Part 4

OVERHAUL (CONTINUED)
76. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY





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.)
77. INSPECT VALVE CLEARANCE
78. ADJUST VALVE CLEARANCE





79. INSTALL FAN BRACKET SUB-ASSEMBLY
a. Install the idler pulley with the 2 bolts and 2 nuts.
Torque:
16 Nm (160 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 as follows:
106 mm (4.17 inch) for 12 mm head (A)
114 mm (4.49 inch) for 14 mm head (B)





80. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (160 kgf-cm, 11 ft. lbs.)

HINT: Use a bolt 106 mm (4.17 inch) in length.





81. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Install the timing belt cover and fit the claws and pins into each part.
b. Install the timing belt cover with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)

HINT: Use bolts 106 mm (4.17 inch) in length.





82. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
a. Install the idler pulley and cover plate with the bolt.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
83. 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.





84. 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 gasket to the cylinder head cover.
d. Install the seal washer to the bolt.
e. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several steps.
Torque: 6.0 Nm (60 kgf-cm, 53 inch lbs.)





85. 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.)
86. INSTALL OIL FILLER CAP SUB-ASSEMBLY
87. INSTALL SPARK PLUG
Torque: 18 Nm (178 kgf-cm, 13 ft. lbs.)
88. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY





a. Apply seal packing to 2 or 3 threads.
Seal packing: Part No. 08826-00100 or equivalent





b. Install the 2 drain cocks.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

HINT: After tightening to the specified torque, rotate the drain union clockwise until its drain port is facing forward.





89. INSTALL ENGINE HANGER NO.1
a. Install the 2 engine hangers with the 4 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)