Part 3

OVERHAUL (CONTINUED)

51. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Measure the worn depth of the chain vibration damper No.1.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain vibration damper No.1.

52. INSPECT CHAIN VIBRATION DAMPER NO.2
a. Measure the worn depth of the chain vibration damper No.2.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain vibration damper No.2.

53. INSTALL ENGINE REAR OIL SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-78010
b. Apply MP grease to the oil seal lip.
54. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.

b. Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Parts must be assembled within 3 minutes of application. Otherwise the seal packing must be removed and reapplied.

c. Install the oil seal retainer with the 5 bolts and 2 nuts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for nut
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt

55. INSTALL KNOCK SENSOR
a. Install the 2 knock sensors with the 2 bolts as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
b. Connect the knock sensor connectors.
56. INSTALL WATER OUTLET PIPE NO.1

a. Install the water outlet pipe with the 3 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
57. INSTALL CYLINDER HEAD GASKET
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

b. Apply seal packing (diameter: 2.5 to 3 mm (0.098 to 0.118 inch)) to a new cylinder head gasket as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: Install the cylinder head within 3 minutes after applying seal packing. After installing it, the cylinder head bolts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.

c. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

NOTICE:
^ Be careful of the installation direction.
^ Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

58. INSTALL CYLINDER HEAD SUB-ASSEMBLY
a. Place the RH cylinder head on the cylinder head gasket.
b. Install the 8 cylinder head bolts and plate washers.

HINT:
^ The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)).
^ If any cylinder head bolt is broken or deformed, replace it.

1 Apply a light coat of engine oil to the threads of the cylinder head bolts.
2 Install the plate washer to the cylinder head bolt.

3 Using several steps, tighten each bolt with a 10 mm bi-hexagon wrench uniformly in the sequence as shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

NOTICE: Do not drop the washers into the cylinder head.

4 Mark the front side of each cylinder head bolt with paint.
5 Retighten the cylinder head bolts by 180° as shown.
6 Check that the painted marks are now at 180° opposite to the engine front.
59. INSTALL CYLINDER HEAD GASKET NO.2
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.

c. Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upper side facing upward.

NOTICE:
^ Be careful of the installation direction.
^ Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

60. INSTALL CYLINDER HEAD LH
a. Place the LH cylinder head on the cylinder head gasket.
b. Install the 8 cylinder head bolts and plate washers.

HINT:
^ The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)).
^ If any cylinder head bolt is broken or deformed, replace it.

1 Apply a light coat of engine oil to the threads of the cylinder head bolts.
2 Install the plate washer to the cylinder head bolt.

c. Install the 2 cylinder head bolts.
1 Apply a light coat of engine oil to the threads of the cylinder head bolts.
2 Install the 2 cylinder head bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

61. INSTALL CAMSHAFT BEARING NO.1
a. Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.

NOTICE:
^ Install the bearing while aligning it with the oil hole in the bearing cap.
^ Clean the backside of the bearing and the contact surface of the bearing cap and prevent oil from adhering to them.

62. INSTALL CAMSHAFT BEARING NO.2
a. Install the camshaft bearing No.2 to the cylinder head.

NOTICE: Clean the backside of the bearing and the bearing surface of the cylinder head.

63. INSTALL CAMSHAFTS

NOTICE: As 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, the portion of the cylinder head which receives 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. Set the crankshaft position.
1 Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key into the left horizontal position.

NOTICE: Having the crankshaft at the wrong angle can cause the piston head and valve head to come into contact with each other when you install the camshaft, causing damage. So always set the crankshaft at the correct angle.

b. Apply new engine oil to the thrust portion and journal of the camshafts.

c. Install the camshaft of the RH bank.
1 Place the 2 camshafts onto the RH cylinder head with the cam lobes of No.1 cylinder facing each direction as shown in the illustration.

2 Install the 8 bearing caps in their proper locations.
3 Apply a light coat of engine oil to the threads of the bearing cap bolts.

4 Install the 16 bearing cap bolts. Using several steps, tighten the bolts uniformly in the sequence as shown in the illustration.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
24 Nm (245 kgf-cm, 18 ft. lbs.) for 12 mm (0.47 inch) head

5 Turn the camshafts clockwise with a wrench until the camshaft knock pin comes 90° position to the cylinder head.

d. Install the camshafts of the LH bank.
1 Place the 2 camshafts onto the LH cylinder head with the cam lobes of No.2 cylinder facing as shown in the illustration.

2 Install the 8 bearing caps in their proper locations.
3 Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.

a. While pushing in the tensioner, insert a pin of [diameter]1.0 mm (0.039 inch) into the hole to fix it.

b. Install the chain tensioner No.2 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
65. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (RH BANK)

a. Align the mark links (yellow) with the timing marks (1-dot mark) of the camshaft timing gears as shown in the illustration.

b. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the RH camshafts.
c. Temporarily install the 2 camshaft timing gear bolts.

NOTICE: Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it.

d. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
e. Remove the pin from the chain tensioner No.2.
66. INSTALL CHAIN TENSIONER ASSEMBLY NO.3

a. While pushing in the tensioner, insert a pin of [diameter]1.0 mm (0.039 inch) into the hole to fix it.

b. Install the chain tensioner No.3 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
67. INSTALL CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)

a. Align the mark links (yellow) with the timing marks (1-dot mark and 2-dot mark) of the camshaft timing gears as shown in the illustration.

b. Align the timing marks on the camshaft timing gears with the timing marks on the bearing caps, and install the camshaft timing gears with the chain to the LH camshafts.
c. Temporarily install the 2 camshaft timing gear bolts.

NOTICE: Do not push the camshaft timing gear assembly to the camshaft forcibly when installing it.

d. Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
e. Remove the pin from the chain tensioner No.3.

68. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper No.1 with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

69. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
a. Align the timing gear set key with the key groove of the timing gear.
b. Install the timing gear onto the crankshaft with the gear facing inward as shown in the illustration.
70. INSTALL CHAIN TENSIONER SLIPPER

71. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
a. While turning the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.
b. While turning the stopper plate of the tensioner counterclockwise, insert a bar of [diameter]3.5 mm (0.138 inch) into the holes on the stopper plate and tensioner to fix the stopper plate.
c. Install the chain tensioner with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
72. INSTALL CHAIN SUB-ASSEMBLY

a. Set the No.1 cylinder to the TDC/ compression.
1 Align the timing marks of the camshaft timing gears and bearing caps.

2 Install the crankshaft pulley set bolt, and turn the crankshaft to align the crankshaft set key with the timing line of the cylinder block.

b. Align the mark link (yellow) with the timing mark of the crankshaft timing gear.

c. Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.
73. INSTALL CHAIN VIBRATION DAMPER NO.2
a. Install the 2 chain vibration damper No. 2.

74. INSTALL IDLE GEAR NO.1
a. Apply a light coat of engine oil to the rotating surface of the idle gear shaft No.1.
b. Temporarily install the idle gear shaft No.1 and idle gear No. 1 with the idle gear shaft No.2 while aligning the knock pin of the idle gear shaft No.1 with the knock pin groove of the cylinder block.

NOTICE: Be careful of the idle gear direction.

c. Using a 10 mm hexagon wrench, tighten the idle gear shaft No.2.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
d. Remove the bar from the chain tensioner.
75. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09226-10010
b. Apply MP grease to the oil seal lip.