Partial Engine Assembly, Intake Manifold, Exhaust Manifold (2AZ-FE): Overhaul

1. Using SST, remove the oil filter.
   1. SST 09228-06501

Fig 1: Removing Oil Filter

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1. Using a 12 mm hexagon wrench, remove the union.

1. Remove the 8 bolts, 2 nuts, and cylinder head cover.

Fig 2: Removing Cylinder Head Cover

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1. Turn the crankshaft pulley and align its groove with timing mark 0 of the timing chain cover.
2. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap, as shown in the illustration.
   Fig 3: Aligning Timing Marks Of Camshaft Timing Sprockets With Timing Marks Of No 1 Bearing Cap

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3. Remove the crankshaft pulley.
   1. Using SST, fix the pulley and loosen the bolt.
      1. SST 09213-54015 (91651-60855), 09330-00021
      Fig 4: Removing Crankshaft Pulley Bolt

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   2. Using SST, remove the bolt and pulley.
      1. SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)

Fig 5: Removing Crankshaft Pulley

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1. Remove the 2 nuts, chain tensioner and gasket.

Fig 6: Removing Chain Tensioner

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1. Using SST, remove the water pump pulley.
   1. SST 09960-10010 (09962-01000, 09963-00700)

Fig 7: Removing Water Pump Pulley

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1. Remove the 4 bolts, 2 nuts, bracket and water pump.

Fig 8: Removing Water Pump Assy

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1. Remove the 12 bolts and 2 nuts.
   Fig 9: Removing Oil Pan Sub-Assy

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2. Insert the blade of SST between the crankcase and oil pan. Cut off the applied sealer and remove the oil pan.
   1. SST 09032-00100

Fig 10: Cutting Off Oil Pan Applied Sealer

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1. Remove the 14 bolts and 2 nuts.
2. Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

Fig 11: Removing Timing Chain Or Belt Cover

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1. Using a screwdriver and hammer, remove the oil seal.

Fig 12: Removing Engine Rear Oil Seal

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1. Turn the crankshaft counterclockwise 90°, and align the adjusting hole of the oil pump driven sprocket with the groove of the oil pump.
   Fig 13: Aligning Adjusting Hole Of Oil Pump Driven Sprocket With Groove Of Oil Pump

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2. Put a bar (phi 4 mm (0.16 in.) in the adjusting hole of the oil pump driven sprocket to temporarily lock the sprocket in position, then remove the nut.
   Fig 14: Putting Bar In Adjusting Hole Of Oil Pump Driven Sprocket For Temporarily Locking Sprocket

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3. Remove the bolt, chain tensioner plate and spring.
4. Remove the oil pump sprocket gear, driven sprocket and chain.

Fig 15: Removing Chain Tensioner Plate And Spring

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1. Remove the 3 bolts, oil pump and gasket.

Fig 16: Removing Oil Pump Assy

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1. Uniformly loosen and remove the No. 2 camshaft (exhaust's 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
2. Remove the camshaft.

Fig 17: Identifying Loosening Sequence Of No 2 Camshaft (Exhaust) Bearing Cap Bolts

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1. Uniformly loosen and remove the camshaft (intake)'s 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
2. Remove the camshaft.

Fig 18: Identifying Loosening Sequence Of Camshaft (Intake) Bearing Cap Bolts

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1. Fix the camshaft with a vise and remove the camshaft timing sprocket.

Fig 19: Removing Camshaft Timing Sprocket

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1. Fix the camshaft with a vise, and make sure that the camshaft timing gear does not move.
2. Cover all the oil ports with vinyl tape except the advanced angle side, as shown in the illustration.
   Fig 20: Identifying Advanced Angle Side

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3. Using an air gun, apply about 150 kPa (1.5 kgf/cm² , 21 psi) of air pressure to the port on the advanced angle side.
   CAUTION: Some oil spraying will occur. Contain the spray with a shop rag.

   HINT:

   This operation releases the lock pin for the extreme retarded angle lock.

4. Under the condition above, check that the camshaft timing gear can be turned by hand to the advanced angle side (counterclockwise), the direction of the arrow shown in the illustration.
   1. Standard: Must turn 
   Fig 21: Applying Air Pressure To Port On Advanced Angle Side

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   HINT:

   The camshaft timing gear will turn to the advanced angle side without applying force by hand depending on the force of the air pressure applied. Also, if applying pressure to the oil path is difficult as a result of air leakage from the port, the lock-pin may be difficult to release.

5. Remove the fringe bolt from the camshaft timing gear.

Fig 22: Removing Fringe Bolt From Camshaft Timing Gear

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1. Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

Fig 23: Identifying Loosening Sequence Of Cylinder Head Bolts

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1. Using a 6 mm socket hexagon wrench, remove the plug and filter.

1. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
   1. Standard thrust clearance: 0.050 to 0.090 mm (0.0020 to 0.0035 in.) 
   2. Maximum thrust clearance: 0.090 mm (0.0035 in.) 

If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.

Fig 24: Inspecting Balance Shaft Thrust Clearance

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1. Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.
   NOTE: Be careful not to damage the contact surfaces of the balance shaft housing and crankcase.

   HINT:

   Keep the lower bearing and balance shaft housing together.

2. Lift out the No. 1 and No. 2 balances hafts.

   HINT:

   Keep the upper bearing with the crankcase.

3. Clean each bearing and journal.
4. Check each bearing and journal for pitting and scratches.

   If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.

5. Place the No. 1 and No. 2 balance shafts on the crankcase.
   Fig 25: Identifying Removal Sequence Of Balance shaft Housing Bolts

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6. Lay a strip of Plastigage across each journal, and install the balance shaft housing.
7. Apply a light coat of engine oil on the threads and under the heads of the balance shaft housing bolts.
   Fig 26: Laying Strip Of Plastigage Across Each Journal

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8. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
   1. Torque: 22 N.m (220 kgf.cm, 16 ft.lbf) 

   HINT:

   The balance shaft housing bolts are tightened in 2 progressive steps.

   Fig 27: [Identifying Tightening Sequence Of Balance Shaft Housing Bolts]

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9. Mark the front side of each balance shaft housing bolt head with paint.
10. Retighten the bolts 90° as shown in the illustration.
11. Check that the paint marks are now at a 90° angle to the front.
    Fig 28: Identifying Retightening Angle Of Balance Shaft Housing Bolts

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12. Remove the balance shaft housing, and measure the Plastigage at its widest point.
    1. Standard oil clearance: 0.004 to 0.031 mm (0.0002 to 0.0012 in.) 
    2. Maximum oil clearance: 0.031 mm (0.0012 in.) 
13. Completely remove the Plastigage after the inspection.
    Fig 29: Measuring Plastigage At Its Widest Point

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    If the clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft. If using a standard bearing, replace it with one of the same number.

    1. Balance Shaft housing journal bore diameter: 
    BALANCE SHAFT HOUSING JOURNAL BORE DIAMETER SPECIFICATION
    
    

    Mark 1	26.000 to 26.006 mm (1.0236 to 1.0239 in.)
    Mark 2	26.007 to 26.012 mm (1.0239 to 1.0241 in.)
    Mark 3	26.013 to 26.018 mm (1.0241 to 1.0243 in.)

    1. Balance Shaft journal diameter: 
    2. 22.985 to 23.000 mm (0.9049 to 0.9055 in.) 
    3. Standard bearing center wall thickness: 
    STANDARD BEARING CENTER WALL THICKNESS SPECIFICATION
    
    

    Mark 1	1.486 to 1.489 mm (0.0585 to 0.0586 in)
    Mark 2	1.489 to 1.492 mm (0.0586 to 0.0587 in)
    Mark 3	1.492 to 1.495 mm (0.0587 to 0.0589 in)

14. Completely remove the Plastigage after the inspection.

Fig 30: Identifying Standard Bearing Number Marks

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1. Using a knife, cut off the oil seal lip.
2. Using a screwdriver with its tip taped, pry out the oil seal.

Fig 31: Removing Engine Rear Oil Seal

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1. Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
2. Using a screwdriver, remove the crankcase by prying the portions between the crankcase and cylinder block.
   NOTE: Be careful not to damage the contact surfaces of the crankcase and cylinder block.
3. Remove the O-ring from the cylinder block.

Fig 32: Identifying Loosening Sequence Of Stiffening Crankcase Bolts

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1. Wrap the chain around the drive gear.
2. Using a vernier caliper, measure the sprocket diameter with the chain.
   1. Minimum sprocket diameter (w/chain): 48.2 mm (1.898 in.) 

If the diameter is less than the minimum, replace the chain and sprocket.

Fig 33: Measuring Oil Pump Drive Sprocket Diameter With Chain

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1. Wrap the chain around the drive shaft gear.
2. Using a vernier caliper, measure the sprocket diameter with the chain.
   1. Minimum gear diameter (w/chain): 48.2 mm (1.898 in.) 

If the diameter is less than the minimum, replace the chain and sprocket.

Fig 34: Measuring Oil Pump Driven Sprocket Diameter With Chain

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1. Wrap the chain around the timing gear.
2. Using a vernier caliper, measure the timing gear diameter with the chain.
   1. Minimum gear diameter (w/ chain): 51.6 mm (2.031 in.) 

If the diameter is less than the minimum, replace the chain and timing gear.

Fig 35: Measuring Crankshaft Timing Gear Diameter With Chain

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1. Measure the tensioner slipper wear.
   1. Maximum wear: 1.0 mm (0.039 in.) 

If the wear is greater than the maximum, replace the tensioner slipper.

Fig 36: Identifying Chain Tensioner Slipper Wear Dimension

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1. Measure the vibration damper wear.
   1. Maximum wear: 1.0 mm (0.039 in.) 

If the wear is greater than the maximum, replace the vibration damper.

Fig 37: Identifying Chain Vibration Damper Wear Dimension

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1. Using a vernier caliper, measure the length of the head bolts from the seat to the end.
   1. Standard bolt length: 
   2. 161.3 to 162.7 mm (6.3503 to 6.4055 in.) 
   3. Maximum bolt length: 164.2 mm (6.4646 in.) 

If the length is greater than the maximum, replace the bolt.

Fig 38: Identifying Cylinder Head Set Bolt Length

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1. Check that the plunger moves smoothly when the ratchet pawl is raised.
2. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.

Fig 39: Inspecting Plunger And Chain Tensioner

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1. Using a vernier caliper, measure the length of 15 links with the chain fully stretched.
   1. Maximum chain elongation: 115.4 mm (4.543 in.) 

If the elongation is greater than the maximum, replace the chain.

Fig 40: Measuring Length Of Timing Chain 15 Links With Chain Fully Stretched

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1. Wrap the chain around the timing sprocket.
2. Using a vernier caliper, measure the timing sprocket diameter with the chain.
   1. Minimum sprocket diameter (w/chain): 97.3 mm (3.831 in.) 

If the diameter is less than the minimum, replace the chain and timing gear.

Fig 41: Measuring Camshaft Timing Sprocket Diameter With Chain

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1. Check the camshaft for runout.
   1. Place the camshaft on V-blocks.
   2. Using a dial indicator, measure the circle runout at the center journal.
      1. Maximum circle runout: 0.03 mm (0.0012 in.) 

   If the circle runout is greater than the maximum, replace the camshaft.

   Fig 42: Measuring Camshaft (Intake) Circle Runout At Center Journal

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2. Using a micrometer, measure the cam lobe height.
   1. Standard cam lobe height: 
   2. 46.495 to 46.595 mm (1.8305 to 1.8344 in.) 
   3. Minimum cam lobe height: 46.385 mm (1.8262 in.) 

   If the cam lobe height is less than the minimum, replace the camshaft.

   Fig 43: Measuring Cam Lobe Height

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3. Using a micrometer, measure the journal diameter.
   1. No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 
   2. Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 in.) 

If the journal diameter is not as specified, check the oil clearance.

Fig 44: Measuring Cam Journal Diameter

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1. Check the camshaft for runout.
   1. Place the camshaft on V-blocks.
   2. Using a dial indicator, measure the circle runout at the center journal.
      1. Maximum circle runout: 0.03 mm (0.0012 in.) 

   If the circle runout is greater than the maximum, replace the camshaft.

   Fig 45: Measuring Camshaft (Exhaust) Circle Runout At Center Journal

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2. Using a micrometer, measure the cam lobe height.
   1. Standard cam lobe height: 45.983 to 46.083 mm (1.8104 to 1.8143 in.) 
   2. Minimum cam lobe height: 45.873 mm (1.8060 in.) 

   If the cam lobe height is less than the minimum, replace the camshaft.

   Fig 46: Measuring Cam (Exhaust) Lobe Height

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3. Using a micrometer, measure the journal diameter.
   1. No. 1 journal diameter: 
   2. 35.971 to 35.985 mm (1.4162 to 1.4167 in.) 
   3. Other journal diameter: 
   4. 22.959 to 22.975 mm (0.9039 to 0.9045 in.) 

If the journal diameter is not as specified, check the oil clearance.

Fig 47: Measuring Cam (Exhaust) Journal Diameter

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1. Install the bearings in the crankcase and balance shaft housing.
2. Apply a light coat of engine oil on the bearings.

1. Rotate the driven gear No. 1 of balance shaft No. 1 for the rotating direction until it hits the stopper.
2. Confirm that the matchmarks on driven gear No. 1 and No. 2 are matched.
   Fig 48: Aligning Matchmarks Of Driven Gear No 1 And 2

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3. Align the timing marks of the No. 1 and No. 2 balance-shafts as shown in the illustration.
4. Place the No. 1 and No. 2 balance shafts on the crank case.
5. Apply a light coat of engine oil under the heads of the balance shaft housing bolts.
   Fig 49: Aligning Timing Marks Of No 1 And No 2 Balance-Shafts

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6. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
   1. Torque: 22 N.m (224 kgf.cm, 16 ft.lbf) 

   HINT:

   The balance shaft housing bolts are tightened in 2 progressive steps.

   Fig 50: Identifying Tightening Sequence Of Balance Shaft Housing Bolts

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7. Mark the front side of each balance shaft housing bolt head with paint.
8. Retighten the bolts by 90° as shown in the illustration.
9. Check that the painted marks are now at a 90° angle to the front.

Fig 51: Identifying Retightening Angle Of Balance Shaft Housing Bolts

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1. Apply seal packing in a continuous bead (seal width: 2.5 to 3.0 mm (0.098 to 0.118 in.)) to the places shown in the illustration.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the crankcase within 3 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 52: Applying Seal Packing To Stiffening Crankcase Assy

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2. Place a new O-ring on the cylinder block, as shown in the illustration.
   Fig 53: Placing New O-Ring On Cylinder Block

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3. With the No. 1 crank pin of the crankshaft placed at 6 o'clock, install the No. 1 and No. 2 balance shaft and the adjusting hole as shown in the illustration.
   Fig 54: [Identifying No 1 Crank Pin Of Crankshaft]

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4. Uniformly tighten the 11 bolts in the sequence shown in the illustration.
   1. Torque: 33 N.m (337 kgf.cm, 24 ft.lbf) 
   Fig 55: Identifying Tightening Sequence Of Stiffening Crankcase Assy Bolts

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5. Confirm that the timing marks of the balance shafts are matched when the key groove is placed at 6 o'clock, as shown in the illustration.

Fig 56: Aligning Timing Marks Of Balance Shafts

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1. Apply MP grease to a new oil seal lip.
   NOTE: Keep the lip off the foreign materials.
2. Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.
   1. SST 09223-15030, 09950-70010 (09951-07100)

Fig 57: Installing Engine Rear Oil Seal

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1. Apply adhesive to the threads of the plug and install it.
   1. Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent 
   2. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) 

Fig 58: Installing W/Head Taper Screw Plug

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1. Check that no foreign substance is on the mesh part of the filter.
2. Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
   1. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) 

Fig 59: Installing Oil Control Valve Filter For Camshaft Timing

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1. Install the water drain cock within the range shown in the illustration.
   1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

Fig 60: Installing Cylinder Block Water Drain Cock

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1. Place a new gasket on the cylinder block surface with the Lot No. stamp upward.

Fig 61: Placing New Gasket On Cylinder Block Surface With Lot No Stamp Upward

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HINT:

The cylinder head bolts are tightened in 2 progressive steps.

1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
2. Install the 10 bolts and plate washers to the cylinder head.
   NOTE: Do not drop the washers into the cylinder head.
3. Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.
   1. Torque: 79 N.m (806 kgf.cm, 58 ft.lbf) 
   Fig 62: Identifying Tightening Sequence Of Cylinder Head Bolts

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

Fig 63: Identifying Retightening Angle Of Cylinder Head Bolts

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1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

1. Install the bearing to the camshaft.

Fig 64: Installing Bearing To Camshaft

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1. Put the camshaft timing gear and the camshaft together with the straight pin and key groove.
2. Turn the camshaft timing gear (as shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin enters the groove.
   CAUTION: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right angle).
3. Check that there is no clearance between the gear's fringe and the camshaft.
4. Tighten the fringe bolt with the camshaft timing gear fixed.
   1. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 
   Fig 65: Putting Camshaft Timing Gear And Camshaft Together With Straight Pin And Key Groove

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5. Check that the camshaft timing gear can move to the retarded angle side (the right direction) and is locked at the extreme retarded angle position.

HINT:

• Apply a light coat of engine oil on the threads and under the heads of the bolt.
• Length of sprocket bolt excluding bolt head: 40 mm (1.57 in.)

1. Fix the camshaft with a vise, and install the camshaft No. 2 timing gear.
   1. Torque: 54 N.m (551 kgf.cm, 40 ft.lbf) 

HINT:

• Apply a light coat of engine oil on the threads and under the heads of the bolt.
• Length of sprocket bolt excluding bolt head: 25 mm (0.98 in.)

Fig 66: Installing Camshaft Timing Gear Or Sprocket

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1. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
   1. Torque: 
   2. 30 N.m (306 kgf.cm, 22 ft.lbf) for bearing cap No. 1 
   3. 9.0 N.m (92 kgf.cm, 80 in..lbf) for bearing cap No. 3 

Fig 67: Identifying Tightening Sequence Of Camshaft (Intake) Bearing Cap Bolts

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1. Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
   1. Torque: 
   2. 30 N.m (306 kgf.cm, 22 ft.lbf) for bearing cap No. 2 
   3. 9.0 N.m (92 kgf.cm, 80 in..lbf) for bearing cap No. 3 

Fig 68: Identifying Tightening Sequence Of Camshaft (Exhaust) Bearing Cap Bolts

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1. Install a new gasket and oil pump with the 3 bolts.
   1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

Fig 69: Installing Oil Pump Assy

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1. Set the crankshaft key into the left horizontal position.
2. Turn the cutout of the drive shaft to the top.
   Fig 70: Setting Crankshaft Key Into Left Horizontal Position

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3. Align the mark links (yellow colored links) with the timing marks of the sprocket as shown in the illustration.
4. Insert the sprocket with chain to the crankshaft and oil pump shaft.
5. Temporarily tighten the oil pump driven sprocket with the nut.
   Fig 71: Aligning Mark Links (Yellow Colored Links) With Timing Marks Of Sprocket

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6. Insert the damper spring into the adjusting hole, and install the chain tensioner plate by the bolt.
   1. Torque: 12 N.m (122 kgf.cm, 9.0 ft.lbf) 
   Fig 72: Installing Chain Tensioner Plate

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7. Align the adjusting hole of the sprocket with the groove of the oil pump.
8. Put a bar (phi 4 mm (0.16 in.)) into the adjusting hole of the sprocket to temporarily lock the sprocket in position. Install the nut.
   1. Torque: 30 N.m (306 kgf.cm, 22 ft.lbf) 
   Fig 73: Putting Bar Into Adjusting Hole Of Sprocket For Temporarily Locking Sprocket

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9. Rotate the crankshaft clockwise 90°, and align the crankshaft key with the top.

Fig 74: Rotating Crankshaft Clockwise 90° And Aligning Crankshaft Key

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1. Install the chain vibration damper with the 2 bolts.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

1. Set the No. 1 cylinder to TDC/compression.
   1. Align the timing marks of the camshaft timing gear/ sprocket and bearing caps (No. 1 and No. 2).
      Fig 75: Aligning Timing Marks Of Camshaft Timing Gear/Sprocket And Bearing Caps

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   2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
   Fig 76: Setting Key On Crankshaft Upward

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2. Align the mark link (blue or orange colored link) with the timing mark of the crankshaft timing sprocket.
   Fig 77: Aligning Mark Link (Blue Or Orange Colored Link) With Timing Mark Of Crankshaft Timing Sprocket

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3. Using SST, tap in the sprocket.
   1. SST 09309-37010
   Fig 78: Installing Sprocket

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4. Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear and camshaft timing sprocket. Then install the chain.

Fig 79: Aligning Timing Chain Mark Links With Timing Marks Of Camshaft Timing Gear And Camshaft Timing Sprocket

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1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

1. Install the sensor plate with the F mark facing forward.

Fig 80: Installing Crankshaft Position Sensor Plate

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1. Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
   1. SST 09223-22010
2. Apply a light coat of MP grease to the lip of the oil seal.

Fig 81: Installing Timing Gear Case Or Timing Chain Case Oil Seal

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1. 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.
2. Apply seal packing in a continuous bead (seal width: 2.0 mm (0.079 in.)) as shown in the illustration.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   Fig 82: Applying Seal Packing To Contact Surface Of Timing Chain Cover

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3. Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   Fig 83: Applying Seal Packing To Timing Chain Cover

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4. Install the timing chain cover with the 14 bolts and 2 nuts.
   1. Torque: 
   2. 9.0 N in (92 kgf.cm, 80 in..lbf) for bolt A 
   3. 21 N.m (214 kgf.cm, 15 ft.lbf) for bolt B 
   4. 43 N.m (438 kgf.cm, 32 ft.lbf) for bolt C 
   5. 9.0 N.m (92 kgf.cm, 80 in..lbf) for nut 
5. Install the stud bolt to the drive belt tensioner.
   1. Torque: 10 N.m (102 kgf.cm, 7 ft.lbf) 

Fig 84: Installing Timing Chain Cover

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1. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
2. Apply seal packing in a continuous bead (seal width: 3.0 to 4.0 mm (0.12 to 0.16 in.)) as shown in the illustration, and install the oil pan.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   Fig 85: Applying Seal Packing To Oil Pan

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3. Uniformly tighten the 12 bolts and 2 nuts in the sequence shown in the illustration.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

Fig 86: Identifying Tightening Sequence Of Oil Pan Bolts

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1. Install a new gasket and the drain plug.
   1. Torque: 25 N.m (255 kgf.cm, 18 ft.lbf) 

1. Clean the contact surface of the cylinder block.
2. Apply seal packing in a continuous bead (seal width: 2.2 to 2.5 mm (0.087 to 0.098 in.)) to the outside edge of the water pump.
   1. Seal packing: Part No. 08826-00100 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the water pump within 5 minutes after applying seal packing.
   • Do not start the engine for at least 2 hours after installing.
   Fig 87: Applying Seal Packing To Water Pump

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3. Install the water pump with the 4 bolts and 2 nuts.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 

Fig 88: Installing Water Pump

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1. Using SST, install the water pump pulley with the 4 bolts.
   1. SST 09960-10010 (09962-01000, 09963-00700)
   2. Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) 

Fig 89: Installing Water Pump Pulley

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1. Install the sensor with the 2 bolts.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 
2. Confirm that the wire harness of the sensor is placed as shown in the illustration.

Fig 90: Installing Crankshaft Position Sensor

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1. Install the pulley.
2. Using SST, tighten the bolt.
   1. SST 09213-54015 (91651-60855), 09330-00021
   2. Torque: 180 N.m (1,835 kgf.cm, 133 ft.lbf) 

HINT:

Apply a light coat of engine oil to the bolt threads and the area beneath the bolt head that come in contact with the washer.

Fig 91: Installing Crankshaft Pulley

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1. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
   Fig 92: Pushing In Plunger And Applying Hook To Pin

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2. Install a new gasket and the chain tensioner with the 2 nuts.
   1. Torque: 9.0 N.m (92 kgf.cm, 80 in..lbf) 
   NOTE: If the hook is released while inserting, apply the hook again, and insert the chain tensioner.
   Fig 93: Installing Chain Tensioner With Gasket

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3. Turn the crankshaft counterclockwise and check that the plunger knock pin is disconnected from the hook.
   Fig 94: Turning Crankshaft Counterclockwise And Disconnecting Plunger Knock Pin From Hook

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4. Turn the crankshaft clockwise and check that the slipper is pushed by the plunger.

Fig 95: Turning Crankshaft Clockwise And Checking That Slipper Pushed By Plunger

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1. Install the gasket to the cylinder head cover.

1. Remove any old packing (FIPG) material.
2. Apply seal packing to the 2 locations shown in the illustration.
   1. Seal packing: Part No. 08826-00080 or equivalent 
   NOTE:

   • Remove any oil from the contact surface.
   • Install the cylinder head cover within 5 minutes after applying seal packing.
   • Do not apply engine oil for at least 2 hours after installing.
   Fig 96: [Applying Seal Packing]

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3. Install the cylinder head cover with the 8 bolts and 2 nuts.
   1. Torque: 
   2. 11 N.m (112 kgf.cm, 8 ft.lbf) for nut 
   3. 11 N.m (112 kgf.cm, 8 ft.lbf) for bolt A 
   4. 14 N.m (143 kgf.cm, 10 ft.lbf) for bolt B 

Fig 97: Installing Cylinder Head Cover

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1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 

1. Apply adhesive on the threads of the ventilation valve.
   1. Torque: 19 N.m (194 kgf.cm, 14 ft.lbf) 
   2. Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent 

1. Using a 12 mm hexagon wrench, install the oil filter union.
   1. Torque: 30 N.m (306 kaf cm, 22 ft.lbf) 

1. Check and clean the oil filter installation surface.
2. Apply clean engine oil to the gasket of a new oil filter.
3. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
4. Using SST, tighten it an additional 3/4 turn.
   1. SST 09228-06501
   Fig 98: Installing Oil Filter Sub-Assy

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