Part 4

RH Bank:

LH Bank:

OVERHAUL
75. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY





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

NOTICE: Install it with the lock-pin engaged and locked at the most retard angle position.

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

NOTICE:
^ Be sure to apply the oil, otherwise the specified torque cannot be obtained.
^ New nuts must be used when replacing the VVT-i unit.





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

NOTICE:
^ The lock nut has LH threads.
^ Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.

76. INSTALL NO.2 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, damage to the cylinder head or to the camshaft may result. 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 the 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 in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Install the No. 1 bearing cap within 5 minutes after applying seal packing.
^ Do not expose the seal to 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 of the bearing cap bolts.





i. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
77. 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, damage to the cylinder head or to the camshaft may result. 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 the mark on the 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 of the bearing cap bolts.





f. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g. Remove the service bolt.
78. INSTALL NO.4 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, damage to the cylinder head or to the camshaft may result. 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 (1 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 in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Install the No. 1 bearing cap within 5 minutes after applying seal packing.
^ Do not expose the seal to 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 of the bearing cap bolts.





i. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
79. 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, damage to the cylinder head or to the camshaft may result. 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 (1 dot marks) of the camshaft drive with the mark on the 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 of the bearing cap bolts.





f. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g. Remove the service bolt.





80. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the keyway of the timing pulley with the key located on the crankshaft and slide the timing pulley into place.

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

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





81. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
82. INSTALL OIL LEVEL GAGE GUIDE
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.)
83. INSTALL OIL FILTER SUB-ASSEMBLY
a. Using a socket hexagon wrench 12, 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
84. INSTALL TIMING BELT IDLER BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
85. INSTALL TIMING BELT NO.3 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.

HINT: If there is a trace that water is entering at the visual check, repair it with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 inch). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 inch) and more.





b. If the timing belt cover gasket is needed to repair, follow the procedure.
1. Repair the cracks and breaks by applying the seal packing to the damaged area.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: When applying the seal packing, apply it as wide and high as the gasket.

c. If the timing belt cover gasket is needed to replace, follow the procedure.
1. Using a screwdriver and gasket scraper, remove the remaining gasket.

NOTICE: Be careful not to damage the timing belt cover.





2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.

NOTICE:
^ Affix the gasket in the center of the groove.
^ At the corners, try to keep the gasket thickness uniform.





HINT:

3. If there is a gap on the joint of the gasket, apply seal packing to close the gap.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: When applying the seal packing, apply it as wide and high as the gasket.

d. Install the timing belt cover with the 6 bolts.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)





86. INSTALL CAMSHAFT TIMING PULLEY
a. Pay attention to the orientation of the belt guide, install the camshaft timing pulley with the belt guide properly oriented and tighten the bolt temporally.

HINT:
^ Face the belt guide of the RH timing pulley toward front of the engine.
^ Face the belt guide of the LH timing pulley toward rear of the engine.





b. Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-10007, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)





c. Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)
87. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
88. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.1
a. Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
89. INSTALL TIMING BELT
a. Remove any oil or water on the pulleys, and keep them clean.

NOTICE:
^ If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
^ Wipe only the pulleys; do not use any cleaning agent.

b. Inspect the idler pulleys.
1. Check that the idler pulley turns smoothly.
2. Visually check the seal portion of the idler pulley for oil leakage.
c. Inspect the water pump.
1. Turn the pulley, and check that water pump bearing moves smoothly and does not make noise.
2. Visually check the drain hole for coolant leakage.
d. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.





e. Turn the crankshaft counterclockwise by approximately 60°.

NOTICE: To prevent contacting the piston head and the valve head, set the crankshaft pulley at 60° BTDC/compression position.





f. Using SST, turn the crankshaft pulley, and align the timing marks of the timing pulley with the No. 3 timing belt cover.
SST 09960-10010 (09962-01000, 09963-01000)





g. Turn the crankshaft, and align the timing mark of the crankshaft timing pulley with the oil pump body.





h. Face the front mark on the timing belt forward.
i. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
j. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.








k. Install the timing belt in this order.
90. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
a. Set the timing belt tensioner upright on the press.





b. Slowly press in the push rod.

NOTICE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbs.) to the rod.

c. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
d. Release the press.
e. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)

NOTICE: Be sure to tighten the bolts equally. Installing the tensioner at an angle may cause failure of its proper operation.

f. Remove the 1.5 mm hexagon wrench from the tensioner.





g. Turn the crankshaft 2 revolutions slowly, and align the timing mark of the crankshaft timing pulley with the oil pump body.

NOTICE: Always turn the crankshaft clockwise.





h. Check the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the No. 3 timing belt cover as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
i. Remove the crankshaft pulley bolt.





91. INSTALL TIMING BELT GUIDE NO.2
a. Install the timing belt guide, facing the cup side toward the engine front.
92. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
93. INSTALL TIMING BELT NO.2 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace that water is entering at the visual check, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
94. INSTALL TIMING BELT NO.1 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace that water is entering at the visual check, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)





95. INSTALL CRANKSHAFT PULLEY
a. Align the keyway of the pulley with the key located on the crankshaft and slide the pulley into place.
b. Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 Nm (2,250 kgf-cm, 162 ft. lbs.)
96. INSTALL VVT SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
97. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
98. INSTALL ENGINE HANGER NO.2
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)





99. INSPECT VALVE CLEARANCE
a. Turn the crankshaft pulley, and align the timing notch with the timing mark "0" of the No. 1 timing belt cover.
b. Check that the valve lifters on the No. 1 (IN and EX) are both loose.
If not, turn the crankshaft 1 revolution (360°) and align the mark as above.





c. Check the valves indicated in the illustration on the left.
1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
Valve clearance (Cold):
Intake 0.15 to 0.25 mm (0.0059 to 0.0098 inch)
Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





d. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
Valve clearance (Cold):
Intake 0.15 to 0.25 mm (0.0059 to 0.0098 inch)
Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





e. Turn the crankshaft 2/3 of a revolution (240°), and check the valves indicated in the illustration on the left.
1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
Valve clearance (Cold):
Intake 0.15 to 0.25 mm (0.0059 to 0.0098 inch)
Exhaust 0.25 to 0.35 mm (0.0098 to 0.0138 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
100. ADJUST VALVE CLEARANCE





a. Turn the camshaft so that the cam lobe faces upward.
b. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.





c. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).
SST 09248-55040 (09248-05410, 09248-05420)





HINT:
^ Apply SST (B) at a slight angle on the side marked with "9" or "7" at the position shown in the illustration.
^ When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side at a slight angle.





d. Using a small screwdriver and magnetic finger, remove the adjusting shim.





e. Using a micrometer, measure the thickness of the removed shim.





f. Calculate the thickness of a new shim so the valve clearance comes within the specified value.
Specified value (Cold): Intake A = B + (C - 0.20 mm (0.0079 inch)) Exhaust A = B + (C - 0.30 mm (0.0118 inch))





g. Select a new shim with a thickness as close as possible to the calculated values.

HINT:
^ Shims are available in 17 sizes in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch).
^ Refer to new shim thickness table on the next 2 tables.





Adjusting Shim Selection Chart (Intake)





Adjusting Shim Selection Chart (Exhaust)





h. Place a new adjusting shim on the valve lifter with imprinted number facing down.
i. Press down the valve lifter with SST (A), and remove SST (B).
SST 09248-55040 (09248-05410, 09248-05420)
j. Recheck the valve clearance.
101. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Install the gasket to the cylinder head cover.





b. Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes after applying seal packing.
^ Do not start the engine within 2 hours after installing.

c. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
102. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Install the gasket to the cylinder head cover.





b. Apply seal packing to the cylinder head as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes after applying seal packing.
^ Do not start the engine within 2 hours after installing.

c. Install the cylinder head cover with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
103. INSTALL SPARK PLUG
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)