Engine Unit - Reassembly

1. Install tight plug

2. Install stud bolt

3. Install straight pin

4. Install ring pin

5. Install piston

6. Install piston ring set

7. Install connecting rod bearing

8. Install crankshaft bearing

9. Install crankshaft thrust washer set

10. Install crankshaft pulley set crankshaft key

11. Install crankshaft

12. Install piston and connecting rod

13. Install no. 1 tight plug

14. Install camshaft bearing cap setting ring pin

15. Install stud bolt

16. Install valve stem oil seal

17. Install valve

18. Install valve lifter

19. Install spark plug tube gasket

20. Install camshaft setting oil seal

21. Install camshaft timing tube assembly

22. Install camshaft sub gear

23. Install oil pump seal

24. Install engine rear oil seal

25. Install engine rear oil seal retainer

26. Install oil pump assembly

27. Install oil strainer sub-assembly

28. Install stud bolt

29. Install oil pan sub-assembly

30. Install oil pan baffle plate

31. Install no. 2 oil pan sub-assembly

32. Install water pump assembly

33. Install cylinder head sub-assembly

34. Install camshafts

35. Install rear timing belt plate rh

36. Install no. 2 rear timing belt plate rh

37. Install rear timing belt plate lh

38. Install no. 2 rear timing belt plate lh

39. Install crankshaft timing pulley

40. Install no. 2 timing belt idler sub-assembly

41. Install no. 1 timing belt idler sub-assembly

42. Install camshaft timing pulleys

43. Install timing belt

44. Install no. 1 crankshaft position sensor plate

45. Install timing gear cover spacer

46. Install no. 1 timing belt cover

47. Install crankshaft damper sub-assembly

48. Inspect valve clearance

49. Adjust valve clearance

50. Install fan bracket sub-assembly

51. Install v-ribbed belt tensioner assembly

52. Install no. 2 timing belt cover sub-assembly

53. Install no. 2 idler pulley sub-assembly

54. Install semicircular plug

55. Install cylinder head cover

56. Install oil filler cap housing

57. Install oil filler cap sub-assembly

58. Install spark plug

59. Install cylinder block water drain cock sub-assembly

60. Install engine hangers

​

HINT:

1. Thoroughly clean all parts to be assembled.
   
2. Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
   
3. Replace all gaskets, O-rings and oil seals with new ones.
   

1. Install the tight plug.
   

   
   
   
   
   
   2. Apply adhesive to the tight plug.

      Adhesive:

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

   3. Using SST and a hammer, tap in a new tight plug as shown in the illustration.

      SST

      09950-60010 (09951-00350)
      09950-70010 (09951-07100)
      

1. Install the stud bolt.
   

   
   
   
   

   Torque:

   For A:

   8.0 N*m{80 kgf*cm, 71 in.*lbf}

   For B:

   20 N*m{200 kgf*cm, 14 ft.*lbf}

   For C:

   12 N*m{120 kgf*cm, 9 ft.*lbf}

   For D:

   14 N*m{145 kgf*cm, 10 ft.*lbf}

   For E:

   8.0 N*m{80 kgf*cm, 71 ft.*lbf}

1. Install the straight pin.
   

   
   
   
   

1. Install the ring pin.
   

   
   
   
   

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

2. Gradually heat the piston to about 60°C (140°F).

3. Coat the piston pin with engine oil.

4. Position the piston front mark with respect to the outside mark on the connecting rod as shown in the illustration.

   NOTICE:

   The installation directions of the piston and connecting rod are different for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".

5. Align the piston pin holes of the piston and connecting rod, and push in the piston pin with your thumb.

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

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

2. Using a piston ring expander, install the 2 piston rings with the code mark facing upward.

   Code mark:

   No. 1	None
   No. 2	2R

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

   NOTICE:

   Do not align the ring ends.

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

2. Install the bearings in the connecting rod and connecting rod cap.

HINT:

1. Main bearings come in widths of 19.5 mm (0.768 in.) and 22.5 mm (0.886 in.). Install the 22.5 mm (0.886 in.) bearings in the No. 1 and No. 5 cylinder block journal positions with the crankshaft bearing cap. Install the 19.5 mm (0.768 in.) bearings in the other positions.
   
2. Upper bearings have an oil groove and oil holes; lower bearings do not.
   

1. Align the bearing claw with the claw groove of the cylinder block, and push in the 5 upper bearings.

2. Align the bearing claw with the claw groove of the crankshaft bearing cap, and push in the 5 lower bearings.

   HINT:

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

1. Install the 2 thrust washers under the No. 3 journal position of the cylinder block with the oil grooves facing outward.

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

1. Place the crankshaft on the cylinder block.

2. Install the 5 crankshaft bearing caps in their proper locations.

   HINT:

   Place the bearing caps level and let them return to their original positions by their own weight.

   NOTICE:

   Do not install the bearing cap by tapping it.

3. Install the crankshaft bearing cap bolts.

   HINT:

   1. The bearing cap bolts are tightened in 2 progressive steps.
      
   2. If any one of the bearing cap bolts is broken or deformed, replace it.
      
   
   

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

   2. Install and uniformly tighten the 10 crankshaft bearing cap bolts in several steps, in the order shown in the illustration.

      Torque:

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

      If any one of the bearing cap bolts does not meet the torque specification, replace the bearing cap bolt.
      

   4. Mark the front of the crankshaft bearing cap bolts with paint.

   5. Retighten the crankshaft bearing cap bolts by 90° in the order shown.

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

   7. Check that the crankshaft turns smoothly.

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:

   The shape of the piston varies for the LH and RH banks. The LH piston is marked with 1 cavity and "2", the RH piston with 2 cavities and "2".

2. Place the connecting rod cap on the connecting rod.
   

   1. Match the numbered connecting rod cap with the connecting rod.

   2. Align the pin groove of the connecting rod cap with the pins of the connecting rod, and install the connecting rod cap.

   4. Check that the outside mark of the connecting rod cap is facing in the correct direction.

3. Install the connecting rod cap bolts.

   HINT:

   1. The connecting rod cap bolts are tightened in 2 progressive steps.
      
   2. If any one of the connecting rod cap bolts is broken or deformed, replace it.
      
   
   

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

   2. Install and alternately tighten the 2 connecting rod cap bolts in several steps.

      Torque:

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

      If any one of the connecting rod cap bolts does not meet the torque specification, replace the connecting rod cap bolts.
      

   4. Mark the front of the connecting cap bolt with paint.

   5. Retighten the cap bolts 90° as shown in the illustration.

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

4. Check that the crankshaft turns smoothly.

1. Apply adhesive to the tight plug.

   Adhesive:

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

2. Using SST and a hammer, tap in a new tight plug as shown in the illustration.

   SST

   09950-60010 (09951-00300)
   09950-70010 (09951-07100)
   

1. Install the camshaft bearing cap setting ring pin.
   

   
   
   
   

1. Install the stud bolt.
   

   
   
   
   

   Torque:

   For A and C:

   9.0 N*m{90 kgf*cm, 80 in.*lbf}

   For B:

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

1. Apply a light coat of engine oil to a new oil seal.

   NOTICE:

   Pay close attention when installing the intake and exhaust oil seals. For example, installing the intake oil seal into the exhaust or installing the exhaust oil seal to the intake can cause installation problems later.

   HINT:

   The intake valve oil seal is gray/brown and the exhaust valve oil seal is black/gray.

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

   SST

   09201-41020
   

   NOTICE:

   Failure to use SST will cause the seal to be damaged or improperly seated.

1. Install the following parts:
   

   1. Valve (1)

   2. Spring seat (2)

   3. Valve spring (3)

   4. Spring retainer (4)

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

   SST

   09202-70020 (09202-00010)
   

3. Using a plastic hammer and the valve stem (not in use) tip wrapped with vinyl tape, lightly tap the valve stem tip to assure proper fit.

   NOTICE:

   Be careful not do damage the valve stem tip.

1. Install the valve lifter and shim.

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

1. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.

   SST

   09950-60010 (09951-00240, 09951-00440, 09952-06010)
   09950-70010 (09951-07100)
   

   NOTICE:

   Be careful of the installation direction.

2. Apply a light coat of MP grease to the gasket lip.

3. Return the 4 ventilation case claws to the original positions.

1. Insert a new oil seal into the camshaft timing tube until it reaches the stopper.

   NOTICE:

   1. Be careful of the installation direction.
      
   2. Do not turn over the oil seal lip.
      

1. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.

2. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several steps.

   SST

   09960-10010 (09962-01000, 09963-00500)
   

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

   NOTICE:

   Be careful not to damage the timing tube.

3. Mount the hexagonal portion of the camshaft in a vise.

   NOTICE:

   Be careful not to damage the camshaft.

4. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.

5. Using a 10 mm hexagon wrench, install the bolt.

   Torque:

   78 N*m{795 kgf*cm, 58 ft.*lbf}

6. Install the seal washer and screw plug.

   Torque:

   15 N*m{152 kgf*cm, 11 ft.*lbf}

1. Install the gear spring [1], sub gear [2] and wave washer [3].

   HINT:

   Attach the pins on the gears to the gear spring ends.

2. Using snap ring pliers, install the snap ring.

3. Mount the hexagonal portion of the camshaft in a vise.

   NOTICE:

   Be careful not to damage the camshaft.

4. Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolt.

   SST

   09960-10010 (09962-01000, 09963-00500)
   

5. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.

   Recommended service bolt:

   Thread diameter	6 mm
   Thread pitch	1.0 mm
   Bolt length	16 to 20 mm (0.63 to 0.79 in.)

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

   SST

   09316-60011 (09316-00011)
   

2. Apply MP grease to the oil seal lip.

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

   09223-56010
   

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.
   

   1. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.

   2. Thoroughly clean all components to remove all the loose material.

   3. Using a non-residue solvent, clean both sealing surfaces.

2. Apply seal packing to the oil seal retainer as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   
   

   1. Use a nozzle that has been cut to a 3 to 4 mm (0.12 to 0.16 in.) opening.

   2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

   3. Immediately remove the nozzle from the tube and reinstall the cap.

3. Install a new O-ring to the cylinder block.

4. Install the oil seal retainer with the 7 bolts.

   Torque:

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

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

   1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.

   2. Thoroughly clean all components to remove all the loose material.

   3. Using a non-residue solvent, clean both sealing surfaces.

2. Apply seal packing to the oil pump as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   NOTICE:

   Avoid applying an excessive amount to the surface, especially around the oil passage.

   
   

   1. Use a nozzle that has been cut to a 2 to 3 mm (0.08 to 0.12 in.) opening.

   2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.

   3. Immediately remove the nozzle from the tube and reinstall the cap.

3. Install a new O-ring to the cylinder block.

4. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.

5. Install the oil pump with a new stud bolt and the 7 bolts. Uniformly tighten the bolts diagonally.

   HINT:

   1. Use a 6mm hexagon wrench to tighten the hexagon head bolt.
      
   2. The following chart is the reference of the oil pump bolt length.
      

   Bolt	Size of Bolt Head	Length
   A	12 mm	50 mm (1.97 in.)
   B	14 mm Stud Bolt	102.8 mm (4.047 in.)
   C	12 mm	35 mm (1.38 in.)
   D	14 mm	44 mm (1.73 in.)
   E	6 mm Hexagon	28 mm (1.10 in.)

   Torque:

   For bolts A, B, C and E:

   16 N*m{160 kgf*cm, 11 ft.*lbf}

   For bolt D:

   31 N*m{311 kgf*cm, 23 ft.*lbf}

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

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

   HINT:

   Use bolts 12 mm (0.47 in.) in length.

1. Install the stud bolt.
   

   
   
   
   

   Torque:

   3.5 N*m{36 kgf*cm, 31 in.*lbf}

1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the No. 1 oil pan, cylinder block, oil pump and rear oil seal retainer.

   1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
      
   2. Thoroughly clean all components to remove all the loose material.
      
   3. Using a non-residue solvent, clean both sealing surfaces.
      

2. Apply seal packing to the No. 1 oil pan as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   1. Use a nozzle that has been cut to a 3 to 5 mm (0.12 to 0.20 in.) opening.
      
   2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
      
   3. Immediately remove the nozzle from the tube and reinstall the cap.
      

3. Temporarily install the oil pan with the 18 bolts and 2 nuts.

   HINT:

   The following chart is the reference for the oil pump bolt length.

   Bolt	Size of Bolt Head	Length
   A	10 mm	20 mm (0.79 in.)
   B	12 mm	25 mm (0.98 in.)
   C	12 mm	60 mm (2.36 in.)
   D	10 mm	35 mm (1.38 in.)

4. Set the oil pan as shown in the illustration.

   NOTICE:

   Make sure that the clearance between the rear end of the oil pan and cylinder block is 0.2 mm (0.008 in.) or less.

   If the clearance is more than 0.2 mm (0.008 in.), the oil pan will be stretched.

5. Uniformly tighten the bolts and nuts diagonally.

   Torque:

   For bolts A and D:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

   For bolts B, C and nut:

   28 N*m{286 kgf*cm, 21 ft.*lbf}

1. Install the baffle plate with the 2 bolts and 2 nuts.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

   HINT:

   Use bolts 12 mm (0.47 in.) in length.

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

   1. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
      
   2. Thoroughly clean all components to remove all the loose material.
      
   3. Using a non-residue solvent, clean both sealing surfaces.
      

   NOTICE:

   Do not use a solvent which will affect the painted surfaces.

2. Apply seal packing to the No. 2 oil pan as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

   1. Use a nozzle that has been cut to a 3 to 5 mm (0.12 to 0.20 in.) opening.
      
   2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
      
   3. Immediately remove the nozzle from the tube and reinstall the cap.
      

3. Install the No. 2 oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several steps.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

   HINT:

   Use bolts 14 mm (0.55 in.) in length.

1. Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several steps.

   Torque:

   Bolt:

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

   Stud bolt and nut:

   18 N*m{184 kgf*cm, 13 ft.*lbf}

   HINT:

   Use bolts 35 mm (1.38 in.) in length.

1. Place 2 new cylinder head gaskets in position on the cylinder block.

   HINT:

   A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank.

   NOTICE:

   Be careful of the installation direction.

2. Place the 2 cylinder heads in position on the cylinder head gaskets.

3. Install the cylinder head bolts.

   HINT:

   1. The cylinder head bolts are tightened in 2 progressive 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 on the threads and under the heads of the cylinder head bolts.

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

   3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several steps in the order shown in the illustration, then do the other side in the same way (Procedure "A").

      Torque:

      40 N*m{408 kgf*cm, 30 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 plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

   5. Mark the front of the cylinder head bolt head with paint.

   6. Retighten the cylinder head bolts by 90° in the numerical order shown (Procedure "B").

   7. Retighten the cylinder head bolts by an additional 90°.

   8. Check that the painted mark is now at a 180° angle to front.

NOTICE:

Since 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 damper bolt, turn the crankshaft, and set the set key of the crankshaft at the position of 90° counterclockwise from the timing mark (dot) of the oil pump body.

      CAUTION:

      Having the crankshaft at a wrong angle can cause the piston head and valve head to come into contact with each other when installing the camshaft, causing damage. So always set the crankshaft at the correct angle.

2. Install the camshafts of the RH bank.
   

   1. Apply engine oil to the thrust portions of the intake and exhaust camshafts.

   2. Align the timing marks (1-dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts.

   3. Set the timing marks (1-dot mark) of the camshaft drive and driven main gears at approx. 10° angle.

   5. Apply seal packing to the camshaft housing plug.

      1. Remove the old packing (FIPG) material.
         
      2. Apply seal packing to the housing plug.
         

      Seal packing:

      Part No. 08826-00080 or equivalent
      

   7. Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

      NOTICE:

      Be careful of the installation direction.

   9. Apply seal packing to the front bearing cap.

      1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
         Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
         Thoroughly clean all components to remove all the loose material.
         Using a non-residue solvent, clean both sealing surfaces.
         
      2. Apply seal packing to the bearing cap as shown in the illustration.
         Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening.
         Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
         Immediately remove the nozzle from the tube and reinstall the cap.
         

      Seal packing:

      Part No. 08826-00080 or equivalent
      

      NOTICE:

      Do not apply seal packing to the front bearing cap grooves.

   11. Install the front bearing cap.

       HINT:

       The thrust position of the camshaft will be determined after installing the front bearing cap.

   12. Install the other bearing caps in the order shown with the arrow mark facing forward.

   14. Push in the camshaft setting oil seal.

   16. Install new seal washers to the bearing cap bolts (A and B).

   17. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E).

       NOTICE:

       Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C).

       HINT:

       Each bolt length is as follows:

       94 mm (3.70 in.) for A with seal washer

       72 mm (2.83 in.) for B with seal washer

       25 mm (0.98 in.) for C

       55 mm (2.17 in.) for D

       40 mm (1.57 in.) for E

   18. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

   20. Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration.

       Torque:

       For bolt C:

       7.5 N*m{76 kgf*cm, 66 in.*lbf}

       For others:

       16 N*m{163 kgf*cm, 12 ft.*lbf}

   22. Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.

   23. Remove the service bolt.

3. Install the camshafts of the LH bank.
   

   1. Apply MP grease to the thrust portion of the camshafts.

   2. Align the timing marks (2-dot marks) of the camshaft drive and driven main gears, and place the 2 camshafts.

   4. Apply seal packing to the camshaft housing plug.

      1. Remove the old packing (FIPG) material.
         
      2. Apply seal packing to the housing plug.
         

      Seal packing:

      Part No. 08826-00080 or equivalent
      

   6. Install the camshaft housing plug and oil control valve filter to the cylinder head as shown in the illustration.

      CAUTION:

      Be careful of the installation direction.

   8. Apply seal packing to the front bearing cap.

      1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
         Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
         Thoroughly clean all components to remove all the loose material.
         Using a non-residue solvent, clean both sealing surfaces.
         
      2. Apply seal packing to the bearing cap as shown in the illustration.
         Use a nozzle that has been cut to 1.5 to 2.0 mm (0.059 to 0.079 in.) opening.
         Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
         Immediately remove the nozzle from the tube and reinstall the cap.
         

      Seal packing:

      Part No. 08826-00080 or equivalent
      

      NOTICE:

      Do not apply seal packing to the front bearing cap grooves.

   10. Install the front bearing cap.

       HINT:

       The thrust position of the camshaft will be determined after installing the front bearing cap.

   11. Install the other bearing cap in the order shown with the arrow mark facing forward.

   13. Push in the camshaft setting oil seal.

   15. Install a new seal washer to the bearing cap bolts (A and B).

   16. Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts (D and E).

       NOTICE:

       Do not apply engine oil under the heads of the bearing cap bolts (A), (B) and (C).

       HINT:

       Each bolt length is as follows:

       94 mm (3.70 in.) for A with seal washer

       72 mm (2.83 in.) for B with seal washer

       25 mm (0.98 in.) for C

       55 mm (2.17 in.) for D

       40 mm (1.57 in.) for E

   17. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.

   19. Uniformly tighten the 22 bearing cap bolts in several steps, in the order shown in the illustration.

       Torque:

       For bolt C:

       7.5 N*m{76 kgf*cm, 66 in.*lbf}

       For others:

       16 N*m{163 kgf*cm, 12 ft.*lbf}

   21. Bring the service bolt installed in the driven sub-gear upward by turning the hexagonal portion of the camshaft with a wrench.

   22. Remove the service bolt.

1. Install the rear timing belt plate with the bolt and stud bolt.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the rear timing belt plate with the 2 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the rear timing belt plate with the bolt.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Install the rear timing belt plate with the 2 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Fit the timing pulley set key to the key groove of the pulley.

2. Using SST and a hammer, tap in the timing pulley with the flange side facing inward.

   SST

   09223-46011
   

1. Install the idler with the bolt.

   Torque:

   35 N*m{352 kgf*cm, 25 ft.*lbf}

2. Check that the idler moves smoothly.

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

   Adhesive:

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

2. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.

   Torque:

   35 N*m{352 kgf*cm, 25 ft.*lbf}

3. Check that the idler bracket moves smoothly.

1. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.

2. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" and "L" marks forward.

3. Hold the hexagonal portion of the camshaft.

4. Using a 5 mm hexagon wrench, install the 8 bolts.

   Torque:

   8.1 N*m{83 kgf*cm, 72 in.*lbf}

NOTICE:

The engine should be cold.

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

   1. Turn the hexagonal portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.

      HINT:

      By turning the camshaft timing pulleys clockwise as follows, installation of the timing pulleys will be easy:

      1/2 teeth turn for the left bank camshaft timing pulley

      1 tooth turn for the right bank camshaft timing pulley

   3. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.

2. Install the timing belt.
   

   1. Remove any oil or water on each pulley. Keep them clean after removal.

      NOTICE:

      Only wipe the pulleys; do not use any cleansing agent.

   2. Face the front mark (arrow) on the timing belt forward.

   3. Connect the timing belt to the crankshaft timing pulley.

      1. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
         

   4. Connect the No. 2 timing belt to the idler.

   5. Connect the timing belt to the camshaft timing pulley LH.

      1. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
         

   6. Connect the timing belt to the water pump pulley.

   7. Connect the timing belt to the camshaft timing pulley (RH bank).

      1. Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
         

   8. Connect the No. 1 timing belt to the idler.

3. Set the belt tensioner.
   

   1. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of pressure.

   2. Align the holes of the push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

   3. Release the press.

   4. Install the dust boot to the belt tensioner.

4. Install the belt tensioner.
   

   1. Temporarily install the belt tensioner with the 2 bolts.

   2. Alternately tighten the 2 bolts.

      Torque:

      26 N*m{270 kgf*cm, 19 ft.*lbf}

   3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.

5. Check the valve timing.
   

   1. Using the crankshaft damper bolt, slowly turn the crankshaft pulley 2 revolutions from the TDC to TDC.

      NOTICE:

      Always turn the crankshaft pulley clockwise.

   3. Check that each pulley aligns with the timing marks as shown in the illustration.
      If the timing marks are not aligned, remove the timing belt and reinstall it.

1. Install the sensor plate as shown in the illustration.

   NOTICE:

   Take care not to install it in a wrong direction.

1. Install the gasket to the cover spacer.

2. Install the cover spacer.

1. Install the timing belt cover with the 4 bolts.

   Torque:

   7.5 N*m{80 kgf*cm, 66 in.*lbf}

1. Align the pulley set key with the key groove of the crankshaft damper.

2. Using SST and a hammer, tap in the crankshaft damper.

   SST

   09223-46011
   

3. Using SST, install the damper bolt.

   SST

   09213-70011 (90105-08076)
   09330-00021
   

   Torque:

   245 N*m{2,498 kgf*cm, 181 ft.*lbf}

1. Check only the valves indicated.
   

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

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

      Valve clearance (Cold):

      Intake:

      0.15 to 0.25 mm (0.006 to 0.010 in.)
      

      Exhaust:

      0.25 to 0.35 mm (0.010 to 0.014 in.)
      

2. Turn the crankshaft 1 complete revolution (360°) and align the camshaft timing marks.

3. Check only the valves indicated as shown in the illustration. Measure the valve clearance.

1. Remove the timing belt (Click here).

2. Remove the camshafts (RH Bank) (Click here).

3. Remove the camshafts (LH Bank) (Click here).

4. Remove the valve lifter and adjusting shim.

   NOTICE:

   Be careful not to drop the adjusting shim into the cylinder head.

5. Determine the replacement adjusting shim size according to the formula or charts on the following pages.
   

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

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

      T:

      Thickness of removed shim
      

      A:

      Measured valve clearance
      

      N:

      Thickness of new shim
      

      Intake:

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

      Exhaust:

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

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

      HINT:

      1. Shims are available in 41 increments of 0.020 mm (0.0008 in.), from 2.00 mm (0.0787 in.) to 2.80 mm (0.1102 in.).
         
      2. Refer to the new adjusting shim thickness table on the next 2 pages.
         
      
      
      
      
      
      
      
      
      
      
      

6. Place a new adjusting shim on the valve.

7. Place the valve lifter.

8. Reinstall the camshafts (LH Bank) (Click here).

9. Reinstall the camshafts (RH Bank) (Click here).

10. Reinstall the timing belt (Click here).

11. Recheck the valve clearance.

1. Install the idler pulley with the 2 bolts and 2 nuts.

   Torque:

   For 12 mm head:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

   For 14 mm head:

   32 N*m{326 kgf*cm, 24 ft.*lbf}

   HINT:

   Each bolt length is as follows:

   106 mm (4.17 in.) for 12 mm head [A]

   114 mm (4.49 in.) for 14 mm head [B]

1. Install the belt tensioner with the bolt and 2 nuts.

   Torque:

   16 N*m{160 kgf*cm, 11 ft.*lbf}

   HINT:

   Use a bolt 106 mm (4.17 in.) in length.

1. Install the timing belt cover and fit the claws and pins into each part.

2. Install the timing belt cover with the 2 bolts.

   Torque:

   16 N*m{160 kgf*cm, 12 ft.*lbf}

   HINT:

   Use bolts 106 mm (4.17 in.) in length.

1. Install the idler pulley and cover plate with the bolt.

   Torque:

   39 N*m{398 kgf*cm, 29 ft.*lbf}

1. Remove any old packing (FIPG) material.

2. Apply seal packing to the semicircular plug grooves.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

3. Install the 4 semicircular plugs to the cylinder heads as shown in the illustration.

1. Remove any old packing (FIPG) material.

2. Apply seal packing to the cylinder heads as shown in the illustration.

   Seal packing:

   Part No. 08826-00080 or equivalent
   

3. Install the gasket to the cylinder head cover.

4. Install the seal washer to the bolt.

5. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.

   Torque:

   6.0 N*m{60 kgf*cm, 53 in.*lbf}

1. Install a new gasket and the oil filler cap housing with the 2 nuts.

   Torque:

   7.5 N*m{76 kgf*cm, 66 in.*lbf}

Torque:

18 N*m{178 kgf*cm, 13 ft.*lbf}

1. Apply seal packing to 2 or 3 threads.

   Seal packing:

   Part No. 08826-00100 or equivalent
   

2. Install the 2 drain cocks.

   Torque:

   49 N*m{500 kgf*cm, 36 ft.*lbf}

   HINT:

   After tightening to the specified torque, rotate the drain union clockwise until its drain port is facing forward.

1. Install the 2 engine hangers with the 4 bolts.

   Torque:

   37 N*m{380 kgf*cm, 27 ft.*lbf}