ENGINE UNIT REASSEMBLY

INSTALL CYLINDER HEAD GASKET

1. 

   Text in Illustration

   *1	Lot No.
   	Engine Front

   Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

   Note

   
   

   • Make sure that the gasket is installed facing the proper direction.

   • Make sure that no oil is on the front end (indicated by the arrows) of the cylinder head gasket.

INSTALL CYLINDER HEAD SUB-ASSEMBLY

INSTALL NO. 2 CYLINDER HEAD GASKET

1. 

   Text in Illustration

   *1	Lot No.
   	Engine Front

   Place a new cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

   Note

   
   

   • Make sure that the gasket is installed facing the proper direction.

   • Make sure that no oil is on the front end (indicated by the arrows) of the No. 2 cylinder head gasket.

INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

INSTALL VALVE STEM CAP

1. Apply a light coat of engine oil to the valve stem caps.

2. Install the 32 valve stem caps to the cylinder head.

INSTALL VALVE LASH ADJUSTER ASSEMBLY

1. Inspect the valve lash adjusters Click here.

2. Install the 32 valve lash adjusters to the cylinder head.

   Note

   Install each valve lash adjuster to the same place it was removed from.

INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

1. Apply engine oil to the valve lash adjuster tips and valve stem cap ends.

2. 

   Text in Illustration

   *1	No. 1 Valve Rocker Arm
   *2	Valve Stem Cap
   *3	Valve Lash Adjuster

   Install the 32 No. 1 valve rocker arms as shown in the illustration.

INSTALL CAMSHAFT BEARING CAP RH

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH

INSTALL CAMSHAFT BEARING CAP LH

INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY LH

INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY

1. 

   Text in Illustration

   *1	Plunger
   *2	Pin
   *a	Push

   Install the No. 2 chain tensioner with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. While raising up the No. 2 chain tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

INSTALL NO. 1 CHAIN SUB-ASSEMBLY RH

1. 

   Text in Illustration

   *1	Mark Plate (Orange)
   *2	Timing Mark

   Align the No. 1 chain's mark plates (orange) with the camshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

2. 

   Text in Illustration

   *1	Timing Mark
   *2	Mark Plate (Orange)

   Align the No. 1 chain's mark plate (orange) with the crankshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

3. 

   Text in Illustration

   *1	Timing Mark
   *2	Mark Plate (Yellow)

   Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot marks) of the camshaft timing gear and camshaft timing exhaust gear, and attach the No. 2 chain to the gears as shown in the illustration.

   Tech Tips

   The crankshaft timing gear and camshaft exhaust gear are installed with the No. 1 and No. 2 chains connected to the gears.

4. Install the crankshaft timing sprocket RH to the crankshaft.

5. Align the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear and install the camshaft timing gear.

6. Using the hexagonal portion of the No. 2 camshaft, align the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear and install the camshaft timing exhaust gear.

7. Remove the pin from the No. 2 chain tensioner.

INSTALL NO. 1 CHAIN VIBRATION DAMPER RH

1. Install the No. 1 chain vibration damper RH with the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL CHAIN TENSIONER SLIPPER RH

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY RH

1. 

   Text in Illustration

   *1	Stopper Plate
   *2	Plunger

   Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

3. Install the No. 1 chain tensioner with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

4. Remove the hexagon wrench from the No. 1 chain tensioner.

INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY

1. 

   Text in Illustration

   *1	Pin
   *2	Plunger
   *a	Push

   Install the No. 3 chain tensioner with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. While pushing down the No. 3 chain tensioner, insert a pin with a diameter of 1.0 mm (0.0394 in.) into the hole to fix the tensioner in place.

INSTALL NO. 1 CHAIN SUB-ASSEMBLY LH

1. 

   Text in Illustration

   *1	Mark Plate (Orange)
   *2	Timing Mark

   Align the No. 1 chain's mark plates (orange) with the camshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

2. 

   Text in Illustration

   *1	Timing Mark
   *2	Mark Plate (Orange)

   Align the No. 1 chain's mark plate (orange) with the crankshaft timing gear's timing mark and attach the chain to the gear as shown in the illustration.

3. 

   Text in Illustration

   *1	Timing Mark
   *2	Mark Plate (Yellow)

   Align the No. 2 chain's mark plates (yellow) with the timing marks (1-dot marks) of the camshaft timing gear and camshaft timing exhaust gear, and attach the No. 2 chain to the gears as shown in the illustration.

   Tech Tips

   The crankshaft timing gear and camshaft exhaust gear are installed with the No. 1 and No. 2 chains connected to the gears.

4. Install the crankshaft timing sprocket LH to the crankshaft.

5. Align the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear and install the camshaft timing gear.

6. Using the hexagonal portion of the No. 4 camshaft, align the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear and install the camshaft timing exhaust gear.

   Note

   Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.

7. Remove the pin from the No. 3 chain tensioner.

INSTALL NO. 1 CHAIN VIBRATION DAMPER LH

1. Install the No. 1 chain vibration damper with the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

2. Remove the hexagon wrench from the No. 1 chain tensioner.

INSTALL CHAIN TENSIONER SLIPPER LH

INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY LH

1. 

   Text in Illustration

   *1	Stopper Plate
   *2	Plunger

   Move the stopper plate upward to release the lock and push the plunger deep into the No. 1 chain tensioner.

2. Move the stopper plate downward to set the lock and insert a hexagon wrench into the hole of the stopper plate.

3. Install a new gasket and the No. 1 chain tensioner with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY

1. for Bank 1:

   
   
   1. 

      Text in Illustration

      *a	Hold
      	Turn

      Using a wrench to hold the hexagonal portion of the No. 3 camshaft, install the camshaft timing gear bolt.

      Torque:

      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

   2. 

      Text in Illustration

      *a	Hold
      	Turn

      Using a wrench to hold the hexagonal portion of the No. 4 camshaft, install the camshaft timing exhaust gear bolt.

      Torque:

      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

2. for Bank 2:

   
   
   1. 

      Text in Illustration

      *a	Hold
      	Turn

      Using a wrench to hold the hexagonal portion of the No. 1 camshaft, install the camshaft timing gear bolt.

      Torque:

      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

   2. 

      Text in Illustration

      *a	Hold
      	Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, install the camshaft timing exhaust gear bolt.

      Torque:

      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

INSTALL WATER INLET PIPE

1. Apply soapy water to 2 new O-rings and install them to the water inlet pipe.

2. Install the water inlet pipe to the No. 1 heat exchanger cover.

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

INSTALL ENGINE WATER PUMP ASSEMBLY

INSTALL FRONT CRANKSHAFT OIL SEAL

INSTALL CRANKSHAFT TIMING GEAR KEY

1. Install the crankshaft timing gear key to the crankshaft.

INSTALL ENGINE OIL LEVEL SENSOR

1. Install a new gasket to the engine oil level sensor.

2. Install the engine oil level sensor with the 4 bolts.

   Torque:

   7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

3. Connect the connector.

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY RH

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH

INSTALL FRONT WATER BY-PASS JOINT

1. Install 2 new gaskets and the water by-pass joint with the 4 nuts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL WATER INLET HOUSING

1. Install a new gasket to the engine water pump.

2. Install the water inlet housing with the 3 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL CRANKSHAFT POSITION SENSOR

1. Install the crankshaft position sensor with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Connect the crankshaft position sensor connector.

INSTALL CRANKSHAFT POSITION SENSOR PROTECTOR

1. Install the crankshaft position sensor protector with the 2 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL CAMSHAFT POSITION SENSOR

1. Install the camshaft position sensor with the bolt.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Connect the camshaft position sensor connector.

INSTALL VVT SENSOR

1. Install the 4 VVT sensors with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

2. Connect the 4 VVT sensor connectors.

INSTALL KNOCK SENSOR

1. 

   Text in Illustration

   *A	for Bank 2 Sensor 1
   *B	for Bank 1 Sensor 1
   *C	for Bank 2 Sensor 2
   *D	for Bank 1 Sensor 2
   	Front
   	Upper Side
   	Rear

   Install the 4 knock sensors with the 4 bolts so that the knock sensors are angled as shown in the illustration.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

2. Connect the 4 knock sensor connectors.

INSTALL SPARK PLUG

1. Using a 16 mm plug wrench, install the 8 spark plugs.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL CRANKSHAFT PULLEY

1. Align the key groove of the pulley with the pulley set key, and slide on the pulley to install it.

2. 

   Text in Illustration

   *a	Hold
   	Turn

   Using SST, install the pulley set bolt.

   SST

   09213-70011

   09330-00021

   Torque:

   300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

INSTALL OIL FILTER BRACKET SUB-ASSEMBLY

1. Apply a light coat of engine oil to 2 new O-rings.

2. Install the 2 O-rings to the timing chain cover.

3. Install the oil filter bracket with the 2 nuts and 2 bolts.

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

INSTALL OIL FILTER ELEMENT

1. Clean the inside of the oil filter cap, threads and O-ring groove.

2. 

   Text in Illustration

   *1	O-Ring
   *a	CORRECT
   *b	INCORRECT

   Apply a light coat of engine oil to a new O-ring for the cap, and then install the O-ring to the groove of the oil filter cap.

   Note

   
   

   • Be sure to install the O-ring in the proper location, otherwise oil may leak.

   • Do not twist the O-ring.

3. Set a new oil filter element to the oil filter cap.

4. Remove any dirt or foreign matter from the installation surface of the engine.

5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

   Note

   
   

   • Do not remove the oil filter bracket clip.

   • Do not pinch the O-ring for the cap.

6. 

   Text in Illustration

   *1	Oil Filter Bracket Clip
   *2	Oil Filter Cap
   *3	O-Ring
   *4	Oil Filter Bracket
   *a	No Gap

   Using SST, tighten the oil filter cap.

   SST

   09228-06501

   Torque:

   25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   Note

   
   

   • When tightening the oil filter cap, do not remove the oil filter bracket clip.

   • After tightening the oil filter cap, make sure that there is no gap and that the O-ring is not protruding.

7. 

   Text in Illustration

   *1

   O-Ring

   Apply a small amount of engine oil to a new drain plug O-ring, and install it to the oil filter cap.

   Note

   Before installing the O-ring, remove any dirt or foreign matter from the installation surface of the oil filter cap.

8. Install the oil filter drain plug.

   Torque:

   13 N*m  { 127 kgf*cm, 9 ft.*lbf }

   Note

   Be careful that the O-ring does not get caught between any surrounding parts.