INSTALL STRAIGHT PIN

INSTALL STUD BOLT

INSTALL TIGHT PLUG

INSTALL NO. 1 OIL NOZZLE SUB-ASSEMBLY

INSTALL CONNECTING ROD SMALL END BUSH

INSTALL PISTON SUB-ASSEMBLY WITH PIN

INSTALL PISTON RING SET

INSTALL CRANKSHAFT BEARING

INSTALL CRANKSHAFT THRUST WASHER SET

INSTALL CRANKSHAFT

INSTALL CONNECTING ROD BEARING

INSTALL PISTON SUB-ASSEMBLY WITH CONNECTING ROD

INSTALL INTAKE VALVE GUIDE BUSH

INSTALL EXHAUST VALVE GUIDE BUSH

INSTALL RING PIN

INSTALL NO. 1 STRAIGHT SCREW PLUG

INSTALL NO. 2 STRAIGHT SCREW PLUG

INSTALL STUD BOLT

INSTALL UNION

INSTALL STRAIGHT PIN

INSTALL VALVE SPRING SEAT

INSTALL VALVE STEM OIL SEAL

INSTALL EXHAUST VALVE

INSTALL INTAKE VALVE

INSTALL VALVE STEM CAP

INSTALL ENGINE REAR OIL SEAL

INSTALL ENGINE REAR OIL SEAL RETAINER

INSTALL WATER OUTLET PIPE SUB-ASSEMBLY

INSTALL KNOCK SENSOR

INSTALL CYLINDER BLOCK WATER JACKET SPACER RH

INSTALL CYLINDER BLOCK WATER JACKET SPACER LH

INSTALL CYLINDER HEAD SUB-ASSEMBLY RH

INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

INSTALL VALVE LASH ADJUSTER ASSEMBLY

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

INSTALL CAMSHAFT BEARING CAP (for Bank 1)

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

INSTALL CAMSHAFT BEARING CAP (for Bank 2)

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)

INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

INSTALL CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)

INSTALL NO. 1 CHAIN VIBRATION DAMPER

INSTALL NO. 2 CHAIN VIBRATION DAMPER

INSTALL CRANKSHAFT TIMING SPROCKET

INSTALL IDLE SPROCKET ASSEMBLY

INSTALL CHAIN SUB-ASSEMBLY

INSTALL CHAIN TENSIONER SLIPPER

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

INSTALL TIMING CHAIN CASE OIL SEAL

INSTALL WATER PUMP ASSEMBLY

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

INSTALL OIL STRAINER SUB-ASSEMBLY

INSTALL OIL PAN SUB-ASSEMBLY

INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

INSTALL OIL PAN DRAIN PLUG

INSTALL SPARK PLUG TUBE GASKET

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

INSTALL REAR WATER BY-PASS JOINT

INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

INSTALL WATER INLET SUB-ASSEMBLY

INSTALL CRANKSHAFT PULLEY

INSTALL OIL FILTER ELEMENT

INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY

INSTALL NO. 1 OIL PIPE

INSTALL NO. 2 OIL PIPE

INSTALL CRANKSHAFT POSITION SENSOR

INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

INSTALL CAMSHAFT POSITION SENSOR

INSTALL VENTILATION VALVE SUB-ASSEMBLY

INSTALL SPARK PLUG

INSTALL RADIATOR CAP SUB-ASSEMBLY

INSTALL OIL FILLER CAP SUB-ASSEMBLY

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

• Standard protrusion:

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

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

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

Apply adhesive around the tight plugs.

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

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

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

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

Align the oil holes of a new bush and the connecting rod.

Using SST and a press, press in the bush.

• SST
• 09222-30010

Using a pin hole grinder, hone the bush to obtain the specified clearance between the bush and piston pin.

• Standard oil clearance:
• -0.002 to 0.004 mm (-0.00007 to 0.0001 in.)

Check that the piston pin fits at normal room temperature.

Coat the piston pin with engine oil, and push it into the connecting rod with your thumb.

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

• HINT:

• Be sure that the 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.

• Front Mark:

• Item	Front Mark
  Piston LH	1
  Piston RH	2

• 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 the 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 and 2 compression rings as shown in the illustration.

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.

• NOTICE:

• Main bearings come in widths between 18.0 mm (0.709 in.) and 21.0 mm (0.827 in.). Install the 21.0 mm (0.827 in.) bearings in the No. 1 and No. 4 cylinder block journal positions with the main bearing cap. Install the 18.0 mm (0.709 in.) bearings in the No. 2 and No. 3 positions.

Install the upper bearing.

Install the lower bearing.

Apply engine oil to the crankshaft thrust washer.

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 projection 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 to 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 hammer, lightly tap the bearing cap to ensure a proper fit.

Apply a light coat of engine oil to 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	105.5 to 107.5 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.

Step 1

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}

If any of the main bearing cap bolts does not meet the torque specified, replace it.

Step 2

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.

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:

• Item	Length
  Bolt A	45 mm (1.77 in.)
  Except bolt A	30 mm (1.18 in.)

Check that the crankshaft turns smoothly.

Check the crankshaft thrust clearance .

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 edges 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 bearings and the contact surfaces.

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.

• Front Mark:

• Item	Front Mark
  Piston LH	1
  Piston RH	2

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.

Step 1

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

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

Step 2

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 caliper gauge, measure the bush bore diameter of the cylinder head.

• Cylinder bore diameter:
• 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

• Select a new guide bush (STD or O/S 0.05):

• Bush size	Bush bore diameter
  Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
  Use O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Heat the cylinder head to 80 to 100°C (176 to 212°F).

Place the cylinder head on wooden blocks.

Using SST, tap in new valve guide bushes to the specified protrusion height.

• SST
• 09201-10000(09201-01050)
  09950-70010(09951-07100)

• Protrusion height:
• 10.20 to 10.24 mm (0.4016 to 0.4031 in.)

Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

• Standard oil clearance:
• 0.025 to 0.060 mm (0.0010 to 0.0023 in.)

Using a caliper gauge, measure the bush bore diameter of the cylinder head.

• Cylinder bore diameter:
• 10.285 to 10.306 mm (0.4049 to 0.4057 in.)

• Select a new guide bush (STD or O/S 0.05):

• Bush size	Bush bore diameter
  Use STD	10.285 to 10.306 mm (0.4049 to 0.4057 in.)
  Use O/S 0.05	10.335 to 10.356 mm (0.4069 to 0.4077 in.)

If the bush bore diameter of the cylinder head is greater than 10.306 mm (0.4057 in.), machine the bush bore to the dimension of 10.335 to 10.356 mm (0.4069 to 0.4077 in.) to install a O/S 0.05 valve guide bush.

If the bush bore diameter of the cylinder head is greater than 10.356 mm (0.4077 in.), replace the cylinder head.

Heat the cylinder head to 80 to 100°C (176 to 212°F).

Place the cylinder head on wooden blocks.

Using SST, tap in new valve guide bushes to the specified protrusion height.

• SST
• 09201-10000(09201-01050)
  09950-70010(09951-07100)

• Protrusion height:
• 9.30 to 9.34 mm (0.3661 to 0.3677 in.)

Using a sharp 5.5 mm reamer, ream the valve guide bushings to obtain the specified clearance.

• Standard oil clearance:
• 0.030 to 0.065 mm (0.0012 to 0.0026 in.)

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}

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

Apply adhesive to the union of the cylinder head.

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

Using SST, install the union to the cylinder head as shown in the illustration.

• SST
• 09023-38201

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

Using a plastic hammer, tap in new straight pins 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 gray 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 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 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 on the valves.

Place the oil seal retainer on wooden blocks.

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

• SST
• 09223-15030
  09950-70010(09951-07100)

• NOTICE:

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:

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

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

Connect the 2 knock sensor connectors.

Connect the knock sensor wire clamp.

Install the water jacket spacer as shown in the illustration.

• HINT:

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

Install the water jacket spacer as shown in the illustration.

• HINT:

• Be sure to face the slope to the 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:

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

• NOTICE:

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.

Step 1

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}

Step 2

Step 3

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:

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

• NOTICE:

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.

Step 1

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}

Step 2

Step 3

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 filled with engine oil.

Insert the 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.

If the result is not as specified, replace the lash adjuster.

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 arms are installed as shown in the illustration.

Apply engine oil to the camshaft journals, camshaft housing and bearing caps.

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}

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

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:

Install the camshaft housing RH and tighten the 14 bolts in the order shown in the illustration.

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

• NOTICE:

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

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

Apply engine oil to the camshaft journals, camshaft housing and bearing caps.

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}

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

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:

Install the camshaft housing LH and tighten the 13 bolts in the order shown in the illustration.

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

• NOTICE:

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

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

Install the No. 2 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 the 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 the 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:
• 23 N*m{ 230 kgf*cm, 17 ft.*lbf}

Install the 2 chain vibration dampers.

Install the 2 timing gear set keys and timing gear as shown in the illustration.

Apply a light coat of engine oil to the 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.

• HINT:

• Check that no foreign objects are on the idle gear shafts No. 1 and No. 2.

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

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

• HINT:

• After installing the idle sprocket assembly, check that the idle sprocket turns smoothly.

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

• HINT:

• The camshaft mark plate is orange.

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

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

• NOTICE:

• When the idle sprocket is reused, align the chain plate with the mark where the plate had been in order to tighten the chain between the banks.

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

• 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.

Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

• SST
• 09223-22010
  09506-35010

• NOTICE:

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

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

• NOTICE:

• Be sure to replace the bolts indicated by A with new ones or reuse them after applying adhesive 1344.

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:

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, THREE BOND 1282B or equivalent

• NOTICE:

• 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	6.0 mm (0.236 in.)	-

Install a new gasket.

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.

Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

• 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.

Fully tighten the 3 bolts as shown in the illustration.

• Torque:
• 43 N*m{ 438 kgf*cm, 32 ft.*lbf}for bolt A
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}for bolts except A

Fully tighten the 3 bolts as shown in the illustration.

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

Fully tighten the 7 bolts and 2 nuts as shown in the illustration.

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

• HINT:

• Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.

Fully tighten the 12 bolts as shown in the illustration.

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

• HINT:

• Tighten the bolts in the order of lower to upper as shown in the illustration.

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

• Torque:
• 9.1 N*m{ 93 kgf*cm, 81 in.*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 the baffle plate with the 8 bolts.

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

• HINT:

• Temporarily tighten the 8 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

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}

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:

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

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:

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}

Using a cutter, cut off the sealing part of the removed plug tube gasket.

Using a plug tube gasket which has had the sealing part cut off, uniformly press in a new plug tube gasket all the way.

• NOTICE:

• HINT:

• If a plug tube gasket that will be used to install a new gasket is deformed, and cannot be positioned on a new gasket, correct the deformation using pliers.

Return the claws of the ventilation baffle plate to their original positions.

Apply seal packing as shown in the illustration.

• Seal packing:
• 08826-00080 or equivalent

• NOTICE:

Install 3 new gaskets as shown in the illustration.

Install a new gasket to the head cover.

Install a head cover with the 14 bolts.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}for bolt A
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}for bolts except A

Apply seal packing as shown in the illustration.

• Seal packing:
• 08826-00080 or equivalent

• NOTICE:

Install 3 new gaskets as shown in the illustration.

Install a new gasket to the head cover.

Install the head cover with the 12 bolts.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}for bolt A
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}for bolts except A

Install 2 new gaskets and a new O-ring.

• HINT:

• Apply soapy water to the O-ring.

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

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

• NOTICE:

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

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

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

Install the 3 water by-pass hoses.

Install 2 new O-rings.

• HINT:

• Apply a small amount of water or soapy water to O-ring (A) in the illustration before installing it.

Install the water inlet with the 4 bolts and nut.

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

• NOTICE:

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

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 any dirt or foreign matter from the installation surface 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 cocks.

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

Install the water drain cocks as shown in the illustration.

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

• NOTICE:

• Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.

Install the water drain cock plugs to the water drain cocks.

• Torque:
• 13 N*m{ 130 kgf*cm, 9 ft.*lbf}

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

• NOTICE:

• Do not touch the mesh when installing the oil control valve filter.

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

Install a new gasket and temporarily install the 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}

• NOTICE:

• If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

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

• NOTICE:

• Do not touch the mesh when installing the oil control valve filter.

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

Install a new gasket and temporarily install the 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}

• NOTICE:

• If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

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:
• 25 N*m{ 255 kgf*cm, 18 ft.*lbf}

Install the radiator cap.

Install a new gasket.

Install the oil filler cap.