Part 2

OVERHAUL





61. INSTALL W/HEAD TAPER SCREW PLUG NO.1 [11432A / 98-7]
a. Apply adhesive to the threads of the plug and install. Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)





62. INSTALL OIL CONTROL VALVE FILTER [15678B / 98-7]
a. Check that no foreign substance on the mesh part of the filter.
b. Using a 6 mm socket hexagon wrench, install the oil control valve filter with a new gasket.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





63. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY [11415 / 98-7]
a. Install the water drain cock sub assembly within the range shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
64. INSTALL UNION(W/ OIL COOLER)
Torque: 40 Nm (408 kgf-cm, 29 ft. lbs.)





65. INSTALL CYLINDER HEAD GASKET [11115 / 98-5]
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
- Remove any oil from contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.

66. INSTALL CYLINDER HEAD SUB-ASSY [11101 / 98-5]

HINT: The cylinder head bolts are tightened in 2 progressive steps.





a. Apply sea[packing in the shape of bead (Diameter 2.5 3 mm (0.098 - 0.118 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
- Remove any oil from contact surface.
- Install the cylinder head within 3 minutes after applying seal packing.
- After installing the cylinder head, cylinder head bolts must be tightened within 15 minutes.

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





c. Install bolts and plate washers to the cylinder head.

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

d. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)





e. Mark the front side of each cylinder head bolt with paint.
f. Retighten the cylinder head bolts by 90° in the sequence shown.
g. Check that the painted marks are now at a 90° angle to the front.





67. INSTALL CAMSHAFT BEARING NO.2 [11821 / 98-14]





68. INSTALL CAMSHAFT TIMING GEAR ASSY [13050 / 98-14]
a. Put the camshaft timing gear assembly and the camshaft together with the straight pin of the key groove.
b. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove.

CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle).

c. Check that there is no clearance between the gear's fringe and the camshaft.
d. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 49 ft. lbs.)
e. Check that the camshaft timing gear assembly can move to the retard angle side (the right direction), and is locked at the most retarded position.





69. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET [13523 / 98-14]
a. Fix the camshaft No. 2 to the vise, and install camshaft No. 2 timing gear.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
70. INSTALL CAMSHAFT BEARING NO.1 [11811 / 98-14]





71. INSTALL CAMSHAFT [13511 / 98-14]
a. Tighten camshaft bearing cap No.1 and No. 3 as the sequence shown in the illustration.
Torque:
Bearing cap No. 1 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
- Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 1.
- Install the camshaft with its timing mark of camshaft timing gear on top.





72. INSTALL NO.2 CAMSHAFT [13512 / 98-14]
a. Tighten camshaft bearing cap No.2 and No. 3 as the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
- Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 2.
- Install the camshaft with its timing mark of camshaft timing gear on top.





73. INSTALL OIL PUMP ASSY [15100 / 98-15]
a. Install oil pump assembly with 3 bolts and a new gaskets.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
74. INSTALL NO.2 CHAIN SUB-ASSY [13507 / 98-14]





a. Set the crankshaft key into the left horizontal position.
b. Turn the cutout of the drive shaft to the top.





c. Align the mark links (yellow colored links) with the timing marks of gear as shown in the illustration.
d. Insert the gear with chain to the crankshaft and oil pump shaft.
e. Temporarily tighten the oil pump drive shaft gear by a nut.





f. Insert the damper spring into the adjusting hole, and install the chain tensioner plate by a bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)





g. Align an adjusting hole of the sprocket with the groove of the oil pump.
h. Put a bar (diameter 4 mm) into the adjusting hole of the sprocket to lock in position, and assemble a nut.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.)





i. Rotate the crankshaft clockwise 90°, and align the crankshaft key with the top.
75. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET [13521 / 98-13]
76. INSTALL CHAIN VIBRATION DAMPER NO.1 [13561 / 98-14]
a. Install the chain vibration damper with the 2 bolts.
Torque: 9 Nm (92 kgf-cm, 80 inch lbs.)
77. INSTALL CHAIN SUB-ASSY [13506 / 98-14]
a. Set No. 1 cylinder to TDC/compression.





1. Align the timing marks of the camshaft timing sprockets and No. 1 bearing caps.





2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.





b. Align the mark plate (blue or orange colored link) with the timing mark of the crankshaft timing gear.





c. Using SST, install the sprocket.
SST 09309-37010





d. Align the mark I;inks (gold or yellow colored links) with the timing marks of the camshaft timing gear, and install the chain.
78. INSTALL CHAIN TENSIONER SLIPPER [13559 / 98-14]
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
79. INSTALL TIMING CHAIN GUIDE [13566B / 98-14]
Torque: 9 Nm (92 kgf-cm, 80 inch lbs.)





80. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1 [19315 / 98-13]
a. Install crank angle sensor plate with the "F" mark facing forward.