ENGINE UNIT > REASSEMBLY

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1. INSTALL STUD BOLT


  1. Install the stud bolts as shown in the illustration.

    Torque:
    11 N*m{ 112 kgf*cm , 8.1 ft.*lbf } for stud bolt A
    4.5 N*m{ 46 kgf*cm , 40 in.*lbf } for stud bolt B
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf } for stud bolt C



    A076061E03



2. INSTALL STRAIGHT PIN


  1. Using a plastic-faced hammer, tap into the straight pin.

    Standard protrusion:
    Pin A 22.5 to 23.5 mm (0.886 to 0.925 in.)
    Pin B 10.5 to 11.5 mm (0.413 to 0.453 in.)
    Pin C 8.5 to 9.5 mm (0.335 to 0.374 in.)
    Pin D 5.5 to 6.5 mm (0.217 to 0.256 in.)



    A076062E03



3. INSTALL TIGHT PLUG

  1. Apply adhesive around tight plugs.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent.



  1. Using SST, tap in the tight plugs as shown in the illustration.

    SST
    09950-60010   (09951-00350)
    09950-70010   (09951-07150)

    Standard depth:
    0.2 to 1.2 mm (0.008 to 0.047 in.)



    A076064E03



4. INSTALL OIL JET


    A076392E01

  1. Using a screwdriver and hammer, tap in a oil jet.



5. INSTALL OIL NOZZLE


    A076051E01

  1. Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



6. INSTALL PISTON PIN HOLE SNAP RING


    A032958E01

  1. Using a small screwdriver, install a new snap ring at one end of the piston pin hole.

    HINT:
    Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston.



7. INSTALL PISTON


    P012417E04

  1. Gradually heat the piston to about 80°C (176°F).



    A075846E01

  1. Coat the piston pin with engine oil.

  1. Align the front marks of the piston and connecting rod, and push in the piston pin with thumb.



8. INSTALL PISTON PIN HOLE SNAP RING


    A032958E01

  1. Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.

    HINT:
    Be sure that end of gap of the snap ring is not aligned with the pin hole cutout portion of the piston.



9. INSTALL PISTON RING SET


    A076073E01

  1. Install the oil ring expander and 2 side rails by hand.

  1. Using a piston ring expander, install the 2 compression rings.

    NOTICE:
    Install the No. 2 compression ring with the painted mark facing right side.



    A076074E01

  1. Position the piston rings so that the ring ends are as shown.



10. INSTALL CONNECTING ROD BEARING


    P012402E01

  1. Align the bearing claw with the groove of the connecting rod or connecting cap.

    NOTICE:
    Clean the backside of the bearing and the bearing surface of the connecting rod and let not stick the oils and fats.



11. INSTALL CRANKSHAFT BEARING


A076063E05

HINT:
Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4mm (0.882 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No. 2 and No. 3 positions.

  1. Clean each main journal and bearing.



    P012599E01

  1. Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.

    NOTICE:
    Do not apply engine oil to the bearing and its contact surface.



    A076065E01

  1. Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

    NOTICE:
    Do not apply engine oil to the bearing and its contact surface.

    HINT:
    A number is marked on each main bearing cap to indicate the installation position.



12. INSTALL CRANKSHAFT

  1. Apply engine oil to upper bearing and install the crankshaft on the cylinder block.



    A076393E01

  1. Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block.

    1. Push the crankshaft toward the front (rear) side.

    2. Install the 2 upper thrust washers with the oil grooves facing outward.



    A076075E01

  1. Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward.



    A076067E01

  1. Examine the front marks and numbers and install the bearing caps on the cylinder block.

  1. Apply a light coat of engine oil on the threads and under the head of bearing cap bolts.

  1. Temporarily install the 8 main bearing cap bolts to the inside positions.



    A076069E01

  1. Insert the main bearing cap with hand until the clearance between the main bearing cap and the cylinder block will become less than 6mm (0.23 in.) by making the 2 internal bearing cap bolts as a guide.



    A076070E01

  1. Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.



    A076071E02

  1. Apply a light coat of engine oil on the threads and under the head of main bearing cap bolts.

  1. Install and uniformly tighten the 16 main bearing cap bolts in several passes, in the sequence shown.

    Torque:
    61 N*m{ 622 kgf*cm , 45 ft.*lbf }



    A076072E02

  1. Mark the front side of the bearing cap bolts with paint.

  1. Retighten the bearing cap bolts by 90°C in the sequence shown.

  1. Check that the painted mark is now at a 90°angle to the front.

  1. Check that the crankshaft turns smoothly.



    A075843E02

  1. Install and uniformly tighten the 8 main bearing cap bolts in several passes, in the sequence shown.

    Torque:
    35 N*m{ 357 kgf*cm , 26 ft.*lbf }



13. INSTALL PISTON WITH CONNECTING ROD


    A076385E01

  1. Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.

  1. Check the position of the piston ring ends.

  1. Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward.

    NOTICE:
    1. Clean the backside of the bearing and the bearing surface of the connecting rod cap and let not stick the oils and fats.
    2. Match the numbered connecting rod cap with the connecting rod.

  1. Check that the protrusion of the connecting rod cap is facing in the correct direction.

  1. Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts.



    A075150E02

  1. Using SST, tighten the bolts in several passes by the specified torque.

    SST
    09011-38121  

    Torque:
    25 N*m{ 250 kgf*cm , 18 ft.*lbf }



    A075151E02

  1. Mark the front side of the each connecting cap bolt with paint.

  1. Retighten the cap bolts by 90° as shown.

  1. Check that the crankshaft turns smoothly.



14. INSTALL RING PIN


  1. Using a plastic-faced hammer, tap in the new ring pins to the specified protrusion height.

    Specified protrusion height:
    2.7 to 3.3 mm (0.106 to 0.130 in.)



    A075625E03



15. INSTALL STRAIGHT PIN


  1. Using a plastic-faced hammer, tap in the new straight pins to the specified protrusion height.

    Specified protrusion height:
    Item
    		Specified Condition
    A
    		17.5 to 19.5 mm (0.689 to 0.768 in.)
    B
    		7.5 to 8.5 mm (0.295 to 0.335 in.)
    C
    		7.0 to 9.0 mm (0.276 to 0.354 in.)



    A075627E03



16. INSTALL STUD BOLT


  1. Using E5 and E7 "torx" socket wrench, install the stud bolts.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf } for stud bolt A
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf } for stud bolt B



    A075629E03



17. INSTALL UNION


    A075631E02

  1. Apply adhesive to 2 or 3 threads of the bolt end.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent



  1. Using a 12 mm deep socket wrench, install the unions.

    Torque:
    15 N*m{ 150 kgf*cm , 11 ft.*lbf }



    A075632E03



18. INSTALL TIGHT PLUG


    A058129E06

  1. Apply adhesive around tight plug.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent



  1. Using SST, tap in the tight plugs to the specified depth.

    SST
    09950-60010   (09951-00250)
    09950-70010   (09951-07150)

    Specified depth:
    1.5 mm (0.059 in.)



    A075633E02



19. INSTALL WITH HEAD STRAIGHT SCREW PLUG


  1. Using a 16 mm hexagon wrench, install a new gasket and straight screw plug.

    Torque:
    80 N*m{ 816 kgf*cm , 59 ft.*lbf }



    A075634E02



20. INSTALL VALVE STEM OIL SEAL

HINT:
The intake valve stem oil seal is light brown and the exhaust valve stem oil seal is gray.



    A076162E01

  1. Apply a light coat of engine oil to the valve guide bush.



    A075639E01

  1. Using SST, push in a new valve stem oil seal.

    SST
    09201-41020  



21. INSTALL VALVE SPRING SEAT


A075638E01


22. INSTALL VALVE


    A075640E01

  1. Apply the engine oil to the valve as shown in the illustration.



    A075602E01

  1. Place the cylinder head on the wooden block.

  1. Install the valve, inner compression spring and valve spring retainer.

  1. Using SST, compress the inner compression spring and place the 2 valve spring retainer locks around the valve stem.

    SST
    09202-70020   (09202-00010)



    A075641E01

  1. Using a 5 mm pin punch, lightly tap the valve stem tip to ensure a proper fit.

    NOTICE:
    Be careful not to damage the valve stem tip.



23. INSTALL VALVE LIFTER


    A075601E01

  1. Apply the engine oil to the valve stem end and valve lifter, and install its.

  1. Check that the valve lifter rotates smoothly by hand.



24. INSTALL ENGINE REAR OIL SEAL RETAINER


    A076269E02

  1. 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. Apply a continuous line of the seal packing to the oil seal retainer as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2 to 3 mm (0.08 to 0.12 in.)

    NOTICE:
    Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied.

  1. Install the oil seal retainer with the 5 bolts and 2 nuts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



25. INSTALL KNOCK SENSOR


    A078438E01

  1. Install the 2 knock sensors with the 2 bolts as shown in the illustration.

    Torque:
    20 N*m{ 204 kgf*cm , 15 ft.*lbf }

  1. Connect the knock sensor connectors.



26. INSTALL NO. 1 WATER OUTLET PIPE


    A076246E01

  1. Install the water outlet pipe with the bolt and 2 nuts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



27. INSTALL CYLINDER HEAD GASKET

  1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.



    A076271E01

  1. Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2.5 to 3 mm (0.098 to 0.118 in.)

    NOTICE:
    Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.



    A076272E02

  1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

    NOTICE:
    1. Be careful of the installation direction.
    2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.



28. INSTALL CYLINDER HEAD

  1. Place the RH cylinder head on the cylinder head gasket.



  1. Install the 8 cylinder head bolts.

    HINT:
    1. The cylinder head bolts are tightened in 2 progressive steps.
    2. 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. A076273E02

    3. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque.

      Torque:
      36 N*m{ 367 kgf*cm , 27 ft.*lbf }

      If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

      NOTICE:
      Do not drop the washers into the cylinder head.



      4. A076274E01

    4. Mark the front side of each cylinder head bolt with paint.

    5. Retighten the cylinder head bolts by 180° in the numerical order shown.

    6. Check that the painted marks are now a 180° angle to the front.



29. INSTALL NO. 2 CYLINDER HEAD GASKET

  1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.



    A076275E01

  1. Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2.5 to 3 mm (0.098 to 0.118 in.)

    NOTICE:
    Install the cylinder head within 3 minutes after applying seal packing. After installing it, cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.



    A076276E01

  1. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

    NOTICE:
    1. Be careful of the installation direction.
    2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.



30. INSTALL CYLINDER HEAD LH

  1. Place the LH cylinder head on the cylinder head gasket.



  1. Install the 8 cylinder head bolts.

    HINT:
    1. The cylinder head bolts are tightened in 2 progressive steps.
    2. 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. A076277E01

    3. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque.

      Torque:
      36 N*m{ 367 kgf*cm , 27 ft.*lbf }

      If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

      NOTICE:
      Do not drop the washers into the cylinder head.



      4. A076274E01

    4. Mark the front side of each cylinder head bolt with paint.

    5. Retighten the cylinder head bolts by 180°in the numerical order shown.

    6. Check that the painted marks are now a 180° angle to the front.



    A072969E03

  1. Install the 2 cylinder head bolts.

    1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

    2. Install and uniformly tighten the 2 cylinder head bolts, in several passes, in the sequence shown.

      Torque:
      30 N*m{ 306 kgf*cm , 22 ft.*lbf }



31. INSTALL NO. 1 CAMSHAFT BEARING


    A076278E01

  1. Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.

    NOTICE:
    1. Install the bearing while aligning with the oil hole in the bearing cap.
    2. Clean the backside of the bearing and the bearing surface of the bearing cap and let not stick the oils and fats.



32. INSTALL NO. 2 CAMSHAFT BEARING


    A076279E01

  1. Install the No. 2 camshaft bearing to the cylinder head.

    NOTICE:
    Clean the backside of the bearing and the bearing surface of the cylinder head and let not stick the oils and fats.



33. INSTALL CAMSHAFT

NOTICE:
As 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 which receives 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.



    A076280E01

  1. Set the crankshaft position.

    1. Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position.

      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.

  1. Apply new engine oil to the thrust portion and journal of the camshafts.



    A076281E01

  1. Install the camshaft of the RH bank.

    1. Place the 2 camshafts onto the RH cylinder head with the cam lobes of No. 1 cylinder faced as shown in the illustration.



      2. A076282E01

    2. Install the 8 bearing caps in their proper locations.

    3. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.



      4. A072967E04

    4. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.

      Torque:
      9.0 N*m{ 92 kgf*cm , 80 in.*lbf } for 10 mm (0.39 in.) head
      24 N*m{ 245 kgf*cm , 18 ft.*lbf } for 12 mm (0.47 in.) head (A)



      5. A076283E01

    5. Rotate the camshafts clockwise using hexagonal portion of the each camshaft at 90° angle of the camshaft knock pin on the cylinder head.



    A076284E01

  1. Install the camshafts of the LH bank.

    1. Place the 2 camshafts onto the LH cylinder head with the cam lobes of No. 2 cylinder faced as shown in the illustration.



      2. A076285E01

    2. Install the 8 bearing caps in their proper locations.

    3. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.



      4. A072968E04

    4. Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.

      Torque:
      9.0 N*m{ 92 kgf*cm , 80 in.*lbf } for 10 mm (0.39 in.) head
      24 N*m{ 245 kgf*cm , 18 ft.*lbf } for 12 mm (0.47 in.) head (A)



34. INSTALL NO. 2 CHAIN TENSIONER


    A076286E01

  1. While pushing in the tensioner, insert a pin of diameter of 1.0 mm (0.039 in.) into the hole to fix it.



    A072962E01

  1. Install the No. 2 chain tensioner with the bolt.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



35. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (RH BANK)


    A076287E02

  1. Align the mark links (yellow) with the timing marks (1 dot mark) of camshaft timing gears as shown in the illustration.



    G036841E01

  1. 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 RH camshafts.

  1. Temporarily install the 2 camshaft timing gear bolts.

    NOTICE:
    Do not push camshaft timing gear assembly to the camshaft forcibly when installing it.



    G036834E02

  1. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

    Torque:
    100 N*m{ 1,020 kgf*cm , 74 ft.*lbf }

  1. Remove the pin from the No. 2 chain tensioner.



36. INSTALL NO. 3 CHAIN TENSIONER


    A076289E01

  1. While pushing in the tensioner, insert a pin of diameter of 1.0 mm (0.039 in.) into the hole to hold it.



    A072965E01

  1. Install the No. 3 chain tensioner with the bolt.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



37. INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (LH BANK)


    A076290E02

  1. Align the mark links (yellow) with the timing marks (1 dot mark and 2 dot mark) of camshaft timing gears as shown in the illustration.



    G036852E01

  1. 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.

  1. Temporarily install the 2 camshaft timing gear bolts.

    NOTICE:
    Do not push camshaft timing gear assembly to the camshaft forcibly when installing it.



    G036836E02

  1. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

    Torque:
    100 N*m{ 1,020 kgf*cm , 74 ft.*lbf }

  1. Remove the pin from the No. 3 chain tensioner.



38. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    A076292E01

  1. Install the No. 1 chain vibration damper with the 2 bolts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }



39. INSTALL CAMSHAFT TIMING SPROCKET


    A076293E01

  1. Align the timing gear set key with the key groove of the timing gear.

  1. Install the timing gear onto the crankshaft, facing the gear side inward.



40. INSTALL CHAIN TENSIONER SLIPPER


41. INSTALL NO. 1 CHAIN TENSIONER


    A076294E01

  1. While rotating the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

  1. While rotating the stopper plate of the tensioner counterclockwise, insert a bar of diameter of 3.5 mm (0.138 in.) into the holes in the stopper plate and tensioner to fix the stopper plate.

  1. Install the chain tensioner with the 2 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



42. INSTALL CHAIN


    G036843E02

  1. Set the No. 1 cylinder to TDC/compression.

    1. Align the timing marks of the camshaft timing gears and bearing caps.



      2. A076296E01

    2. Using the crankshaft pulley set bolt, turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.



    A076297E02

  1. Align the mark link (yellow) with the timing mark of the crankshaft timing gear.



    G036259E01

  1. Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.



43. INSTALL NO .2 CHAIN VIBRATION DAMPER


    G036844E01

  1. Install the 2 No. 2 chain vibration dampers.



44. INSTALL NO. 1 IDLE GEAR

  1. Apply a light coat of engine oil to rotating surface of the No. 1 idle gear shaft.



    A076299E01

  1. Temporarily install the No. 1 idle gear shaft and idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

    NOTICE:
    Be careful of the idle gear direction.

  1. Using a 10 mm hexagon wrench, tighten the No. 2 idle gear shaft.

    Torque:
    60 N*m{ 612 kgf*cm , 44 ft.*lbf }

  1. Remove the bar from the chain tensioner.



45. INSTALL TIMING CHAIN COVER

  1. 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.



    G036845E01

  1. Install a new O-ring to the LH cylinder head as shown in the illustration.



    G036846E01

  1. Apply a continuous bead of the seal packing to 4 locations as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3 to 4 mm (0.12 to 0.16 in.)



    A076303E03

  1. Apply a continuous bead of the seal packing 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

    Seal diameter:
    3 to 4 mm (0.12 to 0.16 in.)

    NOTICE:
    1. 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.
    2. Do not apply seal packing to the "A" position.



    A076304E01

  1. Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft timing gear, and slide the timing chain cover.



    G036855E02

  1. Install the timing chain cover with the 15 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    23 N*m{ 235 kgf*cm , 17 ft.*lbf }

    NOTICE:
    1. Pay attention not to wrap the chain and slipper over the timing chain cover seal line.
    2. After installing the timing chain cover, must install the water pump within 15 minutes.

    HINT:
    Each bolt length in indicated in the illustration.
    A: 25 mm (0.98 in.)
    B: 55 mm (2.17 in.)



46. INSTALL WATER PUMP


    A072954E01

  1. Install a new gasket and the water pump with the 17 bolts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf } for 10 mm (0.39 in.) head
    23 N*m{ 235 kgf*cm , 17 ft.*lbf } for 12 mm (0.49 in.) head



47. INSTALL NO. 1 OIL PAN

  1. 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.



    A113398E01

  1. Install the 4 stud bolts.

    Torque:
    4.0 N*m{ 41 kgf*cm , 35 in.*lbf }



    A076306E01

  1. Install a new O-ring to the oil pump.



    A112959E01

  1. Apply a continuous line of the seal packing to the oil pan as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3 to 4 mm (0.12 to 0.16 in.)

    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.



    A113803E01

  1. Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf } for bolt A, B and nut
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf } for bolt C

    HINT:
    Each bolt length in indicated in the illustration.
    A: 25 mm (0.98 in.)
    B: 40 mm (1.57 in.)
    C: 14 mm (0.55 in.)

    NOTICE:
    The bolts indicated by starts in the illustration are precoated parts. When reusing them, apply adhesive to 2 or 3 threads before installation.

    Adhesive:
    Part No. 08833-00070, THEE BOND 1324 or equivalent



48. INSTALL OIL STRAINER


    A112955

  1. Install a new gasket and the oil strainer with the 2 nuts.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



49. INSTALL NO. 2 OIL PAN

  1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 2 oil pan and oil pan.



    A112960E01

  1. Apply a continuous line of the seal packing as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    3 to 4 mm (0.12 to 0.16 in.)

    NOTICE:
    Install the oil pan No. 2 within 3 minutes after applying seal packing. After installing it, No. 2 oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.



    A112956E01

  1. Install the No. 2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



50. INSTALL OIL PAN DRAIN PLUG

  1. Install the drain plug with a new gasket.

    Torque:
    40 N*m{ 408 kgf*cm , 30 ft.*lbf }



51. INSTALL CRANKSHAFT PULLEY


    A076309E01

  1. Using SST, install the pulley set bolt.

    SST
    09213-54015   (91651-60855)
    09330-00021  

    Torque:
    250 N*m{ 2,549 kgf*cm , 184 ft.*lbf }



52. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    A072945E01

  1. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.



    G038065E01

  1. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.
    If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.



53. INSPECT VALVE CLEARANCE


54. INSTALL CYLINDER HEAD COVER RH

  1. 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.

  1. Install the gasket to the cylinder head cover.



    A076310E01

  1. Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.

    Seal packing:
    Part No. 0882-00080 or equivalent

    Seal diameter:
    2 to 3 mm (0.08 to 0.12 in.)

    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.

  1. Install the seal washers to the bolts.



    A072943E01

  1. Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



55. INSTALL CYLINDER HEAD COVER LH

  1. 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.

  1. Apply adhesive on the threads of the ventilation valve.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent

  1. Install the ventilation valve to the cylinder head cover.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }

  1. Install the gasket to the cylinder head cover.



    A076311E01

  1. Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    2 to 3 mm (0.08 to 0.12 in.)

    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.

  1. Install the seal washers to the bolts.



    A072944E01

  1. Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



56. INSTALL OIL CONTROL VALVE FILTER


    A076312E01

  1. Check that no foreign objects on the mesh part of the 2 filters.

  1. Install 2 new gaskets to each new plug.

  1. Insert the filters to the plugs.

  1. Apply adhesive to 2 or 3 threads of the plugs.

    Adhesive:
    Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent

  1. Install the plugs to each cylinder head.

    Torque:
    62 N*m{ 632 kgf*cm , 46 ft.*lbf }



57. INSTALL CRANKSHAFT POSITION SENSOR

  1. Install the crankshaft position sensor with the bolt.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



58. INSTALL VVT SENSOR

  1. Apply a light coat of engine oil to the O-ring of each VVT sensor.

  1. Install the 2 VVT sensors with the 2 bolts.

    Torque:
    8.0 N*m{ 82 kgf*cm , 71 in.*lbf }



59. INSTALL CYLINDER BLOCK WATER DRAIN COCK


    A076531E02

  1. Apply adhesive to 2 or 3 threads of the drain cocks end.

    Adhesive:
    Part No. 08833-00070, THREE BOND 1324 or equivalent



    A076313E01

  1. After applying the specified torque, rotate the drain cocks clockwise as shown in the illustration.

    Torque:
    25 N*m{ 255 kgf*cm , 18 ft.*lbf }

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



60. INSTALL OIL DIPSTICK GUIDE


    A112958E01

  1. Install a new O-ring to the oil level gauge guide.

  1. Apply a light coat of engine oil to the O-ring.

  1. Push in the oil level gauge guide end into the guide hole of the oil pan.

  1. Install the oil dipstick gauge guide with the bolt.

    Torque:
    9.0 N*m{ 92 kgf*cm , 80 in.*lbf }



61. INSTALL NO. 2 ENGINE HANGER


    A072941E01

  1. Install the engine hanger with the 2 bolts.

    Torque:
    33 N*m{ 336 kgf*cm , 24 ft.*lbf }



62. INSTALL NO.1 ENGINE HANGER

  1. Install the engine hanger with the 2 bolts.

    Torque:
    33 N*m{ 336 kgf*cm , 24 ft.*lbf }