ENGINE UNIT > REASSEMBLY |
| 1. INSTALL CYLINDER HEAD GASKET |
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Place a new cylinder head gasket on the cylinder block sub-assembly.
| 2. INSTALL CYLINDER HEAD SUB-ASSEMBLY |
Place the cylinder head on the cylinder block sub-assembly.
Install the 8 plate washers to the cylinder head sub-assembly.
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Apply engine oil to each bolt thread and seating surface.
| *1 | Apply Engine Oil. |
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Using several passes, uniformly install and tighten the 8 cylinder head bolts with an 8 mm bi-hexagon wrench in the order shown in the illustration.
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Mark the front of each cylinder head bolt with paint.
Retighten the cylinder head bolts by additional 180° as shown in the illustration.
| *1 | Paint Mark |
Check that the paint mark are now 180° from the front.
| 3. INSTALL VALVE LIFTER |
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Apply engine oil to the circumference of the valve lifters.
Install the valve lifters straight into the lifter holes.
| 4. INSTALL ENGINE REAR OIL SEAL |
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Apply engine oil to the lip of a new oil seal.
| *1 | Apply Engine Oil. |
Using SST, tap the oil seal straight in.

| *1 | Rear Oil Seal Retainer | - | - |
| 5. INSTALL ENGINE REAR OIL SEAL RETAINER |
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Install the stud bolt.
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Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 in.)) as shown in the illustration.
| *1 | Seal Packing |
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Install the oil seal retainer with the 4 bolts.
| 6. INSTALL CAMSHAFTS |
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Before installing the camshaft, turn the crankshaft approximately 90° in the engine revolution direction from the point where the No. 1 piston is set at the TDC/ compression so that the lifted valve and piston do not touch each other.
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Apply engine oil to the contact areas of the cam and journal of the camshaft and No. 2 camshaft.
| *1 | Apply Engine Oil. |
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Install the camshafts as shown in the illustration.
| *1 | No. 1 Camshaft |
| *2 | No. 2 Camshaft |
| *3 | No. 3 Cylinder |
| *4 | No. 1 Cylinder |
| *5 | No. 2 Cylinder |
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Set the No. 1 camshaft bearing cap and No. 2 camshaft bearing caps and tighten the bolts in the order shown in the illustration.
| Installation position | Inscribed No. |
| Intake No. 1 cylinder | I2 |
| Intake No. 2 cylinder | I3 |
| Intake No. 3 cylinder | I4 |
| Exhaust No. 1 cylinder | E2 |
| Exhaust No. 2 cylinder | E3 |
| Exhaust No. 3 cylinder | E4 |
| 7. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET |
Insert the camshaft timing gear or sprocket so that the knock pin on the No. 2 camshaft end fits into the groove.
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While holding the hexagonal portion of the No. 2 camshaft, tighten the bolts to install the camshaft timing gear or sprocket.
| 8. INSTALL CAMSHAFT TIMING SPROCKET ASSEMBLY |
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Apply engine oil to the camshaft timing sprocket installation portion of the camshaft.
| *1 | Apply Engine Oil. |
Insert the knock pin on the camshaft end into the knock hole in the camshaft timing sprocket.
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While holding the hexagonal portion of the camshaft, tighten the bolts to install the camshaft timing sprocket.
| 9. INSPECT VALVE CLEARANCE |
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Check only the valves indicated.
Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
| *1 | Intake Side |
| *2 | Exhaust Side |
Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
Turn the crankshaft 1 revolution (360°).
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Check only the valves indicated.
Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
| *1 | Intake Side |
| *2 | Exhaust Side |
Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
| 10. ADJUST VALVE CLEARANCE |
Remove the No. 1 and No. 2 camshafts (Click here).
Remove the valve lifters (Click here).
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Using a micrometer, measure the thickness of the removed valve lifters.
Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
| A | Thickness of new lifter |
| B | Thickness of used lifter |
| C | Measured valve clearance |
Install the valve lifters (Click here).
Install the No. 1 and No. 2 camshafts (Click here).


| Lifter No. | Thickness | Lifter No. | Thickness | Lifter No. | Thickness |
| 12 | 5.12 (0.2016) | 32 | 5.32 (0.2094) | 52 | 5.52 (0.2173) |
| 14 | 5.14 (0.2024) | 34 | 5.34 (0.2102) | 54 | 5.54 (0.2181) |
| 16 | 5.16 (0.2031) | 36 | 5.36 (0.2110) | 56 | 5.56 (0.2189) |
| 18 | 5.18 (0.2039) | 38 | 5.38 (0.2118) | 58 | 5.58 (0.2197) |
| 20 | 5.20 (0.2047) | 40 | 5.40 (0.2126) | 60 | 5.60 (0.2205) |
| 22 | 5.22 (0.2055) | 42 | 5.42 (0.2134) | 62 | 5.62 (0.2213) |
| 24 | 5.24 (0.2063) | 44 | 5.44 (0.2142) | 64 | 5.64 (0.2220) |
| 26 | 5.26 (0.2071) | 46 | 5.46 (0.2150) | 66 | 5.66 (0.2228) |
| 28 | 5.28 (0.2079) | 48 | 5.48 (0.2157) | 68 | 5.68 (0.2236) |
| 30 | 5.30 (0.2087) | 50 | 5.50 (0.2165) | - | - |
| 11. INSTALL CRANKSHAFT STRAIGHT PIN |
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Install the crankshaft straight pin into the crankshaft groove.
| 12. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET |
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Align the groove of the crankshaft timing sprocket with the key of the crankshaft and install the crankshaft timing sprocket.
| 13. INSTALL TIMING CHAIN GUIDE |
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Install the timing chain guide with the 2 bolts.
| 14. INSTALL CHAIN SUB-ASSEMBLY |
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Align the yellow mark plate with the timing mark of the crankshaft timing sprocket and install the timing chain, as shown in the illustration.
| *1 | Yellow Mark Plate |
| *2 | Timing Mark |
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Align the 2 orange mark plates with the timing marks of the camshaft timing sprockets and install the timing chain, as shown in the illustration.
| *1 | Timing Mark |
| *2 | Orange Mark Plate |
| 15. INSTALL TIMING CHAIN TENSION ARM |
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Install the timing chain tension arm with the bolt.
| 16. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY |
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Slightly turn the hexagonal portion of the camshaft (intake side) counterclockwise to leave some slack on the chain of the timing chain tensioner side.
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Install the No. 1 chain tensioner assembly with the 2 bolts.
Remove the hexagon wrench, turn the crankshaft 2 complete revolutions and operate the chain tension assembly.
| *1 | Hexagon Wrench |
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Make sure that the timing mark of the sprocket camshaft timing is at the top with the timing chain tensed (set No. 1 piston to the TDC/ compression).
| *1 | Timing Mark |
| 17. INSTALL OIL PUMP GASKET |
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Install a new oil pump gasket onto the cylinder block.
| 18. INSTALL VENTILATION CASE SUB-ASSEMBLY |
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Install the ventilation case sub-assembly with the 3 bolts.
| 19. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL |
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Apply engine oil to the lip of a new oil seal.
| *1 | Apply Engine Oil. |
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Using SST, tap the oil seal straight in.
| 20. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY |
Remove any oil packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover sub-assembly, cylinder head, and cylinder block.
Apply seal packing as shown in the illustration.

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Temporarily install the timing chain cover sub-assembly with the 12 bolts.
| Item | Length |
| Bolt A | 80 mm (3.15 in.) |
| Bolt B | 40 mm (1.57 in.) |
| Bolt C | 45 mm (1.77 in.) |
| Bolt D | 70 mm (2.78 in.) |
| Bolt E | 45 mm (1.77 in.) |
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Install the new gasket to the timing chain cover sub-assembly.
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Temporarily install the oil filter bracket with the 2 bolts.
| Item | Length |
| Bolt A | 20 mm (0.79 in.) |
| Bolt B | 119 mm (4.69 in.) |
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Install the new gasket to the timing chain cover sub-assembly.
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Temporarily install the water pump assembly with 5 bolts.
| Item | Length |
| Bolt A | 55 mm (2.17 in.) |
| Bolt B | 20 mm (0.79 in.) |
Fully tighten the timing chain cover sub-assembly with the 19 bolts as shown in the illustration.

| Item | Length |
| Bolt A | 80 mm (3.15 in.) |
| Bolt B | 40 mm (1.57 in.) |
| Bolt C | 45 mm (1.77 in.) |
| Bolt D | 70 mm (2.78 in.) |
| Bolt E | 55 mm (2.17 in.) |
| Bolt F | 20 mm (0.79 in.) |
| Bolt G | 119 mm (4.69 in.) |
| Bolt H | 45 mm (1.77 in.) |
Remove excess seal packing.
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Install the 2 stud bolts.
| 21. INSTALL TIMING GEAR COVER TIGHT PLUG |
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Clean the timing gear cover tight plug and installation surface of the timing chain cover.
Apply a light coat of the seal packing black to the timing gear cover tight plug.
| *1 | Seal Packing |
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Using an 8 mm socket hexagon wrench, install the timing gear cover tight plug onto the timing chain cover.
| *1 | 8 mm Socket Hexagon Wrench |
| 22. INSTALL CRANKSHAFT PULLEY |
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Align the pulley set key with the key groove of the pulley.
Using SST, hold the pulley in place and tighten the bolt.
| 23. INSTALL OIL FILTER SUB-ASSEMBLY |
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Check and clean the oil filter installation surface.
Apply clean engine oil to the gasket of a new oil filter.
Gently screw the oil filter into place, and then tighten it until the gasket comes into contact with the seat.
Using SST, tighten it an additional 3/4 turn.
| 24. INSTALL WATER INLET |
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Install the water inlet with 2 nuts.
| 25. INSTALL NO. 1 WATER BY-PASS PIPE |
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Install a new gasket to the No. 1 water by-pass pipe.
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Install a new gasket to the cylinder head.
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Temporarily tighten the bolt and install the 2 nuts.
Fully tighten the bolt.
| 26. INSTALL WATER VALVE |
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Install a new gasket to the water valve.
Install the water valve with the 2 bolts.
| 27. INSTALL OIL STRAINER SUB-ASSEMBLY |
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Install a new oil strainer gasket onto the oil strainer.
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Install the oil strainer with the 2 bolts.
| 28. INSTALL OIL PAN SUB-ASSEMBLY |
Remove any grease from the installation surfaces of the cylinder block sub-assembly and oil pan sub-assembly.
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Using a plastic hammer, tap into the straight pin, as shown in the illustration.
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Apply seal packing to the oil pan sub-assembly and install it onto the cylinder block assembly.
| *1 | Seal Packing |
| *2 | Contact surface between timing chain cover and cylinder block |
| *3 | Contact surface between oil seal retainer and cylinder block |
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Tighten the specified 6 bolts in the order shown in the illustration.
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Tighten the 6 bolts and 3 nuts.
| *1 | Nut |
| *2 | Bolt A |
| *3 | Bolt B |
| 29. INSTALL OIL FILTER BRACKET STAY |
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Install the oil filter bracket stay with 2 bolts.
| 30. INSTALL OIL PAN DRAIN PLUG |
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Install the engine oil drain plug with a new gasket.
| 31. INSPECT VALVE CLEARANCE |
| 32. ADJUST VALVE CLEARANCE |
| 33. INSTALL VENTILATION VALVE SUB-ASSEMBLY |
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Install the grommet, as shown in the illustration.
| *1 | Grommet |
| *2 | Ventilation Valve Sub-Assembly |
Install the ventilation valve sub-assembly.
| 34. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY |
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Fit the cylinder head cover gasket into the groove on the cylinder head cover and onto the center bosses.
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Apply a continuous bead of seal packing (diameter: 3 to 4 mm (0.118 to 0.157 in.)) to the contact surface between the cylinder head assembly and timing chain cover assembly, as shown in the illustration.
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Tighten the bolts A, and then the bolts B.
| *1 | Bolt A |
| *2 | Bolt B |
Check once more that the bolts A meet the specified torque.
| 35. INSTALL OIL FILLER CAP SUB-ASSEMBLY |
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Install a new gasket onto the oil filler cap.
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Install the oil filler cap.
| 36. INSTALL OIL CONTROL VALVE FILTER |
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Install the oil control valve filter onto the head taper screw plug.
| *1 | Oil Control Valve Filter |
| *2 | Gasket |
| *3 | Head Taper Screw Plug |
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Install a new gasket and install the oil control valve filter using an 8 mm hexagon wrench.
| *1 | 8 mm Hexagon Wrench |
| 37. INSTALL KNOCK CONTROL SENSOR |
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Install the knock control sensor with the bolt.
| 38. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY |
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Apply adhesive to 2 or 3 threads of the oil pressure switch.
| *1 | Adhesive |
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Using a 24 mm deep socket wrench, install the oil pressure switch assembly.
| *1 | 24 mm Deep Socket Wrench |
| 39. INSTALL CRANKSHAFT POSITION SENSOR |
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Apply a light coat of engine oil to the O-ring.
Install the crankshaft position sensor with the bolt.
| 40. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY |
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Apply a light coat of engine oil to the O-ring.
Install the camshaft timing oil control valve with the bolt.
| 41. INSTALL ENGINE COOLANT TEMPERATURE SENSOR |
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Install a new gasket onto the engine coolant temperature sensor.
Using a 19 mm deep socket wrench, install the engine coolant temperature sensor.
| *1 | 19 mm Deep Socket Wrench |
| 42. INSTALL CAMSHAFT POSITION SENSOR |
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Apply a light coat of engine oil to the O-ring.
Install the camshaft position sensor with the bolt.
| 43. INSTALL SPARK PLUG |
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Install the 3 spark plugs.
| 44. INSTALL ENGINE HANGERS |
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Install the 2 engine hangers with the 2 bolts.