Part 2
ENGINE UNIT REASSEMBLY Continued25. INSTALL CAMSHAFT (for Bank 2)
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 receiving 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.
a. Set the crankshaft position.
(1) Using the crankshaft damper bolt, turn the crankshaft, and set the set key of the crankshaft to 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body.
NOTICE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.
b. Apply MP grease to the thrust portion of the camshafts.
c. Align the timing marks (1 dot mark each) of the camshaft drive and driven main gears, and place the 2 camshafts.
d. Set the timing marks (1 dot mark each) of the camshaft drive and driven main gears at approximately 10° angle.
e. Apply seal packing to the camshaft housing plug.
(1) Remove the old packing (FIPG) material.
(2) Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
f. Install the camshaft housing plug to the cylinder head as shown in the illustration.
g. Install the oil control valve filter to the cylinder head.
NOTICE: Be careful of the installation direction.
h. 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.
(2) Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal width: 1.5 to 2.0 mm (0.059 to 0.079 inch)
NOTICE: Do not apply seal packing to the front bearing cap grooves.
i. Install the front bearing cap.
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.
j. Install the other bearing caps in the sequence shown with the arrow mark facing forward.
k. Push in the camshaft setting oil seal.
l. Install new seal washers to the bearing cap bolts (A and B).
m. Apply a light coat of engine oil on 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 bolt A, B and C.
Bolt length:
94 mm (3.70 inch) for A with seal washer
72 mm (2.83 inch) for B with seal washer
25 mm (0.98 inch) for C
52 mm (2.05 inch) for D
38 mm (1.50 inch) for E
n. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
o. Uniformly tighten the 22 bearing for other bolts
p. Remove the service bolt.
26. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY (for Bank 1)
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 receiving 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.
a. Check that the set key of the crankshaft is at the position 45° counterclockwise from the timing mark (1 dot mark) of the oil pump body
NOTICE: The crankshaft must be at the correct angle to avoid damage in later steps. If the crankshaft is at the wrong angle and then the camshaft is installed, the piston head and valve head may come in contact and be damaged.
b. Apply MP grease to the thrust portion of the camshafts.
LH Bank:
c. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the 2 camshafts.
d. Apply seal packing to the camshaft housing plug.
(1) Remove the old packing (FIPG) material.
(2) Apply seal packing to the housing plug as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
e. Install the camshaft housing plug to the cylinder head as shown in the illustration.
f. Install the oil control valve filter to the cylinder head.
NOTICE: Be careful of the installation direction.
g. Apply seal packing to the front bearing cap.
(1) Remove any old packing (FIPG) material.
(2) Apply seal packing to the bearing cap as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal width: 1.5 to 2.0 mm (0.059 to 0.079 inch)
NOTICE: Do not apply seal packing to the front bearing cap grooves.
h. Install the front bearing cap.
HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.
i. Install the other bearing cap in the sequence shown with the arrow mark facing forward.
j. Push in the camshaft setting oil seal.
k. Install new seal washers to the bearing cap bolts (A and B).
l. Apply a light coat of engine oil on 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 bolt A, B and C.
Bolt length:
94 mm (3.70 inch) for A with seal washer
72 mm (2.83 inch) for B with seal washer
25 mm (0.98 inch) for C
52 mm (2.05 inch) for D
38 mm (1.50 inch) for E
m. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.
n. Uniformly tighten the 22 bearing for other bolts
o. Remove the service bolt.
27. INSTALL REAR TIMING BELT PLATE RH
a. Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
28. INSTALL REAR NO.2 TIMING BELT PLATE RH
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
29. INSTALL REAR TIMING BELT PLATE LH
a. Install the timing belt plate with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
30. INSTALL REAR NO.2 TIMING BELT PLATE LH
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
31. 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.
32. 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.
33. 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, facing the flange side inward.
SST 09223-46011
34. INSTALL NO.2 TIMING BELT IDLER SUB-ASSEMBLY
a. Install the idler with the bolt.
Torque: 34.5 Nm (351 kgf-cm, 25 ft. lbs.)
b. Check that the idler moves smoothly.
35. INSTALL NO.1 TIMING BELT IDLER SUB-ASSEMBLY
a. Apply adhesive to 2 to 3 threads of the pivot bolt.
Adhesive: Part No.08833-00080, THREE BOND 1344, LOCATE 242 or equivalent
b. Using a 10 mm hexagon wrench, install the plate washer and idler with the pivot bolt.
Torque: 34.5 Nm (351 kgf-cm, 25 ft. lbs.)
c. Check that the idler bracket moves smoothly.
36. 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 aligned.
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 belt forward.
(3) Connect the belt to the crankshaft timing pulley Align the installation mark of the crankshaft timing pulley
(4) Connect the belt to the No.2 idler.
(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. Align the installation mark on the belt with the timing mark of the camshaft timing pulley
(8) Connect the timing belt to the No.1 idler.
c. 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 lbs.) 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.
d. 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.
e. Check the valve timing.
(1) Using the crankshaft damper bolt, slowly turn the crankshaft timing 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 belt and reinstall it.
37. INSTALL NO.1 CRANKSHAFT POSITION SENSOR PLATE
a. Install the crankshaft position sensor plate as shown in the illustration.
NOTICE: Be careful of the installation direction.
38. INSTALL TIMING GEAR COVER SPACER
a. Install the gasket to the cover spacer.
b. Install the cover spacer.
39. INSTALL NO.1 TIMING BELT COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
40. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY
a. Align the damper set key with the key groove of the crankshaft damper.
b. Using SST and a hammer, tap in the crankshaft damper.
SST 09223-46011
c. Using SST, install the damper bolt.
SST 09213-70011, 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)
41. ADJUST VALVE CLEARANCE
42. INSTALL IDLER PULLEY ASSEMBLY
43. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
44. INSTALL NO.2 TIMING BELT COVER SUB-ASSEMBLY
45. INSTALL NO.2 IDLER PULLEY SUB-ASSEMBLY
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
46. 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.
47. 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.)
48. INSTALL OIL FILLER CAP SUB-ASSEMBLY
49. INSTALL SPARK PLUG