Part 2

ENGINE UNIT REASSEMBLY continued

31. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH
a. Apply seal packing in a continuous bead 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 inch)

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

b. Tighten the 12 bolts in the order shown in the illustration.
Torque: 28 Nm (286 kgf-cm 21 ft. lbs.)

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

c. Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm 12 ft. lbs.)

NOTICE: Thoroughly wipe clean any seal packing.

d. Install 3 new gaskets.

32. INSTALL CAMSHAFT BEARING CAP LH
a. Apply engine oil to the camshaft journal, camshaft housing and bearing cap.
b. Install the camshaft No.3 and camshaft No.4 to the camshaft housing LH.
c. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.

d. Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

33. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH
a. Apply seal packing in a continuous bead 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 inch)

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

c. Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm 12 ft. lbs.)

NOTICE: Thoroughly wipe clean any seal packing.

d. Install 3 new gaskets.

34. INSTALL NO.2 CHAIN TENSIONER ASSEMBLY
a. Install the chain tensioner No.2 with the bolt.
Torque: 21 Nm (214 kgf-cm 15 ft. lbs.)
b. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 inch) into the hole to fix it.

35. INSTALL NO.2 CAMSHAFT TIMING GEARS AND CHAIN (for Bank 1)
a. Align the mark plate (yellow) with the timing marks (1 dot mark) of the camshaft timing gears as shown in the illustration.
b. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
c. 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.

d. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm 74 ft. lbs.)
e. Remove the pin from the chain tensioner No.2.

36. INSTALL NO.3 CHAIN TENSIONER ASSEMBLY
a. Install the chain tensioner No.3 with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
b. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 inch) into the hole to hold it.

37. INSTALL NO.2 CAMSHAFT TIMING GEARS AND CHAIN (for Bank 2)
a. Align the mark plate (yellow) with the timing marks (2 dot mark) of the camshaft timing gears as shown in the illustration.
b. Apply a light coat of engine oil to the bolt threads and bolt-seating surface.
c. 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.

d. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm 74 ft. lbs.)
e. Remove the pin from the chain tensioner No.2.

38. INSTALL NO.1 CHAIN VIBRATION DAMPER
a. Install the chain vibration damper No.1 with the 2 bolts.
Torque: 20 Nm (204 kgf-cm 15 ft. lbs.)

39. INSTALL NO.2 CHAIN VIBRATION DAMPER
a. Install the 2 chain vibration damper No.2.

40. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
a. Install the timing gear set keys and timing gear as shown in the illustration.

41. INSTALL IDLE SPROCKET ASSEMBLY
a. Apply a light coat of engine oil to rotating surface of the idle gear shaft No.1.
b. Temporarily install the idle gear shaft No.1 and idle sprocket with the idle gear shaft No.2 while aligning the knock pin of the idle gear No.1 with the knock pin groove of the cylinder block.

NOTICE: Be careful of the idle gear direction.

c. Using a 10 mm hexagon wrench, tighten the idle gear shaft No.2.
Torque: 60 Nm (612 kgf-cm 44 ft. lbs.)

42. INSTALL CHAIN SUB-ASSEMBLY
a. 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.

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

c. 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.

d. Temporarily tighten the pulley set bolt.

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

43. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper.

44. INSTALL NO.1 CHAIN TENSIONER ASSEMBLY
a. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
b. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the hole of the stopper plate.
c. Install the chain tensioner No.1 with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

d. Remove the lock pin of the chain tensioner assembly No.1. Check that each timing mark is aligned with the crankshaft at the TDC/compression.
e. Remove the pulley set bolt.

5. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Install a new gasket and the chain cover plate with the 4 bolts.
Torque: 9.1 Nm (93 kgf-cm 81 inch lbs.)
b. Apply seal packing in a continuous bead to the engine unit as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 5.0 to 5.5 mm (0.197 to 0.217 inch)

NOTICE:
^ Be sure to clean and degrease the contact surfaces, especially 8 areas indicated by C in the illustration.
^ When the contact surfaces are wet, wipe off with an oil-free cloth before applying seal packing.
^ Install the crankcase within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

c. Apply seal packing in a continuous bead to the timing chain cover as shown in the illustration.
Seal packing:
08826-00080 or equivalent
08826-00100 or equivalent

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

HINT: Apply seal packing referring to the table and illustration below.

d. Install a new O-ring.

e. 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.

f. Install the timing chain cover with the 16 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt A 21 Nm (214 kgf-cm, 15 ft. lbs.) for except bolt A 21 Nm (214 kgf-cm, 15 ft. lbs.) for nut

Bolt Length:

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

g. Install a new gasket.
h. Install the timing chain cover plate to the timing chain cover with the 4 bolts.
Torque: 9.1 Nm (93 kgf-cm 81 inch lbs.)

46. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and the water pump with the 16 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt A 9.1 Nm (93 kgf-cm, 81 inch lbs.) for except bolt A

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

47. INSTALL OIL PAN BAFFLE PLATE
a. Install the oil pan baffle plate with the 8 bolts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

48. INSTALL OIL STRAINER SUB-ASSEMBLY (for 2WD)

a. Using an E6 torx socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm 35 inch lbs.)

2wd:

b. Install anew gasket and the oil strainer with the 3 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)
c. Install 2 new O-rings.

49. INSTALL OIL STRAINER SUB-ASSEMBLY (for 4WD)

a. Using an E6 torx socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm 35 inch lbs.)

4wd:

b. Install anew gasket and the oil strainer with the 2 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)
c. Install 2 new O-rings.

50. INSTALL OIL PAN SUB-ASSEMBLY (for 2WD)
a. Using an E6 torx socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm 35 inch lbs.)

b. Apply seal packing in a continuous bead 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 inch)

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

c. Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.) for nut

51. INSTALL OIL PAN SUB-ASSEMBLY (for 4WD)
a. Using an E6 torx socket wrench, install the stud bolts as shown in the illustration.
Torque: 4.0 Nm (41 kgf-cm 35 inch lbs.)

c. Install the oil pan with the 16 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.) for nut

4wd:

52. INSTALL OIL STRAINER SUB-ASSEMBLY (for 4WD)
a. Install anew gasket and the oil strainer with the 3 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

53. INSTALL NO.2 OIL PAN SUB-ASSEMBLY (for 2WD)
a. Apply seal packing in a continuous bead 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 inch)

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

2wd:

b. Install the oil pan No.2 with the 15 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)
c. Install a new gasket and the drain plug.
Torque: 40 Nm (408 kgf-cm 30 ft. lbs.)

54. INSTALL NO.2 OIL PAN SUB-ASSEMBLY (for 4WD)
a. Apply seal packing in a continuous bead 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 inch)

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

4wd:

b. Install the oil pan No.2 with the 14 bolts and 2 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)
c. Install a new gasket and the drain plug.
Torque: 40 Nm (408 kgf-cm 32 ft. lbs.)

55. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH
a. Apply seal packing as shown in the illustration.
Seal packing: 08826-00080 or equivalent

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

b. Install the gasket to the head cover.

c. Install the head cover with the 14 bolts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.) for bolts except A

56. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Apply seal packing as shown in the illustration.
Seal packing: 08826-00080 or equivalent

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

b. Install the gasket to the head cover.

c. Install the head cover with the 14 bolts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.) for bolts except A

57. INSTALL WATER BY-PASS JOINT RR
a. Install 2 new gaskets and a new O-ring.
b. Apply soapy water to the O-ring.
c. Install the water by-pass joint RR with the 2 bolts and 4 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

58. INSTALL WITH THERMOSTAT WATER INLET SUB-ASSEMBLY
a. Install anew gasket and with thermostat water inlet with the 3 nuts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

59. INSTALL WATER INLET
a. Install 2 new O-rings.
b. Apply soapy water to the O-ring.
c. Install the water inlet with the 4 bolts and nut.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)
d. Install the 3 water by-pass hose inlet with the water inlet.

60. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 250 Nm (2,550 kgf-cm 184 ft. lbs.)

61. INSTALL OIL FILTER ELEMENT (for 2WD)
a. Clean the inside of the oil filter cap, the threads and O-ring groove.
b. Apply a light coat of engine oil to a new O-ring and install it to the oil filter cap.
c. Set a new oil filter element to the oil filter cap.
d. Remove dirt or foreign matter from the installation surface and inside of the engine.
e. 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.

f. Using SST, tighten the oil filter cap.
SST 09228-06501
Torque: 25 Nm (255 kgf-cm 18 ft. lbs.)

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

62. INSTALL OIL FILTER BRACKET (for 4WD)
a. Install anew gasket and the oil filter bracket with the bolt and 2 nuts.
Torque: 21 Nm (214 kgf-cm 15 ft. lbs.)

63. REMOVE OIL FILTER ELEMENT (for 4WD)
a. Clean the inside of the oil filter cap, the threads and O-ring groove.
b. Apply a light coat of engine oil to a new O-ring and install it to the oil filter.
c. Set a new oil filter element to the oil filter cap.
d. Remove dirt or foreign matter from the installation surface and inside of the engine.
e. Apply a light coat of engine oil to the O-ring again and install the oil filter cap.

f. Using SST, tighten the oil filter cap.
SST 09228-06501
Torque: 25 Nm (255 kgf-cm 18 ft. lbs.)

NOTICE:
^ Make sure that the oil filter is installed securely as shown in the illustration.
^ Be careful that the O-ring does not get caught between the parts.

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

NOTICE: Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

Torque: 13 Nm (133 kgf-cm 10 ft. lbs.)

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

64. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Apply adhesive around the drain cock.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent

b. Install the cylinder block water drain cock as shown in the illustration.
Torque: 30 Nm (306 kgf-cm 22 ft. lbs.)

NOTICE:
^ Do not rotate the drain cocks more than 1 revolution (360°) after tightening the drain cocks with the specified torque.
^ Do not loosen the drain cock plug to the water drain cock sub-assembly.

c. Install the water drain cock plug to the water drain cock sub-assembly.
Torque: 13 Nm (130 kgf-cm ft. lbs.)

65. INSTALL NO.1 OIL PIPE
a. Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.
b. Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install oil pipe No.1 (on the head cover side).
c. Install a new gasket and temporarily install oil pipe No.1 (on the cylinder head side) with the oil check valve bolt.
d. Tighten the oil pipe union (on the head cover side).
Torque: 60 Nm (612 kgf-cm 44 ft. lbs.)
e. Tighten the oil check valve bolt (on the cylinder head side).
Torque: 60 Nm (612 kgf-cm 44 ft. lbs.)

66. INSTALL NO.2 OIL PIPE
a. Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.
b. Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install oil pipe No.2 (on the head cover side).
c. Install a new gasket and temporarily install oil pipe No.2 (on the cylinder head side) with the oil check valve bolt.
d. Tighten the oil pipe union (on the head cover side).
Torque: 60 Nm (612 kgf-cm 44 ft. lbs.)
e. Tighten the oil check valve bolt (on the cylinder head side).
Torque: 60 Nm (612 kgf-cm 44 ft. lbs.)

67. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

68. INSTALL CAMSHAFT OIL CONTROL VALVE ASSEMBLY LH
a. Install the 4 camshaft timing oil control valves with the 4 bolts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

69. INSTALL CAMSHAFT POSITION SENSOR
a. Install the 4 camshaft position sensors with the 4 bolts.
Torque: 10 Nm (102 kgf-cm 7 ft. lbs.)

70. INSTALL VENTILATION VALVE SUB-ASSEMBLY
a. Apply adhesive around the ventilation valve.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
b. Install the ventilation valve sub-assembly
Torque: 27 Nm (275 kgf-cm 20 ft. lbs.)

71. INSTALL SPARK PLUG
a. Install the spark plugs.
Torque: 18 Nm (184 kgf-cm 13 ft. lbs.)

72. INSTALL NO.2 ENGINE HANGER
a. Install the engine hanger with the 2 bolts.
Torque: 33 Nm (337 kgf-cm 24 ft. lbs.)

73. INSTALL NO.1 ENGINE HANGER
a. Install the engine hanger with the 2 bolts.
Torque: 33 Nm (337 kgf-cm 24 ft. lbs.)

74. INSTALL RADIATOR CAP SUB-ASSEMBLY
a. Install the radiator cap sub-assembly

75. INSTALL OIL FILTER CAP SUB-ASSEMBLY
a. Install the oil filter cap sub-assembly.