Part 3

PARTIAL ENGINE ASSEMBLY
OVERHAUL
67. INSTALL TIMING BELT PLATE RR LH NO.2
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)





68. INSTALL CAMSHAFT TIMING PULLEY
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "R" mark forward.
c. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)





69. INSTALL CAMSHAFT TIMING PULLEY SUB-ASSEMBLY LH
a. Align the camshaft timing tube knock pin with the knock pin groove of the timing pulley.
b. Attach the timing pulley to the camshaft timing tube. Face the timing pulley's "L" mark forward.
c. Hold the hexagon wrench head portion of the camshaft and install the 4 pulley bolts.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)





70. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the timing pulley set key with the key groove of the pulley.
b. Using SST and a hammer, tap in the timing pulley. Face the flange side inward.
SST 09223-46011
71. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
a. Install the idler with the bolt.
Torque: 34.5 Nm (352 kgf-cm, 25 ft. lbs.)
b. Check that the idler moves smoothly.





72. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1
a. Apply adhesive to 2 or 3 threads of the pivot bolt.
Adhesive: Part No. 08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
b. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.
Torque: 34.5 Nm (352 kgf-cm, 25 ft. lbs.)
c. Check that the idler bracket moves smoothly.





73. INSTALL TIMING BELT

NOTICE: The engine should be cold.

a. Set the No. 1 cylinder to TDC/compression.
1. Turn the hexagon wrench head portion of the camshaft to align the timing marks of the camshaft timing pulleys and timing belt plates.





HINT: Turn the camshaft timing pulleys slightly clockwise to make installation of the timing belt easier.
Camshaft timing pulley of LH bank: 1/2 of a tooth
Camshaft timing pulley of RH bank: 1 tooth





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





b. Install the timing belt.
1. Remove any oil or water on each pulley, and keep them clean.

NOTICE: Only wipe the pulleys. Do not use cleaning agents on the pulleys.

2. Face the front mark (arrow) on the timing belt forward.
3. Connect the timing belt to the crankshaft timing pulley.
Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
4. Connect the timing belt to the idler No. 2.
5. Connect the timing belt to the camshaft timing pulley LH.
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).
Align the installation mark on the timing belt with the timing mark of the camshaft timing pulley.
8. Connect the timing belt to the idler No. 1.
9. Using a press, slowly press in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbs.) of pressure.
10. 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.
11. Release the press.
12. Install the dust boot to the belt tensioner.





c. Install the belt tensioner.
1. Temporarily install the belt tensioner with the 2 bolts.
2. Alternately tighten the 2 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
3. Using pliers, remove the 1.27 mm hexagon wrench from the belt tensioner.





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

NOTICE: Always turn the crankshaft pulley clockwise.





2. Check that each pulley aligns with the timing marks as shown in the illustration.
If the timing marks do not align, remove the timing belt and reinstall it.
74. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the sensor plate. Face the cup side outward.
75. INSTALL TIMING GEAR COVER SPACER
a. Install the gasket to the cover spacer.
b. Install the cover spacer.
76. INSTALL TIMING BELT NO.1 COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
77. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY





a. Using SST and a hammer, tap in the crankshaft damper.
SST 09223-46011





b. Using SST, install the damper bolt.
SST 09213-70010, 09330-00021
Torque: 245 Nm (2,500 kgf-cm, 181 ft. lbs.)
c. Align the pulley set key with the key groove of the crankshaft damper.
78. ADJUST VALVE CLEARANCE
79. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (163 kgf-cm, 11 ft. lbs.)

HINT: Use a bolt that is 106 mm (4.18 inch) in length.

80. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)





81. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Fit the timing belt cover, matching the claws and pin with each part.
b. Install the timing belt cover with the 2 bolts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)

HINT: Use bolts that are 106 mm (4.17 inch) in length.





82. INSTALL IDLER PULLEY ASSEMBLY
a. Install the idler pulley with the 2 bolts and 2 nuts.
Torque:
32 Nm (326 kgf-cm, 24 ft. lbs.) for 14 mm head bolt A
16 Nm (163 kgf-cm, 12 ft. lbs.) for 12 mm head bolt B

HINT: Each bolt length is indicated.

Bolt length:
114 mm (4.49 inch) for 14 mm head (A)
106 mm (4.17 inch) for 12 mm head (B)





83. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Install the gasket to the cover.
b. Run the camshaft position sensor wire through the cover hole.
c. Install the cover with the 4 bolts.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
d. Install the wire grommet to the cover.
e. Install the sensor connector to the sensor holder.
f. Connect the sensor connector.
g. Install the sensor wire to the wire clamp on the cover.
h. Install the engine wire to the 2 wire clamps on the cover.





i. Connect the 2 water by-pass hoses, as shown in the illustration.
j. Install the No. 3 water by-pass pipe to the cover with the cap nut.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
k. Install the engine wire to the 2 wire clamps on the cover.





84. INSTALL TIMING CHAIN OR BELT COVER NO.2
a. Install the gasket to the cover.
b. Install the cover with the cap nut and 3 bolts.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
c. Install the 2 PS air hoses to the clamp on the cover.





85. INSTALL SEMICIRCULAR PLUG
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the semicircular plug grooves.
Seal packing: Part No. 08826-00080 or equivalent





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





86. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove any old packing (FIPG) material.
b. Apply seal packing to the cylinder heads as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the gasket to the cylinder head cover.
d. Install the seal washer to the bolt.
e. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
87. INSTALL OIL FILLER CAP SUB-ASSEMBLY
88. INSTALL SPARK PLUG