Engine Unit Reassembly

Apply adhesive around the tight plugs.

Adhesive:

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

Using SST, tap in the tight plugs.

SST

09950-60010(09951-00340)
09950-70010(09951-07100)

Using a plastic-faced hammer, tap in new straight pins to the cylinder block.

Standard protrusion:

Item	Protrusion
Pin A	23 mm (0.906 in.)
Pin B	6 mm (0.236 in.)
Pin C	11 mm (0.433 in.)
Pin D	9 mm (0.354 in.)

Using an E8 "torx" socket, install the stud bolt.

Torque:

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

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

Torque:

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

Using a 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.

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

Coat the piston pin with engine oil.

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

HINT:

The piston and pin are a matched set.

Check the fitting condition between the piston and piston pin by trying to move the piston back and forth on the piston pin.

Using a screwdriver, install a new snap ring at the other 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.

Install the oil ring expander by hand.

Using a piston ring expander, install the oil ring rail.

Using a piston ring expander, install the 2 compression rings so that the painted marks are positioned as shown in the illustration.

NOTICE:

Do not align the ring ends.

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

NOTICE:

Do not align the ring ends.

Clean the main journal and the both surfaces of the bearing.

Install the upper bearing.

1. Install the upper bearing to the cylinder block as shown in the illustration.
   

   NOTICE:

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

Install the lower bearing.

1. Install the lower bearing to the bearing cap.
   

2. Using vernier calipers, measure the distance between the bearing cap's edge and the lower bearing's edge.
   

   Dimension (A - B):

   0.7 mm (0.0276 in.) or less.
   

   NOTICE:

   Do not apply engine oil to the bearing's contact area and backside.

Install the crankshaft thrust washer to the cylinder block.

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

Apply engine oil to the upper bearing, then place the crankshaft on the cylinder block.

Confirm the front marks and numbers of the main bearing caps and install the bearing caps on the cylinder block.

HINT:

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

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

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

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

Bolt length:

100 to 102 mm (3.94 to 4.02 in.)

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

Apply a light coat of engine oil on the threads and under the heads of the 8 main bearing cap bolts.

Install the 8 main bearing cap bolts to the outside positions.

Bolt length:

Item	Length
Bolt A	100 to 102 mm (3.94 to 4.02 in.)
Except bolt A	105.0 to 107.0 mm (4.15 to 4.23 in.)

Install the crankshaft bearing cap bolts.

HINT:

The main bearing cap bolts are tightened in 2 progressive steps.

Install and uniformly tighten the 16 main bearing cap bolts in the sequence shown in the illustration.

Torque:

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

Mark the front of the bearing cap bolts with paint.

Retighten the bearing cap bolts by 90° in the order above.

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

Check that the crankshaft turns smoothly.

Check the crankshaft thrust clearance (see page).

Install 8 new seal washers and uniformly tighten the 8 main bearing cap bolts in several steps and in the sequence shown in the illustration.

Torque:

26 N*m{265 kgf*cm, 19 ft.*lbf}

Bolt length:

45 mm (1.77 in.)

Check that the crankshaft turns smoothly.

Check the crankshaft thrust clearance (see page).

Install the connecting rod bearing to the connecting rod and bearing cap.

Using vernier calipers, measure the distance between the connecting rod's and bearing cap's edge and the connecting rod bearing's edge.

Dimension (A - B):

0.7 mm (0.0276 in.) or less

NOTICE:

Do not apply engine oil to the bearing's contact area and backside.

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

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

NOTICE:

Do not align the ring ends.

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

NOTICE:

Match the numbered connecting rod cap with the connecting rod.

Check that the front mark of the connecting rod cap is facing forward.

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

Install the connecting cap bolts.

HINT:

The connecting cap bolts are tightened in 2 progressive steps.

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

Torque:

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

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

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

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

Check that the crankshaft turns smoothly.

Check the connecting rod thrust clearance.

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

Specified protrusion height:

2.5 to 3.8 mm (0.098 to 0.150 in.)

Using a 10 mm hexagon wrench, install 4 new gaskets and the straight screw plugs.

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

Using a 14 mm hexagon wrench, install 2 new gaskets and the 2 straight screw plugs.

Torque:

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

Apply adhesive to the union of the cylinder head.

Adhesive:

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

Install the union to the cylinder head as shown in the illustration.

Torque:

15 N*m{153 kgf*cm, 11 ft.*lbf}

Using E6 and E8 "torx" sockets, install the stud bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf} for bolts A, B and D

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

Using a plastic-faced hammer, tap in a new straight pin as shown in the illustration.

Protrusion height:

17.5 to 19.5 mm (0.689 to 0.768 in.)

Install the valve spring seats to the cylinder head.

Apply a light coat of engine oil to new oil seals.

NOTICE:

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

HINT:

The intake valve oil seals are white and the exhaust valve oil seals are black.

Using SST, push in the oil seals.

SST

09201-41020

NOTICE:

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

Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE:

Install the same parts in the same combination to the original locations.

Using SST, compress the spring and install the 2 retainer locks.

SST

09202-70020(09202-00010)

Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:

Be careful not to damage the retainer.

Apply a sufficient coat of engine oil to the tip area of the intake valve shown in the illustration.

Install the valve, compression spring and spring retainer to the cylinder head.

NOTICE:

Install the same parts in the same combination to the original locations.

Using SST, compress the spring and install the 2 retainer locks.

SST

09202-70020(09202-00010)

Using a plastic-faced hammer, lightly tap the valve stem tip to ensure a proper fit.

NOTICE:

Be careful not to damage the retainer.

Apply a light coat of engine oil to the valve stem caps.

Install the valve stem caps to the cylinder head.

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

Seal packing:

Part No. 08826-00080 or equivalent

Seal diameter:

2.0 to 3.0 mm (0.079 to 0.118 in.)

NOTICE:

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

Install the oil seal retainer with the 6 bolts.

Torque:

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

NOTICE:

Be sure to apply adhesive 1324 to the bolts in the places indicated by A before installing them.

Adhesive:

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

Install the water outlet pipe with the 2 bolts.

Torque:

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

Install the water jacket spacer as shown in the illustration.

HINT:

Be sure to face the slope to front of the engine.

Install the water jacket spacer as shown in the illustration.

HINT:

Be sure to face the slope to front of the engine.

Apply a continuous line of 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 3.0 mm (0.098 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head gasket within 3 minutes after applying the seal packing.
   
3. Install the cylinder head bolt within 15 minutes after applying the seal packing.
   
4. Do not apply engine oil within 2 hours of installation.
   

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. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
   

Place the cylinder head on the cylinder block.

NOTICE:

Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT:

The cylinder head bolts are tightened in 3 progressive steps.

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

Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.

Torque:

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

Mark the cylinder head bolt head with paint as shown in the illustration.

Tighten the cylinder head bolts another 90°.

Tighten the cylinder head bolts by an additional 90°.

Check that the painted mark is now facing rearward.

Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.

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 3.0 mm (0.098 to 0.118 in.)

NOTICE:

1. Remove any oil from the contact surface.
   
2. Install the cylinder head gasket within 3 minutes after applying the seal packing.
   
3. Install the cylinder head bolt within 15 minutes after applying the seal packing.
   
4. Do not apply engine oil within 2 hours of installation.
   

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. Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.
   

Place the cylinder head on the cylinder block.

NOTICE:

Be careful not to allow oil to adhere to the bottom part of the cylinder head.

HINT:

The cylinder head bolts are tightened in 3 progressive steps.

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

Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps in the sequence shown in the illustration.

Torque:

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

Mark the cylinder head bolt head with paint as shown in the illustration.

Tighten the cylinder head bolts by 90°.

Tighten the cylinder head bolts by an additional 90°.

Check that the painted mark is now facing rearward.

Tighten the 2 bolts in the order shown in the illustration.

Torque:

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

Seal packing will seep out on the engine's front side. Thoroughly wipe off seeped out seal packing.

Place the lash adjuster into a container full of engine oil.

Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball inside the plunger.

SST

09276-75010

Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.

Check the movement of the plunger and bleed the air.

OK:

Plunger moves up and down.

NOTICE:

When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

After bleeding the air, remove SST. Then, try to quickly and firmly press the plunger with a finger.

OK:

Plunger is very difficult to move.

Install the lash adjusters.

NOTICE:

Install the lash adjuster to the same place it was removed from.

Apply engine oil to the lash adjuster tip and valve stem cap end.

Make sure that the valve rocker arm is installed as shown in the illustration.

Apply engine oil to the camshaft journal, camshaft housing and bearing cap.

Install the camshaft and camshaft No. 2 to the camshaft housing RH.

Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

Temporarily tighten the 9 bolts in the order shown in the illustration.

Torque:

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

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

Seal packing:

Part No. 08826-00080 or equivalent

Seal diameter:

3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:

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

Tighten the 14 bolts in the order shown in the illustration.

Torque:

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

NOTICE:

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

Tighten the 9 bolts in the order shown in the illustration.

Torque:

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

NOTICE:

Thoroughly wipe clean any seal packing.

Install 3 new gaskets.

Apply engine oil to the camshaft journal, camshaft housing and bearing cap.

Install the camshaft No. 3 and camshaft No. 4 to the camshaft housing LH.

Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

Temporarily tighten the 8 bolts in the order shown in the illustration.

Torque:

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

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

Seal packing:

Part No. 08826-00080 or equivalent

Seal diameter:

3.5 to 4.0 mm (0.138 to 0.158 in.)

NOTICE:

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

Tighten the 12 bolts in the order shown in the illustration.

Torque:

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

NOTICE:

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

Tighten the 8 bolts in the order shown in the illustration.

Torque:

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

NOTICE:

Thoroughly wipe clean any seal packing.

Install 3 new gaskets.

Install the chain tensioner with the bolt.

Torque:

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

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

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

Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear RH with No. 2 chain installed.

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}

Remove the pin from the chain tensioner.

Install the chain tensioner with the bolt.

Torque:

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

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

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

Apply a light coat of engine oil to the bolt threads and bolt-seating surface.

Align the knock pin of the camshaft with the pin hole of the camshaft timing gear. Install the camshaft timing gear and camshaft timing exhaust gear LH with No. 2 chain installed.

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}

Remove the pin from the chain tensioner.

Install the chain vibration damper with the 2 bolts.

Torque:

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

Install the 2 chain vibration dampers.

Install the timing gear set keys and timing gear as shown in the illustration.

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

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

NOTICE:

Be careful of the idle gear direction.

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

Torque:

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

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

NOTICE:

Do not pass the chain over the crankshaft, just put it on it.

HINT:

The camshaft mark plate is orange.

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

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

HINT:

The crankshaft mark plate is yellow.

Temporarily tighten the pulley set bolt.

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

Install the chain tensioner slipper.

Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.

Install the chain tensioner with the 2 bolts.

Torque:

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

Remove the lock pin of the chain tensioner. Check that each timing mark is aligned with the crankshaft at the TDC / compression.

Remove the pulley set bolt.

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

Torque:

9.1 N*m{93 kgf*cm, 81 in.*lbf}

Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

Seal packing:

Part No. 08826-00080 or equivalent

Seal diameter:

5.0 to 5.5 mm (0.197 to 0.217 in.)

NOTICE:

1. Be sure to clean and degrease the contact surfaces, especially 7 areas indicated by C in the illustration.
   
2. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   
3. Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
4. Do not start the engine for at least 2 hours after installing.
   

Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

Seal packing:

08826-00080 or equivalent

08826-00100 or equivalent

NOTICE:

1. When the contact surfaces are wet, wipe them with an oil-free cloth before applying seal packing.
   
2. Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
   
3. Do not start the engine for at least 2 hours after installing.
   

Apply seal packing as follows:

Area	Seal Packing Diameter	Application Position from Inside Seal Line
Continuous Line Area	3.5 to 4.0 mm (0.138 to 0.158 in.)	3.0 to 4.0 mm (0.118 to 0.158 in.)
Alternate Long and Dashed Line Area	3.5 to 4.0 mm (0.138 to 0.158 in.)	2.0 to 3.0 mm (0.079 to 0.118 in.)
Dashed Line Area	4.0 to 5.0 mm (0.158 to 0.197 in.)	1.0 to 2.0 mm (0.039 to 0.079 in.)

Install a new O-ring.

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

Install the timing chain cover with the 16 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:

43 N*m{438 kgf*cm, 32 ft.*lbf} for bolt A

21 N*m{214 kgf*cm, 15 ft.*lbf} for except bolt A

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

Bolt length:

Item	Length
Bolt A	50 mm (1.97 in.)
Bolt B	25 mm (0.98 in.)
Bolt C	55 mm (2.17 in.)

NOTICE:

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

Install a new gasket.

Install the timing chain cover plate to the timing chain cover with the 4 bolts.

Torque:

9.1 N*m{93 kgf*cm, 81 in.*lbf}

Install a new gasket and the water pump with the 16 bolts.

Torque:

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

9.1 N*m{93 kgf*cm, 81 in.*lbf} for except bolt A

NOTICE:

1. Be sure to replace the bolts indicated by B with new ones or reuse them after applying adhesive 1344.
   
2. Make sure that there is no oil on the bolt A threads.
   

Install the baffle plate with the 8 bolts.

Torque:

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

Using an E6 "torx" socket, install the stud bolts as shown in the illustration.

Torque:

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

Install a new gasket and the oil strainer with the 3 nuts.

Torque:

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

Install 2 new O-rings.

When replacing a stud bolt, install it by using an E6 "torx" socket wrench.

Torque:

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

Bolt length A:

20 mm (0.787 in.)

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

Seal packing:

Part No. 08826-00080 or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.156 in.)

NOTICE:

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

Install the oil pan with the 16 bolts and 2 nuts.

Torque:

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

21 N*m{214 kgf*cm, 15 ft.*lbf} for bolts except A

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

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

Seal packing:

Part No. 08826-00080 or equivalent

Seal diameter:

3.0 to 4.0 mm (0.118 to 0.156 in.)

NOTICE:

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

Install the oil pan with the 15 bolts and 2 nuts.

Torque:

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

Install a new gasket and the drain plug.

Torque:

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

Apply seal packing as shown in the illustration.

Seal packing:

08826-00080 or equivalent

NOTICE:

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

Install the gasket to the head cover.

Install the head cover with the 13 bolts.

Torque:

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

21 N*m{214 kgf*cm, 15 ft.*lbf}for bolts except A

Apply seal packing as shown in the illustration.

Seal packing:

08826-00080 or equivalent

NOTICE:

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

Install the gasket to the head cover.

Install the head cover with the 12 bolts.

Torque:

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

21 N*m{214 kgf*cm, 15 ft.*lbf} for bolts except A

Install 2 new gaskets and a new O-ring.

Apply soapy water to the O-ring.

Install the water by-pass joint RR with the 2 bolts and 4 nuts.

Torque:

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

Install a new gasket and water inlet with thermostat with the 3 nuts.

Torque:

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

Install 2 new O-rings.

Apply soapy water to the O-ring.

Install the water inlet with the 4 bolts and nut.

Torque:

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

Install the 3 water by-pass hoses.

Align the pulley set key with the key groove of the pulley, and slide on the pulley.

Using SST, install the pulley bolt.

SST

09213-70011(09213-70020)
09330-00021

Torque:

250 N*m{2,550 kgf*cm, 184 ft.*lbf}

Clean the inside of the oil filter cap, the threads and O-ring groove.

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

Set a new oil filter element to the oil filter cap.

Remove dirt or foreign matter from the installation surface and inside of the engine.

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

NOTICE:

Be careful that the O-ring does not get caught between the parts.

Using SST, tighten the oil filter cap.

SST

09228-06501

Torque:

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

NOTICE:

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

Apply adhesive around the drain cock.

Adhesive:

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

Install the water drain cock as shown in the illustration.

Torque:

30 N*m{306 kgf*cm, 22 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 cock plug of the water drain cock.
   

Install the water drain cock plug to the water drain cock.

Torque:

13 N*m{130 kgf*cm, ft.*lbf}

Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install oil pipe (on the head cover side).

Install a new gasket and temporarily install oil pipe (on the cylinder head side) with the oil check valve bolt.

Tighten the oil pipe union (on the head cover side).

Torque:

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

Tighten the oil check valve bolt (on the cylinder head side).

Torque:

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

Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install oil pipe (on the head cover side).

Install a new gasket and temporarily install oil pipe (on the cylinder head side) with the oil check valve bolt.

Tighten the oil pipe union (on the head cover side).

Torque:

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

Tighten the oil check valve bolt (on the cylinder head side).

Torque:

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

Install the sensor with the bolt.

Torque:

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

Install the 4 oil control valves with the 4 bolts.

Torque:

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

Install the 4 sensors with the 4 bolts.

Torque:

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

Apply adhesive around the ventilation valve.

Adhesive:

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

Install the ventilation valve.

Torque:

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

Install the spark plugs.

Torque:

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

Install the engine hanger with the 2 bolts.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}

Install the engine hanger with the 2 bolts.

Torque:

33 N*m{337 kgf*cm, 24 ft.*lbf}