Part 2

PARTIAL ENGINE ASSEMBLY
OVERHAUL
34. REMOVE OIL PAN SUB-ASSEMBLY NO.2
35. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 3 bolts, 2 nuts and baffle plate.
36. REMOVE OIL PAN SUB-ASSEMBLY
37. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt, 2 nuts, oil strainer and gasket.
38. REMOVE OIL PUMP ASSEMBLY





39. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 7 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
c. Remove the O-ring.





40. REMOVE SPARK PLUG TUBE GASKET
a. Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more.
b. Using a screwdriver, pry out the gasket.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to damage the cylinder head cover.





41. INSTALL SPARK PLUG TUBE GASKET
a. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010, 09950-70010 (09951-00240, 09951-00440, 09951-07100, 09952-06010)

NOTICE: Be careful of the installation direction.

b. Apply a light coat of MP grease to the gasket lip.
c. Return the 4 ventilation case claws to its original position.





42. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY
a. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE:
^ Be careful not to damage the camshaft.
^ Do not remove the 4 bolts shown in the illustration. The bolts determine the backlash of the gear in the timing tube. If any of the bolts are removed, install a new timing tube assembly.





b. Remove the screw plug and seal washer.
c. Using a 10 mm hexagon wrench, and remove the bolt.
d. Pull out the timing tube and drive gear assembly from the camshaft.





e. Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.
SST 09960-10010 (09962-01000, 09963-00500)

NOTICE: Be careful not to damage the timing tube.





43. INSTALL CAMSHAFT SETTING OIL SEAL
a. Place a new oil seal onto the timing tube.

NOTICE: Be careful of the installation direction.

44. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY





a. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
b. Using SST and a 5 mm hexagon wrench, uniformly tight en the 4 bolts in several passes.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)

NOTICE: Be careful not to damage the timing tube.





c. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.





d. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
e. Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft. lbs.)
f. Install the seal washer and screw plug.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
45. REMOVE CAMSHAFT SUB GEAR





a. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.





b. Using SST, turn the sub gear clockwise and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)





c. Using snap ring plier, remove the snap ring.
d. Remove the wave washer, sub gear and bolt washer.

HINT: Arrange the driven sub gears and bolt washers (RH and LH sides).





46. INSPECT CAMSHAFT TIMING GEAR BOLT WASHER
a. Using a vernier caliper, measure the gap between the washer ends.
Gap: 18.2 to 18.8 mm (0.712 to 0.740 inch)
If the result is not as specified, replace the washer.
47. INSTALL CAMSHAFT SUB GEAR





a. Install the bolt washer (1), sub gear (2) and wave washer (3).

HINT: Attach the pins on the gears to the gear bolt washer ends.





b. Using snap ring pliers, install the snap ring.





c. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.





d. Using SST, align the holes of the driven main gear and sub gear by turning the sub gear clockwise. Temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
e. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.





48. REMOVE OIL PUMP SEAL
a. Using a screwdriver and wooden block, pry out the oil seal.

HINT: Tape the screwdriver tip before use.

NOTICE: Be careful not to damage the oil pump body.





49. INSTALL OIL PUMP SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09316-60011 (09316-00011)
b. Apply MP grease to the oil seal lip.





50. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and hammer, tap out the oil seal.





51. INSTALL ENGINE REAR OIL SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-56010
b. Apply MP grease to the oil seal lip.
52. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
1. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
2. Thoroughly clean all components to remove all the loose material.
3. Using a non-residue solvent, clean both sealing surfaces.





b. Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
1. Install a nozzle that has its opening cut to 3 to 4 mm (0.12 to 0.16 inch).
2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
3. Immediately remove the nozzle from the tube and reinstall the cap.





c. Install a new O-ring to the cylinder block.
d. Install the oil seal retainer with the 7 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
53. INSTALL OIL PUMP ASSEMBLY
54. INSTALL OIL STRAINER SUB-ASSEMBLY





55. INSTALL OIL PAN STUD BOLT
56. INSTALL OIL PAN SUB-ASSEMBLY
57. INSTALL OIL PAN BAFFLE PLATE
58. INSTALL OIL PAN SUB-ASSEMBLY NO.2





59. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and water pump with the 5 bolts, 2 stud bolts and nut. Uniformly tighten the bolts, stud bolts and nut in several passes.
Torque:
21 Nm (214 kgf-cm, 16 ft. lbs.) for bolt
18 Nm (184 kgf-cm, 13 ft. lbs.) for stud bolt and nut

HINT: Use bolts that are 30 mm (1.18 inch) in length.

60. INSTALL CYLINDER HEAD SUB-ASSEMBLY





a. Place a new cylinder head gasket on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3R" mark is on the RH bank's gasket.

NOTICE: Be careful of the installation direction.

b. Place the cylinder head on the cylinder head gasket.





c. Install the cylinder head bolts.

HINT:
^ The cylinder head bolts are tightened in 2 progressive steps (steps (3) and (5)).
^ If any cylinder head bolt is broken or deformed, replace it.

1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
2. Install the plate washer to the cylinder head bolt.
3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown in the illustration.

Torque: 59 Nm (602 kgf-cm, 44 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.





NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.





4. Mark the front of the cylinder head bolt head with paint.
5. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
6. Check that the painted mark is now at a 90° angle to front.
61. INSTALL CYLINDER HEAD LH





a. Place a new cylinder head gasket on the cylinder block.

HINT: The rear side of the cylinder head gasket has marks so that the RH and LH banks can be distinguished. A "3L" mark is on the LH bank's gasket.

NOTICE: Be careful of the installation direction.

b. Place the cylinder head on the cylinder head gasket.





c. Install the cylinder head bolts.

HINT:
^ The cylinder head bolts are tightened in 2 progressive steps (steps (3) and (5)).
^ If any cylinder head bolt is broken or deformed, replace it.

1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
2. Install the plate washer to the cylinder head bolt.
3. Install and uniformly tighten the 10 cylinder head bolts on one side of the cylinder head in several passes in the sequence shown in the illustration.
Torque: 59 Nm (602 kgf-cm, 44 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.





NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.





4. Mark the front of the cylinder head bolt head with paint.
5. Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
6. Check that the painted mark is now at a 90° angle to front.

62. INSTALL CAMSHAFT

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 90° 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. Install the camshafts of the RH bank.
1. Apply MP grease to the thrust portion of the camshafts.
2. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and place the 2 camshafts.
3. Set the timing mark (1 dot mark) of the camshaft drive and driven main gears at approximately 10° angle.





4. Apply seal packing to the camshaft housing plug.
- Remove the old packing (FIPG) material.
- Apply seal packing to the housing plug.
Seal packing: Part No. 08826-00080 or equivalent





5. Install the camshaft housing plug to the cylinder head as shown in the illustration.
6. Install the oil control valve filter to the cylinder head.

NOTICE: Be careful of the installation direction.





7. Apply seal packing to the front bearing cap.
- 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.
- Using a razor blade and gasket scraper, re move all the old packing (FIPG) material from the gasket surfaces and groove.
- Thoroughly clean all components to remove all loose material.
- Using a non-residue solvent, clean both sealing surfaces.
- Apply seal packing to the bearing cap as shown in the illustration.
- Install a nozzle that has been cut to a 1.5 to 2.0 mm (0.059 to 0.79 inch) opening.
- Parts must be assembled within 5 minutes of application. Otherwise, the seal packing must be removed and reapplied.
- Immediately remove the nozzle from the tube and reinstall the cap.

Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Do not apply seal packing to the front bearing cap grooves.





8. Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

9. Install the other bearing caps in the sequence shown with the arrow mark facing forward.





10. Push in the camshaft setting oil seal.





11. Install a new seal washer to the bearing cap bolts (A and B).
12. 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 bolts (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

13. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.





14. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque:
7.5 Nm (77 kgf-cm, 66 inch lbs.) for bolt 21 and 22
16 Nm (163 kgf-cm, 12 ft. lbs.) for others





15. Remove the service bolt.
63. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY

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 the set key of the crankshaft is at the position of 90° 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. Install the camshafts of the LH bank.
1. Apply MP grease to the thrust portion of the camshafts.
2. Align the timing marks (2 dot marks each) of the camshaft drive and driven main gears, and place the 2 camshafts.





3. Apply seal packing to the camshaft housing plug.
- Remove the old packing (FIPG) material.
- Apply seal packing to the housing plug.
Seal packing: Part No. 08826-00080 or equivalent





4. Install the camshaft housing plug to the cylinder head as shown in the illustration.
5. Install the oil control valve filter to the cylinder head.

NOTICE: Be careful of the installation direction.





6. Apply seal packing to the front bearing cap.
- Remove any old packing (FIPG) material and be care not to drop any oil on the contact surfaces of the bearing cap and cylinder head.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and groove.
- Thoroughly clean all components to remove all loose material.
- Using a non-residue solvent, clean both sealing surfaces.
- Apply seal packing to the bearing cap as shown in the illustration.
- Install a nozzle that has its opening cut to 1.5 to 2.0 mm (0.059 to 0.79 inch).
- Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove the nozzle from the tube and reinstall the cap.

Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Do not apply seal packing to the front bearing cap grooves.





7. Install the front bearing cap.

HINT: Installing the front bearing cap will determine the thrust portion of the camshaft.

8. Install the other bearing cap in the sequence shown with the arrow mark facing forward.





9. Push in the camshaft setting oil seal.





10. Install a new seal washer to the bearing cap bolts (A and B).
11. 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

12. Install the oil feed pipe and the 22 bearing cap bolts as shown in the illustration.





13. Uniformly tighten the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
Torque:
7.5 Nm (77 kgf-cm, 66 inch lbs.) for bolt C
16 Nm (163 kgf-cm, 12 ft. lbs.) for others





14. Remove the service bolt.
64. INSTALL TIMING BELT PLATE RR RH
a. Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
65. INSTALL TIMING BELT PLATE RR RH NO.2
a. Install the timing belt plate with the 2 bolts.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
66. INSTALL TIMING BELT PLATE RR LH
a. Install the timing belt plate with the bolt.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)