Part 3
OVERHAUL61. INSTALL CRANKSHAFT TIMING PULLEY
a. Fit the timing pulley set key to the key groove of the pulley.
b. Using a SST and a hammer, tap in the timing pulley with the flange side is put inward.
SST 09223-46011
62. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
a. Install the idler with the bolt.
Torque: 35 Nm (352 kgf-cm, 25 ft. lbs.)
b. Check that the idler moves smoothly.
63. INSTALL TIMING BELT IDLER SUB-ASSY NO. 1
a. Apply adhesive 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: 35 Nm (352 kgf-cm, 25 ft. lbs.)
c. Check that the idler bracket moves smoothly
64. INSTALL CAMSHAFT TIMING PULLEYS
a. Fit the camshaft knock pin to the knock pin grove of the timing pulley. Likewise, Fit the knock pin for the rest of the timing pulleys.
b. Using a SST, install the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 108 Nm (1,101 kgf-cm, 80 ft. lbs.)
65. 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: By turning the camshaft timing pulleys clockwise as follows, the installing the timing pulleys will be easy:
1/2 teeth turn for the left bank camshaft timing pulley 1 teeth turn for the right bank camshaft timing pulley
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 the each pulley. Keep them clean after removal.
NOTICE: Only wipe the pulleys; do not use any cleansing agent.
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.
c. Set the belt tensioner.
1. Using a press, slowly press in the push rod using 981 - 9,807 N (100 - 1,000 kgf, 220 - 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 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 be aligned, remove the timing belt and reinstall it.
66. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the sensor plate with the cup side is put outward.
67. INSTALL TIMING GEAR COVER SPACER
a. Install the gasket to the cover spacer.
b. Install the cover spacer.
68. INSTALL TIMING BELT NO.1 COVER
a. Install the timing belt cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
69. INSTALL CRANKSHAFT DAMPER SUB-ASSY
a. Align the pulley 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 (90105-08076), 09330-00021
Torque: 245 Nm (2,498 kgf-cm, 181 ft. lbs.)
70. INSPECT VALVE CLEARANCE
71. ADJUST VALVE CLEARANCE
72. INSTALL FAN BRACKET SUB-ASSY
a. Install the idler pulley with the 2 bolts and 2 nuts.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.) for 12 mm head
32 Nm (326 kgf-cm, 24 ft. lbs.) for 14 mm head
HINT: Each bolt length is indicated in the illustration.
Bolt Length:
106 mm (4.17 inch) for 12 mm head (A)
114 mm (4.49 inch) for 14 mm head (B)
73. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (158 kgf-cm, 11 ft. lbs.)
HINT: Use a bolt 106 mm (4.17 inch) in length.
74. INSTALL TIMING BELT COVER SUB-ASSY NO.2
a. Install the timing belt cover and fit the claws and pins into each part.
b. Tighten the 2 bolts of the timing belt cover.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
HINT: Use bolts 106 mm (4.17 inch) in length.
75. INSTALL IDLER PULLEY SUB-ASSY NO.2
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
76. 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.
77. INSTALL CYLINDER HEAD COVER
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 casket to the cylinder head cover.
d. Install We seal washer to the bolt
e. Install tire cylinder head cover with the 9 bolts. Uniformly tighter, tire bolts in several passes.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
78. INSTALL OIL FILLER CAP HOUSING
a. Install a new gasket and the oil filler cap housing with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
79. INSTALL OIL FILLER CAP SUB-ASSY
80. INSTALL SPARK PLUG
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)
81. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a. Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent
b. Install the 2 drain unions.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing forward.
82. INSTALL ENGINE HANGER NO. 1
a. Install the 2 engine hangers with 4 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)