Part 2

ENGINE UNIT

COMPONENTS:

REASSEMBLY (STEPS 21-40)

21. 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 09223-00010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects.

b. Apply MP grease to the oil seal lip.
22. INSTALL OIL PUMP ASSEMBLY
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 a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

d. Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.

e. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
Bolt A 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt B 20 Nm (199 kgf-cm, 14 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)
23. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
24. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

25. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old seal packing from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 inch)) 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 outer side of the bolt holes in the region "X".
^ Apply seal packing to the inner side of the bolt holes in the region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install the oil pan No. 1 with the 15 bolts and 2 nuts.
Tighten the bolts uniformly in several steps.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
26. INSTALL OIL STRAINER SUB-ASSEMBLY
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.)

27. INSTALL OIL PAN SUB-ASSEMBLY NO. 2
a. Remove any old seal packing from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 inch)) 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 holes.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
28. INSTALL OIL PAN DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
29. INSTALL WATER INLET HOUSING
a. Remove any old packing material from the contact surface.

b. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 inch)) 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 expose the seal to coolant within 2 hours after installing.

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

30. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

31. INSTALL CYLINDER HEAD SUB-ASSEMBLY

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

a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.

c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (procedure B).
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

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

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

32. INSTALL CYLINDER HEAD GASKET NO. 2
a. Place a new cylinder head gasket on the cylinder block with the L mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

33. INSTALL CYLINDER HEAD LH
a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.

c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration (procedure C).
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

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

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

34. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign object is on the mesh part of the filter.
b. Assemble the valve filter and the plug.
c. Install the plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
35. INSTALL CYLINDER HEAD COVER REAR
a. Install the rear cover and a new gasket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
36. INSTALL CAMSHAFT SUB GEAR

a. Clamp the camshaft in a vise on the hexagonal lobe.

NOTICE: Be careful not to damage the camshaft.

b. Install the camshaft gear bolt washer and the camshaft sub-gear.

HINT: Attach the pins on the gears to the gear bolt washer 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 installation of the service bolt.

37. 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 to 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.

38. 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 to 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.)
39. 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 gear 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 to 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.
40. 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 the timing mark (1-dot mark) 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.

g. Install the 5 bearing caps in their proper locations.
h. Apply a light coat of engine oil to 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.)