БЛОК ДВИГАТЕЛЯ ПОВТОРНАЯ СБОРКА

Install the stud bolts as shown in the illustration.

Torque:

11 N*m  { 112 kgf*cm, 8.1 ft.*lbf, for stud bolt A }

4.5 N*m  { 46 kgf*cm, 40 in.*lbf, for stud bolt B }

4.0 N*m  { 41 kgf*cm, 35 in.*lbf, for stud bolt C }

Using a plastic-faced hammer, tap into the straight pin.

Using SST, tap in the tight plugs as shown in the illustration.

SST

09950-60010   ( 09951-00350 )

09950-70010   ( 09951-07150 )

Using a screwdriver and hammer, tap in a oil jet.

Using a 5 mm socket hexagon wrench, install the 3 oil nozzles.

Torque:

9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

Using a small screwdriver, install a new snap ring at one end of the piston pin hole.

Gradually heat the piston to about 80°C (176°F).

Coat the piston pin with engine oil.

Using a small screwdriver, install a new snap ring on the other end of the piston pin hole.

Install the oil ring expander and 2 side rails by hand.

Position the piston rings so that the ring ends are as shown.

Align the bearing claw with the groove of the connecting rod or connecting cap.

Align the bearing claw with the claw groove of the cylinder block, and push in the 4 upper bearings.

Align the bearing claw with the claw groove of the main bearing cap, and push in the 4 lower bearings.

Install the 2 upper thrust washers to the No. 2 journal position of the cylinder block.

1. Push the crankshaft toward the front (rear) side.

2. Install the 2 upper thrust washers with the oil grooves facing outward.

Install the 2 lower thrust washers on the No. 2 bearing cap with the grooves facing outward.

Examine the front marks and numbers and install the bearing caps on the cylinder block.

Insert the main bearing cap with hand until the clearance between the main bearing cap and the cylinder block will become less than 6mm (0.23 in.) by making the 2 internal bearing cap bolts as a guide.

Using a plastic-faced hammer, lightly tap the bearing cap to ensure a proper fit.

Apply a light coat of engine oil on the threads and under the head of main bearing cap bolts.

Mark the front side of the bearing cap bolts with paint.

Install and uniformly tighten the 8 main bearing cap bolts in several passes, in the sequence shown.

Torque:

35 N*m  { 357 kgf*cm, 26 ft.*lbf }

Apply engine oil to the cylinder walls, the pistons, and the surfaces of connecting rod bearings.

Using SST, tighten the bolts in several passes by the specified torque.

SST

09011-38121

Torque:

25 N*m  { 250 kgf*cm, 18 ft.*lbf }

Mark the front side of the each connecting cap bolt with paint.

Using a plastic-faced hammer, tap in the new ring pins to the specified protrusion height.

Using a plastic-faced hammer, tap in the new straight pins to the specified protrusion height.

Using E5 and E7 "torx" socket wrench, install the stud bolts.

Torque:

4.0 N*m  { 41 kgf*cm, 35 in.*lbf, for stud bolt A }

9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for stud bolt B }

Apply adhesive to 2 or 3 threads of the bolt end.

Using a 12 mm deep socket wrench, install the unions.

Torque:

15 N*m  { 150 kgf*cm, 11 ft.*lbf }

Apply adhesive around tight plug.

Using SST, tap in the tight plugs to the specified depth.

SST

09950-60010   ( 09951-00250 )

09950-70010   ( 09951-07150 )

Using a 16 mm hexagon wrench, install a new gasket and straight screw plug.

Torque:

80 N*m  { 816 kgf*cm, 59 ft.*lbf }

Apply a light coat of engine oil to the valve guide bush.

Using SST, push in a new valve stem oil seal.

SST

09201-41020

Apply the engine oil to the valve as shown in the illustration.

Place the cylinder head on the wooden block.

Using a 5 mm pin punch, lightly tap the valve stem tip to ensure a proper fit.

Apply the engine oil to the valve stem end and valve lifter, and install its.

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.

Install the 2 knock sensors with the 2 bolts as shown in the illustration.

Torque:

20 N*m  { 204 kgf*cm, 15 ft.*lbf }

Install the water outlet pipe with the bolt and 2 nuts.

Torque:

10 N*m  { 102 kgf*cm, 7 ft.*lbf }

Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.

Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

Apply a continuous line of the seal packing to a new cylinder head gasket as shown in the illustration.

Place the cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

Install the 2 cylinder head bolts.

1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

2. Install and uniformly tighten the 2 cylinder head bolts, in several passes, in the sequence shown.

   Torque:

   30 N*m  { 306 kgf*cm, 22 ft.*lbf }

Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.

Install the No. 2 camshaft bearing to the cylinder head.

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.

   Note

   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.

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 faced as shown in the illustration.

2. 

   Install the 8 bearing caps in their proper locations.

3. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

4. 

   Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }

   24 N*m  { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }

5. 

   Rotate the camshafts clockwise using hexagonal portion of the each camshaft at 90° angle of the camshaft knock pin on the cylinder head.

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 faced as shown in the illustration.

2. 

   Install the 8 bearing caps in their proper locations.

3. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

4. 

   Install and uniformly tighten the 16 bearing cap bolts, in several passes, in the sequence shown.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }

   24 N*m  { 245 kgf*cm, 18 ft.*lbf, for 12 mm (0.47 in.) head (A) }

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

Install the No. 2 chain tensioner with the bolt.

Torque:

19 N*m  { 194 kgf*cm, 14 ft.*lbf }

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

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.

Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

Torque:

100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

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

Install the No. 3 chain tensioner with the bolt.

Torque:

19 N*m  { 194 kgf*cm, 14 ft.*lbf }

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

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.

Hold the hexagonal portion of the camshaft with a wrench, and tighten the 2 bolts.

Torque:

100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

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

Torque:

19 N*m  { 194 kgf*cm, 14 ft.*lbf }

Align the timing gear set key with the key groove of the timing gear.

While rotating the stopper plate of the tensioner clockwise, push in the plunger of the tensioner as shown in the illustration.

Set the No. 1 cylinder to TDC/compression.

1. Align the timing marks of the camshaft timing gears and bearing caps.

2. 

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

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

Align the mark links (orange) with the timing marks of the camshaft timing gears, and install the chain.

Install the 2 No. 2 chain vibration dampers.

Temporarily install the No. 1 idle gear shaft and idle gear with the No. 2 idle gear shaft while aligning the knock pin of the No. 1 idle gear shaft with the knock pin groove of the cylinder block.

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

Apply a continuous bead of the seal packing to 4 locations as shown in the illustration.

Apply a continuous bead of the seal packing to the timing chain cover as shown in the illustration.

Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft timing gear, and slide the timing chain cover.

Install the timing chain cover with the 15 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:

23 N*m  { 235 kgf*cm, 17 ft.*lbf }

Install a new gasket and the water pump with the 17 bolts.

Torque:

9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for 10 mm (0.39 in.) head }

23 N*m  { 235 kgf*cm, 17 ft.*lbf, for 12 mm (0.49 in.) head }

Install the 4 stud bolts.

Torque:

4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

Install a new O-ring to the oil pump.

Apply a continuous line of the seal packing to the oil pan as shown in the illustration.

Install the oil pan with the 17 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:

21 N*m  { 214 kgf*cm, 15 ft.*lbf, for bolt A, B and nut }

9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for bolt C }

Install a new gasket and the oil strainer with the 2 nuts.

Torque:

9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

Apply a continuous line of the seal packing as shown in the illustration.

Install the No. 2 oil pan with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:

9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

Using SST, install the pulley set bolt.

SST

09213-54015   ( 91651-60855 )

09330-00021

Torque:

250 N*m  { 2,549 kgf*cm, 184 ft.*lbf }

Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.

Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing cap as shown in the illustration.

If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.

Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:

10 N*m  { 102 kgf*cm, 7 ft.*lbf, for bolt A }

9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for bolt B }

9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for nut }

Apply a continuous bead of the seal packing to the cylinder head and timing chain cover as shown in the illustration.

Install the cylinder head cover with the 10 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.

Torque:

10 N*m  { 102 kgf*cm, 7 ft.*lbf, for bolt A }

9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for bolt B }

9.0 N*m  { 92 kgf*cm, 80 in.*lbf, for nut }

Check that no foreign objects on the mesh part of the 2 filters.

Apply adhesive to 2 or 3 threads of the drain cocks end.

After applying the specified torque, rotate the drain cocks clockwise as shown in the illustration.

Torque:

25 N*m  { 255 kgf*cm, 18 ft.*lbf }

Install a new O-ring to the oil level gauge guide.

Install the engine hanger with the 2 bolts.

Torque:

33 N*m  { 336 kgf*cm, 24 ft.*lbf }