Engine Unit - Reassembly

1. Install stud bolt

2. Install straight pin

3. Install tight plug

4. Install oil jet

5. Install no. 1 oil nozzle sub-assembly

6. Install piston pin hole snap ring

7. Install with pin piston sub-assembly

8. Install piston pin hole snap ring

9. Install piston ring set

10. Install connecting rod bearing

11. Install crankshaft bearing

12. Install crankshaft

13. Install piston sub-assembly with connecting rod

14. Install ring pin

15. Install straight pin

16. Install stud bolt

17. Install union

18. Install tight plug

19. Install with head straight screw plug

20. Install valve stem oil o seal or ring

21. Install valve spring seat

22. Install valve

23. Install valve lifter

24. Install engine rear oil seal

25. Install engine rear oil seal retainer

26. Install knock sensor

27. Install no. 1 water outlet pipe

28. Install cylinder head gasket

29. Install cylinder head sub-assembly

30. Install no. 2 cylinder head gasket

31. Install cylinder head lh

32. Install no. 1 camshaft bearing

33. Install no. 2 camshaft bearing

34. Install camshafts

35. Install no. 2 chain tensioner assembly

36. Install camshaft timing gears and no. 2 chain (for bank 1)

37. Install no. 3 chain tensioner assembly

38. Install camshaft timing gears and no. 2 chain (for bank 2)

39. Install no. 1 chain vibration damper

40. Install crankshaft timing gear or sprocket

41. Install chain tensioner slipper

42. Install no. 1 chain tensioner assembly

43. Install chain sub-assembly

44. Install no. 2 chain vibration damper

45. Install no. 1 idle gear shaft

46. Install timing gear case or timing chain case oil seal

47. Install timing chain or belt cover sub-assembly

48. Install water pump assembly

49. Install oil pan sub-assembly

50. Install oil strainer sub-assembly

51. Install no. 2 oil pan sub-assembly

52. Install oil pan drain plug

53. Install crankshaft pulley

54. Set no. 1 cylinder to tdc / compression

55. Inspect valve clearance

56. Adjust valve clearance

57. Install cylinder head cover sub-assembly

58. Install cylinder head cover sub-assembly lh

59. Install oil control valve filter

60. Install crankshaft position sensor

61. Install vvt sensor

62. Install cylinder block water drain cock sub-assembly

63. Install oil level gauge guide

64. Install no. 2 engine hanger

65. Install no. 1 engine hanger

​

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

   Torque:

   For stud bolt A:

   11 N*m{112 kgf*cm, 8.1 ft.*lbf}

   For stud bolt B:

   4.5 N*m{46 kgf*cm, 40 in.*lbf}

   For stud bolt C:

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

   
   
   
   
   
   

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

   Standard protrusion:

   22.5 to 23.5 mm (0.886 to 0.925 in.) for pin A
   

   10.5 to 11.5 mm (0.413 to 0.453 in.) for pin B
   

   8.5 to 9.5 mm (0.335 to 0.374 in.) for pin C
   

   5.5 to 6.5 mm (0.217 to 0.256 in.) for pin D
   

   
   
   
   
   
   

1. Apply adhesive around the tight plugs.

   Adhesive:

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

2. Using SST, install 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.)
   

   
   
   
   
   
   

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

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

   Torque:

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

1. Using a screwdriver, install a new snap ring on one side of the piston pin hole.

   HINT:

   Check that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston.

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

2. Coat the piston pin with engine oil.

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

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

   HINT:

   Be sure that an end gap of the snap ring is not overlapped to the pin hole cutout portion of the piston.

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

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

   NOTICE:

   Install the No. 2 compression ring with the painted mark facing upward.

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

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

   NOTICE:

   Clean the backside of the bearing and the contact surface of the connecting rod and prevent oil from adhering to them.

HINT:

Main bearings come in widths of 19.0 mm (0.748 in.) and 22.4 mm (0.882 in.). Install the 22.4 mm (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.

2. 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.

3. 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:

   The number marked on each main bearing cap indicates the installation position.

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

2. 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.

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

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

5. Apply a light coat of engine oil to the threads of the bearing cap bolts.

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

7. Install the main bearing caps. Tighten the 2 bolts for each bearing cap until the clearance between the bearing cap and the cylinder block becomes less than 6 mm (0.23 in.).

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

9. Apply a light coat of engine oil to the threads of the main bearing cap bolts.

10. Install the 16 main bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

    Torque:

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

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

12. Retighten the bearing cap bolts 90° in the sequence as shown.

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

14. Check that the crankshaft turns smoothly.

15. Using several steps, tighten the 8 main bearing cap bolts uniformly in the sequence as shown in the illustration.

    Torque:

    26 N*m{262 kgf*cm, 19 ft.*lbf}

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

2. Check the positions of the piston ring ends.

3. 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 contact surface of the connecting rod cap and prevent oil from adhering to them.
      
   2. Match the numbered connecting rod cap with the connecting rod.
      

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

5. Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

6. Tighten the bolts alternately with the specified torque.

   Torque:

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

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

8. Retighten the cap bolts 90° as shown.

9. Check that the crankshaft turns smoothly.

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

   Specified protrusion height:

   2.7 to 3.3 mm (0.106 to 0.130 in.)
   

   
   
   
   
   
   

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

   Specified protrusion height:

   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.)

   
   
   
   
   
   

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

   Torque:

   For stud bolt A:

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

   For stud bolt B:

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

   For stud bolt C:

   20 N*m{199 kgf*cm, 14 ft.*lbf}

   
   
   
   
   
   

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

   Adhesive:

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

2. Using a deep socket wrench 12, install the unions.

   Torque:

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

   
   
   
   
   
   

1. Apply adhesive around the tight plug.

2. 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.)
   

   
   
   
   
   
   

1. Using a straight hexagon wrench 14, install a new gasket and straight screw plug.

   Torque:

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

   
   
   
   
   
   

HINT:

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

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

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

   SST

   09201-41020
   

1. Install the valve spring seat.

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

2. Place the cylinder head on a wooden block.

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

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

   SST

   09202-70020 (09202-00010)
   

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

   NOTICE:

   Be careful not to damage the valve stem tip.

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

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

1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.

   SST

   09223-78010
   

2. Apply MP grease to the oil seal lip.

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.

2. Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 in.)) to the oil seal retainer as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

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

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

   Torque:

   For nut:

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

   For bolt:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

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}

2. Connect the knock sensor connectors.

1. Install the water outlet pipe with the 3 bolts.

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

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.

2. Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

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

3. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

   NOTICE:

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

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

2. Install the 8 cylinder head bolts and plate washers.

   HINT:

   1. The cylinder head bolts are tightened in 2 successive steps (procedures "A" and "B").
      
   2. If any cylinder head bolt is broken or deformed, replace it.
      
   
   

   1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

   2. Install the plate washer to the cylinder head bolt.

   4. Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration (Procedure "A").

      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.

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

   7. Retighten the cylinder head bolts by 180° as shown (Procedure "B").

   8. Check that the painted marks are now at 180° opposite to the engine front.

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.

2. Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 in.)) to a new cylinder head gasket as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

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

3. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

   NOTICE:

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

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

2. Install the 8 cylinder head bolts and plate washers.

   HINT:

   1. The cylinder head bolts are tightened in 2 successive steps (procedures "A" and "B").
      
   2. If any cylinder head bolt is broken or deformed, replace it.
      
   
   

   1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

   2. Install the plate washer to the cylinder head bolt.

   4. Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration (Procedure "A").

      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.

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

   7. Retighten the cylinder head bolts by 180° as shown (Procedure "B").

   8. Check that the painted marks are now at 180° opposite to the engine front.

3. Install the 2 cylinder head bolts.
   

   1. Apply a light coat of engine oil to the threads of the cylinder head bolts.

   2. Install the 2 cylinder head bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

      Torque:

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

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 it with the oil hole in the bearing cap.
      
   2. Clean the backside of the bearing and the contact surface of the bearing cap and prevent oil from adhering to them.
      

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.

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.

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.

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

3. 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 facing each direction as shown in the illustration.

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

   4. Apply a light coat of engine oil to the threads of the bearing cap bolts.

   6. Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

      Torque:

      For 10 mm (0.39 in.) head:

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

      For 12 mm (0.47 in.) head:

      24 N*m{245 kgf*cm, 18 ft.*lbf}

   8. Turn the camshafts clockwise with a wrench until the camshaft knock pin comes 90° position to the cylinder head.

4. 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 facing as shown in the illustration.

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

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

   6. Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

      Torque:

      For 10 mm (0.39 in.) head:

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

      For 12 mm (0.47 in.) head:

      24 N*m{245 kgf*cm, 18 ft.*lbf}

1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

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

   Torque:

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

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

2. 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.

3. Temporarily install the 2 camshaft timing gear bolts.

   NOTICE:

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

4. 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}

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

1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

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

   Torque:

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

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

2. 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.

3. Temporarily install the 2 camshaft timing gear bolts.

   NOTICE:

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

4. 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}

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

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

   Torque:

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

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

2. Install the timing gear onto the crankshaft with the gear facing inward as shown in the illustration.

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

2. While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.

3. Install the chain tensioner with the 2 bolts.

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

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

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

   3. Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

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

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

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

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

2. Temporarily install the No. 1 idle gear shaft and No. 1 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.

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

   Torque:

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

4. Remove the bar from the chain tensioner.

1. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.

   SST

   09226-10010
   

2. Apply MP grease to the oil seal lip.

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.

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

3. Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 in.)) to 4 locations as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

4. Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 in.)) 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
   

   NOTICE:

   1. Install the timing chain cover within 3 minutes after applying seal packing. After installing it, the 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" as shown in the illustration.
      

5. Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.

6. Install the timing chain cover with the 15 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   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, install the water pump within 15 minutes.
      

   HINT:

   Each bolt length is as follows:

   A: 25 mm (0.98 in.)

   B: 55 mm (2.17 in.)

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

   Torque:

   For 10 mm (0.39 in.) head:

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

   For 12 mm (0.47 in.) head:

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

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.

2. Install the 4 stud bolts.

   Torque:

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

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

4. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) to the oil pan as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Install the oil pan within 3 minutes after applying seal packing. After installing it, the oil pan bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

5. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   For bolt A:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

   For bolt B:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

   For bolt C:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

   For nut:

   21 N*m{214 kgf*cm, 15 ft.*lbf}

   HINT:

   Each bolt length is as follows:

   A: 25 mm (0.98 in.)

   B: 45 mm (1.77 in.)

   C: 14 mm (0.55 in.)

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

   Torque:

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

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

2. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

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

3. Install the No. 2 oil pan with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   For bolt:

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

   For nut:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

1. Install the drain plug and a new gasket.

   Torque:

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

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}

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

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

1. Check the valves indicated in the illustration.
   

   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (Cold):

      Intake:

      0.15 to 0.25 mm (0.006 to 0.010 in.)
      

      Exhaust:

      0.29 to 0.39 mm (0.011 to 0.015 in.)
      

   2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.

2. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.
   

   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (Cold):

      Intake:

      0.15 to 0.25 mm (0.006 to 0.010 in.)
      

      Exhaust:

      0.29 to 0.39 mm (0.011 to 0.015 in.)
      

   2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.

3. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration.
   

   1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (Cold):

      Intake:

      0.15 to 0.25 mm (0.006 to 0.010 in.)
      

      Exhaust:

      0.29 to 0.39 mm (0.011 to 0.015 in.)
      

   2. Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.

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

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

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

   5. Place paint marks on the No. 1 chain links that correspond with the timing marks of the camshaft timing gears.

2. Remove the No. 1 chain tensioner assembly.

   NOTICE:

   1. Never rotate the crankshaft with the chain tensioner removed.
      
   2. When rotating the camshaft with the timing chain removed, turn the crankshaft counterclockwise 40° from the TDC first.
      
   
   
   2. Remove the 4 bolts, timing chain cover plate and gasket.

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

   5. While rotating the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.

   6. Remove the 2 bolts and chain tensioner.

3. Remove the No. 2 camshaft.

   NOTICE:

   As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. 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.

   
   
   2. While raising the No. 2 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

   4. Hold the hexagonal portion of the No. 2 camshaft with a wrench, and remove the camshaft timing gear set bolt.

      NOTICE:

      Be careful not to damage the cylinder head and valve lifter with the wrench.

   5. Separate the camshaft timing gear from the No. 2 camshaft.

   7. Rotate the camshaft counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face upward as shown in the illustration.

   9. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration.

   10. Remove the 4 bearing caps and No. 2 camshaft.

4. Remove the No. 2 chain tensioner assembly.
   

   1. Remove the No. 2 chain tensioner bolt, and then remove the No. 2 chain tensioner and camshaft timing gear.

5. Remove the camshaft.

   NOTICE:

   As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. 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.

   
   
   2. Hold the hexagonal portion of the No. 1 camshaft with a wrench, and loosen the camshaft timing gear set bolt.

      NOTICE:

      1. Be careful not to damage the cylinder head and valve lifter with the wrench.
         
      2. Do not disassemble the camshaft timing gear assembly.
         

   4. Slide the camshaft timing gear and separate the No. 1 chain from the camshaft timing gear.

   6. Rotate the No. 1 camshaft counterclockwise using a wrench so that the cam lobes of the No. 1 cylinder face upward as shown in the illustration.

   8. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration.

   9. Remove the 4 bearing caps.

   11. Remove the camshaft timing gear set bolt with the No. 1 camshaft lifted up, and then remove the No. 1 camshaft and camshaft timing gear with No. 2 chain.

   13. Tie the No. 1 chain with a string as shown in the illustration.

       NOTICE:

       Be careful not to drop anything inside the timing chain cover.

6. Remove the No. 4 camshaft sub-assembly.

   NOTICE:

   As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. 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.

   
   
   2. While pushing down the No. 3 chain tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

   4. Hold the hexagonal portion of the No. 4 camshaft with a wrench, and remove the camshaft timing gear set bolt.

      NOTICE:

      Be careful not to damage the cylinder head and valve lifter with the wrench.

   5. Separate the camshaft timing gear from the No. 4 camshaft.

   7. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration.

   8. Remove the 4 bearing caps and No. 4 camshaft.

7. Remove the No. 3 chain tensioner assembly.
   

   1. Remove the No. 3 chain tensioner bolt, and then remove the No. 3 chain tensioner and camshaft timing gear.

8. Remove the No. 3 camshaft sub-assembly.

   NOTICE:

   As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. 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.

   
   
   2. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence as shown in the illustration.

   3. Remove the 4 bearing caps.

   5. Hold the No. 1 chain, and remove the No. 3 camshaft, camshaft timing gear and No. 2 chain.

   7. Tie the No. 1 chain with a string as shown in the illustration.

      NOTICE:

      Be careful not to drop anything inside the timing chain cover.

9. Remove the valve lifters.

10. Determine the size of the valve lifter to be installed according to the following formulas or charts.
    

    1. Using a micrometer, measure the thickness of the removed lifter.

    2. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

       T:

       Thickness of removed lifter
       

       A:

       Measured valve clearance
       

       N:

       Thickness of new lifter
       

       Intake:

       N = T + (A - 0.20 mm (0.008 in.))
       

       Exhaust:

       N = T + (A - 0.30 mm (0.012 in.))
       

    3. Select a new lifter with a thickness as close as possible to the calculated value.

       HINT:

       Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).

       
       
       
       
       
       
       
       
       
       
       

11. Install the No. 3 camshaft sub-assembly.

    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.

    
    
    2. Align the mark link (yellow) with the timing mark (2-dot mark) of the camshaft timing gear as shown in the illustration.

    3. Apply new engine oil to the thrust portions and journals of the camshafts.

    5. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.

    7. Set the No. 3 camshaft onto the LH cylinder head with the cam lobes of the No. 2 cylinder facing downward as shown in the illustration.

    9. Install the 4 bearing caps in their proper locations.

    10. Apply a light coat of engine oil to the threads of the bearing cap bolts.

    12. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

        Torque:

        For 10 mm (0.39 in.) head:

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

        For 12 mm (0.47 in.) head:

        24 N*m{245 kgf*cm, 18 ft.*lbf}

    14. Set the paint mark of the No. 1 chain between the timing marks of the camshaft timing gear.

12. Install the No. 3 chain tensioner assembly.
    

    1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

    3. Temporarily install the camshaft timing gear and No. 3 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gears.

    4. Tighten the No. 3 chain tensioner bolt.

       Torque:

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

13. Install the No. 4 camshaft sub-assembly.

    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.

    
    
    2. Align the knock pin hole on the camshaft timing gear with the knock pin of the No. 4 camshaft, and insert the No. 4 camshaft into the camshaft timing gear.

    3. Temporarily install the camshaft timing gear set bolt.

    5. Install the 4 bearing caps in their proper locations.

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

    8. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

       Torque:

       For 10mm (0.39 in.) head:

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

       For 12 mm (0.47 in.) head:

       24 N*m{245 kgf*cm, 18 ft.*lbf}

    10. Hold the hexagonal portion of the No. 4 camshaft with a wrench, and tighten the camshaft timing gear set bolt.

        Torque:

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

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

14. Install the 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.

    
    
    2. Align the mark link (yellow) with the timing mark (1-dot mark) of the camshaft timing gear as shown in the illustration.

    3. Apply new engine oil to the thrust portions and journals of the camshafts.

    5. Temporarily put the No. 1 chain on the No. 2 chain of the camshaft timing gear.

    7. Align the knock pin hole of the camshaft timing gear with the knock pin of the No. 1 camshaft, and insert the No. 1 camshaft into the camshaft timing gear.

    8. Temporarily install the camshaft timing gear set bolt.

    10. Set the No. 1 camshaft onto the RH cylinder head with the cam lobes of the No. 1 cylinder facing downward as shown in the illustration.

    12. Install the 4 bearing caps in their proper locations.

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

    15. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

        Torque:

        For 10 mm (0.39 in.) head:

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

        For 12 mm (0.47 in.) head:

        24 N*m{245 kgf*cm, 18 ft.*lbf}

    17. Rotate the No. 1 camshaft clockwise using the hexagonal portion of the No. 1 camshaft so that the timing mark of the camshaft timing gear is aligned with the timing mark of the camshaft bearing cap.

    19. Align the paint mark of the No. 1 chain with the timing mark of the camshaft timing gear.

    21. Hold the hexagonal portion of the No. 1 camshaft with a wrench, and tighten the camshaft timing gear set bolt.

        Torque:

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

15. Install the No. 2 chain tensioner assembly.
    

    1. While pushing in the tensioner, insert a pin of φ1.0 mm (0.039 in.) into the hole to fix it.

    3. Temporarily install the camshaft timing gear and No. 2 chain tensioner and align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gears.

    4. Tighten the No. 2 chain tensioner bolt.

       Torque:

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

16. Install the No. 2 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.

    
    
    2. Set the No. 2 camshaft onto the RH cylinder head with the cam lobes of No. 1 cylinder facing upward as shown in the illustration.

    4. Install the 4 bearing caps in their proper locations.

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

    7. Install the 8 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.

       Torque:

       For 10 mm (0.39 in.) head:

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

       For 12 mm (0.47 in.) head:

       24 N*m{245 kgf*cm, 18 ft.*lbf}

    9. Rotate the No. 2 camshaft clockwise using a wrench so that the knock pin of the No. 2 camshaft is aligned with the knock pin hole of the camshaft timing gear.

    11. Hold the hexagonal portion of the No. 2 camshaft with a wrench, and install the camshaft timing gear set bolt.

        Torque:

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

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

17. Install the No. 1 chain tensioner assembly.
    

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

    2. While turning the stopper plate of the tensioner counterclockwise, insert a bar of φ3.5 mm (0.138 in.) into the holes on the stopper plate and tensioner to fix the stopper plate.

    3. Install the chain tensioner with the 2 bolts.

       Torque:

       10 N*m{102 kgf*cm, 7 ft.*lbf}

    4. Remove the bar from the chain tensioner.

    5. Install a new gasket and the timing chain cover plate with the 4 bolts.

       Torque:

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

    7. Turn the crankshaft pulley 2 complete revolutions slowly, and align the notch with the timing mark "0" of the timing chain cover.

    9. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.

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.

2. Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.

   Seal packing::

   Part No. 08826-00080 or equivalent
   

   NOTICE:

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

3. Install the gasket to the cylinder head cover.

4. Install the seal washers to the bolts.

5. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   For bolt A:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

   For bolt B:

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

   For nut:

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

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.

2. Apply adhesive to the threads of the ventilation valve.

   Adhesive:

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

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

   Torque:

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

4. Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 in.)) to the cylinder head and timing chain cover as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

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

5. Install the gasket to the cylinder head cover.

6. Install the seal washers to the bolts.

7. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.

   Torque:

   For bolt A:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

   For bolt B:

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

   For nut:

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

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

2. Install 2 new gaskets to each new plug.

3. Insert the filters to the plugs.

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

   Adhesive:

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

5. Install the plugs to each cylinder head.

   Torque:

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

1. Install the crankshaft position sensor with the bolt.

   Torque:

   10 N*m{102 kgf*cm, 7 ft.*lbf}

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

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

   Torque:

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

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

   Adhesive:

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

2. After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.

   Torque:

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

   NOTICE:

   1. Install the drain cock within 3 minutes after applying adhesive.
      
   2. Do not expose the drain cock to coolant within 1 hour after installing.
      
   3. Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock with the specified torque.
      
   4. Do not loosen the drain cock after setting it correctly.
      

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

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

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

4. Install the oil level gauge guide with the bolt.

   Torque:

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

1. Install the engine hanger with the 2 bolts.

   Torque:

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

1. Install the engine hanger with the 2 bolts.

   Torque:

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