Part 4

OVERHAUL (CONTINUED)
76. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.





b. Install a new O-ring to the LH cylinder head as shown in the illustration.





c. Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 inch)) to 4 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent





d. Apply a continuous bead of seal packing (diameter 3.0 to 4.0 mm (0.12 to 0.16 inch)) to the timing chain cover as shown in the illustration.
Seal packing:
Water pump part: Part No. 08826-00100 or equivalent
Other part: Part No. 08826-00080 or equivalent

NOTICE:
^ Install the timing chain cover within 3 minutes after applying seal packing. After installing it, the timing chain cover bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.
^ Do not apply seal packing to the "A" as shown in the illustration.





e. Align the key way of the oil pump drive rotor with the rectangular portion of the crankshaft timing gear, and slide the timing chain cover into place.





f. Install the timing chain cover with the 15 bolts and 2 nuts.
Tighten the bolts and nuts uniformly in several steps.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)

NOTICE:
^ Pay attention not to wrap the chain and slipper over the timing chain cover seal line.
^ After installing the timing chain cover, install the water pump within 15 minutes.

HINT: Each bolt length is as follows:
A: 25 mm (0.98 inch)
B: 55 mm (2.17 inch)





77. INSTALL WATER PUMP ASSEMBLY
a. Install a new gasket and the water pump with the 17 bolts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
23 Nm (235 kgf-cm, 17 ft. lbs.) for 12 mm (0.47 inch) head
78. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block, rear oil seal retainer and oil pan.





b. Install the 4 stud bolts.
Torque: 4.0 Nm (41 kgf-cm, 35 inch lbs.)





c. Install a new O-ring to the oil pump.





d. Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.12 to 0.16 inch)) to the oil pan as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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





e. Install the oil pan with the 17 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for bolt B
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt C
21 Nm (214 kgf-cm, 15 ft. lbs.)for nut

HINT: Each bolt length is as follows:
A 25 mm (0.98 inch)
B 45 mm (1.77 inch)
C 14 mm (0.55 inch)





79. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
80. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil pan and oil pan No.2.





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: Install the oil pan No.2 within 3 minutes after applying seal packing. After installing it, the oil pan No.2 bolts and nuts must be tightened within 15 minutes. Otherwise the seal packing must be removed and reapplied.





c. Install the oil pan No.2 with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt
10 Nm (102 kgf-cm, 7 ft. lbs.) for nut
81. INSTALL OIL PAN DRAIN PLUG
a. Install the drain plug and a new gasket.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)





82. INSTALL CRANKSHAFT PULLEY
a. Using SST, install the pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 250 Nm (2,549 kgf-cm, 184 ft. lbs.)
83. SET NO. 1 CYLINDER TO TDC/COMPRESSION
84. INSPECT VALVE CLEARANCE
85. ADJUST VALVE CLEARANCE
86. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.





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

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

c. Install the gasket to the cylinder head cover.
d. Install the seal washers to the bolts.





e. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt A
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt B
9.0 Nm (92 kgf-cm, 80 inch lbs.) for nut
87. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder head, timing chain cover and cylinder head cover.
b. Apply adhesive to the threads of the ventilation valve.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
c. Install the ventilation valve to the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)





d. Apply a continuous bead of seal packing (diameter: 2 to 3 mm (0.08 to 0.12 inch)) to the cylinder head and timing chain cover as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

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

e. Install the gasket to the cylinder head cover.
f. Install the seal washers to the bolts.





g. Install the cylinder head cover with the 10 bolts and 2 nuts. Tighten the bolts and nuts uniformly in several steps.
Torque:
10 Nm (102 kgf-cm, 7 ft. lbs.) for bolt A
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt B
9.0 Nm (92 kgf-cm, 80 inch lbs.) for nut





88. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign objects are present on the mesh part of the 2 filters.
b. Install 2 new gaskets to each new plug.
c. Insert the filters to the plugs.
d. Apply adhesive to 2 or 3 threads of the plugs.
Adhesive: Part No. 08833-00080, THREE BOND 1344 LOCTITE 242 or equivalent
e. Install the plugs to each cylinder head.
Torque: 62 Nm (632 kgf-cm, 46 ft. lbs.)
89. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
90. INSTALL VVT SENSOR
a. Apply a light coat of engine oil to the O-ring of each VVT sensor.
b. Install the 2 VVT sensors with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
91. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY





a. Apply adhesive to 2 or 3 threads of the drain cocks end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. After applying the specified torque, rotate the drain cock clockwise as shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

NOTICE:
^ Install the drain cock within 3 minutes after applying adhesive.
^ Do not expose the drain cock to coolant within 1 hour after installing.
^ Do not rotate the drain cock by more than 1 revolution (360°) after tightening the drain cock with the specified torque.
^ Do not loosen the drain cock after setting it correctly.





92. INSTALL OIL LEVEL GAUGE GUIDE
a. Install a new O-ring to the oil level gauge guide.
b. Apply a light coat of engine oil to the O-ring.
c. Push in the oil level gauge guide end into the guide hole of the oil pan.
d. Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





93. INSTALL ENGINE HANGER NO.2
a. Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
94. INSTALL ENGINE HANGER NO.1
a. Install the engine hanger with the 2 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)