Part 2

OVERHAUL
61. INSTALL ENGINE REAR OIL SEAL RETAINER [11381 / 98-9]
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 2 - 3 mm (0.08 - 0.12 inch) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Remove any oil from the contact surface. Install the oil seal retainer within 3 minutes after applying seal packing. Do not put into engine oil within 2 hours after installing.

c. Install the oil seal retainer with the 6 bolts, uniformly tighten the bolt in several passes.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





62. INSTALL OIL PUMP SEAL [15100C / 98-15]
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

NOTICE: Be careful not to tap the oil seal slantingly. Keep the lip off foreign materials. Apply MP grease to the oil seal lip.

63. INSTALL OIL PUMP ASSY [15100 / 98-15]





a. Remove any old packing material from the contact surface.
b. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.





c. Apply seal packing in the shape of bead (Diameter 2 - 3 mm (0.08 - 0.12 inch) consequently as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
- Apply seal packing to the inner side of the bolt hole.
- Remove any oil from contact surface. Install the oil pump within 3 minutes after applying seal packing. Do not put into engine oil within 2 hours after installing.]





d. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.
e. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
64. INSTALL CRANK POSITION SENSOR [15100R / 98-15]
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
65. INSTALL OIL PAN BAFFLE PLATE [12121 / 98-7]
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
66. INSTALL OIL PAN SUB-ASSY [12101 / 98-7]
a. Remove any old packing material from the contact surface.





b. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.12 - 0.16 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
- Apply seal packing to the outer side of the bolt hole in the region "X".
- Apply seal packing to the inner side of the bolt hole in the region "Y".
- Remove any oil from the contact surface.
- Install the No. 1 oil pan within 3 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.

c. Install the No. 1 oil pan with the 15 bolts and 2 nuts. Uniformly tighten the bolts in several passes.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
67. INSTALL OIL STRAINER SUB-ASSY [15104 / 98-15]
a. Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)


68. INSTALL OIL PAN SUB-ASSY NO.2 [12102A / 98-7]
a. Remove any old packing material from the contact surface.





b. Apply seal packing in the shape of bead (Diameter 4 - 5 mm (0.16 - 0.20 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Remove any oil from the contact surface. Apply seal packing to the inner side of the bolt hole. Install the oil pan within 3 minutes after applying seal packing. Do not put into engine oil within 2 hours after installing.

c. Install the No. 2 oil pan with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
69. INSTALL OIL PAN DRAIN PLUG [12101A / 98-7]
a. Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
70. INSTALL CYLINDER BLOCK SIDE COVER (2WD DRIVE TYPE) [11271C / 98-7]
a. Install a new gasket and the cylinder block side cover with the 3 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
71. INSTALL CYLINDER BLOCK SIDE COVER DRAIN COCK PLUG (2WD DRIVE TYPE) [11271D / 98-7]
a. Install the drain cock plug with a new O-ring.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
72. INSTALL WATER INLET HOUSING [16323 / 98-20]
a. Remove any old packing material form the contact surface.





b. Apply seal packing in the shape of bead (Diameter 3 - 5 mm (0.12 - 0.20 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent

NOTICE:
- Remove any oil from the contact surface.
- Install the water inlet housing within 3 minutes after applying seal packing.
- Do not put into coolant within 2 hours after installing.





c. Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes, in the sequence shown.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





73. INSTALL CYLINDER HEAD GASKET [11115 / 98-5]
a. Place a new cylinder head gasket on the cylinder block surface with the R mark upward.

NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.

74. INSTALL CYLINDER HEAD SUB-ASSY [11101 / 98-5]

NOTICE: The cylinder head bolts are tightened in 2 progressive steps.

a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.





c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)




d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.





g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





75. INSTALL CYLINDER HEAD GASKET NO.2 [11116 / 98-5]
a. Place a new cylinder head gasket on the cylinder block surface with the L mark upward.

NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.

76. INSTALL CYLINDER HEAD LH [11102/ 98-5]

NOTICE: The cylinder head bolts are tightened in 2 progressive steps.

a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.





c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.





g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





77. INSTALL OIL CONTROL VALVE FILTER [15678A / 98-5]
a. Check that no foreign substance is on the mesh part of the filter.
b. Assemble the valve filter and plug.
c. Install the plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
78. INSTALL CYLINDER HEAD COVER REAR [11181A / 98-5]
a. Install the rear cover and a new gasket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
79. INSTALL CAMSHAFT SUB GEAR [13529 / 98-14]





a. Fix the hexagonal wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.





b. Install the camshaft gear spring and camshaft sub-gear.

HINT: Attach the pins on the gears to the gear spring ends.

c. Install the wave washer.





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





e. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
f. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: Be careful not to damage the camshaft journals.

HINT: When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the operation.

80. INSTALL CAMSHAFT TIMING GEAR ASSY [13050 / 98-14]





a. Align the knock pin with knock pin groove and install VVT-i on the camshaft.

NOTICE: Install it under the condition that the lock pin is operated and locked at the maximum delay angle position.

b. Apply the engine oil on the nut, the placing surface of VVT-i and the screw portion.

NOTICE:
- Be sure to apply the oil, otherwise the specified torque cannot be obtained.
- The nuts must be changed to the new one when changing VVT-1.





c. Using a 46 mm socket wrench, install and tighten a new lock nut by turning it counterclockwise.
Torque: 150 ± 5 Nm (1,530 ± 50 kgf-cm, 111 ± 4 ft. lbs.)

NOTICE: The lock nut has LH threads. Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion.

81. INSTALL NO.2 CAMSHAFT [13512 / 98-14]

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not 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. Apply new engine oil to the thrust portion and journal of the camshaft.





b. Place the No. 2 camshaft at a 90° angle of timing mark (2 dot marks) on the cylinder head.
c. Apply MP grease to a new oil seal lip.





d. Install the oil seal to the camshaft.

NOTICE:
- Do not turn over the oil seal lip.
- Insert the oil seal until it stops.

e. Remove any old packing material from the contact surface.





f. Apply seal packing to the No. 1 bearing cap as shown.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
- Install the No. 1 bearing cap within 5 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.





g. Install the 5 bearing caps in their proper locations.
h. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





i. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
82. INSTALL CAMSHAFT [13511 / 98-14]

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not 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. Apply new engine oil to the thrust portion and journal of the camshaft.





b. Align the timing marks (2 dot marks) of the camshaft drive with driven gears.
c. Place the camshaft on the cylinder head.





d. Install the 5 bearing caps in their proper locations.
e. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





f. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g. Remove the service bolt.
83. INSTALL NO.1 CAMSHAFT SUB-ASSY [13054 / 98-14]

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not 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. Apply new engine oil to the thrust portion and journal of the camshaft.





b. Place the No. 4 camshaft at a 90° angle of timing mark (2 dot marks) on the cylinder head.
c. Apply MP grease to a new oil seal lip.





d. Install the oil seal to the camshaft.

NOTICE:
- Do not turn over the oil seal lip.
- Insert the oil seal until it stops.

e. Remove any old packing material from the contact surface.





f. Apply seal packing to the No. 1 bearing cap as shown.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Install the No. 1 bearing cap within 5 minutes after applying seal packing. Do not put into engine oil within 2 hours after installing.





g. Install the 5 bearing caps in their proper locations.
h. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





i. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
84. INSTALL NO.3 CAMSHAFT SUB-ASSY [13053 / 98-14]

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being Installed. If the camshaft is not 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. Apply new engine oil to the thrust portion and journal of the camshaft.





b. Align the timing marks (2 dot marks) of the camshaft drive with driven gears. Place the camshaft on the cylinder head.





c. Install the 5 bearing caps in their proper locations.
d. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.





e. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
f. Remove the service bolt.





85. INSTALL CRANKSHAFT TIMING PULLEY [13521P / 98-13]
a. Align the pulley set key with the key groove of the timing pulley, and slide on the timing pulley.

NOTICE: Do not scratch the sensor part of the crankshaft timing pulley.

b. Install the timing belt plate with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





86. INSTALL WATER PUMP ASSY [16100 / 98-19]
a. Install a new gasket and the water pump with the 4 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
87. INSTALL OIL LEVEL GAGE GUIDE [11452 /98-7]
a. Apply a light coat of engine oil to a new O-ring and install it to the level gage guide.
b. Install the level gage guide.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
88. INSTALL OIL FILTER SUB-ASSY [15601 / 98-16]
a. Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
b. Check and clean the oil filter installation surface.
c. Apply clean engine oil to the gasket of a new oil filter.
d. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.





e. Using SST, tighten it an additional 3/4 turn.
SST 09228-07501
89. INSTALL TIMING BELT IDLER BRACKET [13584 / 98-141]
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)