter from the installation surface and inside of the engine.
e. Apply a small amount of engine oil to the O-ring again and install the oil filter cap.

NOTICE:
- Be careful that the O-ring does not get caught between the parts.
- The O-ring must not twisted on the groove.





f. Using SST, install the oil filter cap.
SST 09228-06501
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

NOTICE: Make sure that the oil filter is installed securely as shown in the illustration.





g. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.

NOTICE: Remove all dirt and foreign matter from the installation surface.

h. Install the oil filter drain plug to the oil filter cap.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)

NOTICE: Make sure that the O-ring does not get caught between the parts.
105. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY





a. Apply adhesive around the drain cocks.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.





b. Install the cylinder block water drain cocks as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 inch lbs.)

NOTICE:
- Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks to the specified torque.
- Do not loosen the drain cocks after setting correctly.

c. Install the water drain cock plug to the water drain cocks.
Torque: 13 Nm (130 kgf-cm, 9 inch lbs.)





106. INSTALL OIL PIPE NO.1
a. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
b. Install the oil control valve filter LH to the oil pipe union. Install 2 new gaskets and temporarily install oil pipe No.1 (on the head cover side) with the oil pipe union.
c. Install a new gasket and temporarily install oil pipe No.1 (on the cylinder head side) with the oil pipe union.

NOTICE: Remove any oil from the contact surface.

NOTICE: Remove any oil from the contact surface.

d. Tighten the oil pipe union (on the head cover side).
Torque: 57 Nm (581 kgf-cm, 42 ft. lbs.)
e. Tighten the oil pipe union (on the cylinder head side).
Torque: 57 Nm (581 kgf-cm, 42 ft. lbs.)





107. INSTALL OIL PIPE
a. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
b. Install the oil control valve filter RH to the oil pipe union. Install 2 new gaskets and temporarily install oil pipe (on the head cover side) with the oil pipe union.

NOTICE: Remove any oil from the contact surface.

c. Install a new gasket and temporarily install oil pipe (on the cylinder head side) with the oil pipe union.

NOTICE: Remove any oil from the contact surface.

d. Install the bolt (A) to the cylinder head.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
e. Tighten the oil pipe union (on the head cover side).
Torque: 57 Nm (581 kgf-cm, 42 ft. lbs.)
f. Tighten the oil pipe union (on the cylinder head side).
Torque: 57 Nm (581 kgf-cm, 42 ft. lbs.)





108. INSTALL CRANK POSITION SENSOR
a. Install the crank position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





109. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Install the 4 camshaft timing oil control valves with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





110. INSTALL CAMSHAFT POSITION SENSOR
a. Install the 4 camshaft position sensors with the 4 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)





111. INSTALL VENTILATION VALVE SUB-ASSEMBLY
a. Apply adhesive around the ventilation valve.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.
b. Install the ventilation valve sub-assembly.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
112. INSTALL SPARK PLUG
a. Install the 6 spark plugs.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
113. INSTALL OIL FILLER CAP SUB-ASSEMBLY
a. Install the oil filler cap sub-assembly.