19251-ZY3-621 Honda TUBE, WATER (XXL)

1. Remove covers (1) from flywheel housing (4). Check the condition of the gaskets beneath covers (1) and replace as needed. 2. Remove the bolt and timing ring (2). 3. Remove the bolt and plate (5) from camshaft drive gear (3). 4. Put the three washers from tooling (A) behind plate (5) and install the bolt and plate (5).
Do not apply more than 51675 kPa (7500 psi) pressure to 1P820 Hydraulic Puller. 8B7559 adapters are rated at 6 1/2 ton each and 1P820 Hydraulic Puller is rated at 17 ton at 68900 kPa (10000 psi). If to much pressure is applied, the gear may be damaged.
5. Install tooling (A) on camshaft drive gear (3). Apply 51,675 kPa (7500 psi) to the puller. If necessary, use a hammer to impact the head of the puller screw on tooling (A). This should break the gear free from the tapered end of the camshaft.6. Install tooling (A) on the remaining camshaft drive gear (3) and repeat step 5.7. Put stands or blocks under the rear of the engine block. The weight of the engine is approximately 6090 kg (13,400 lb).8. Install tooling (B) on the top of flywheel housing (4) and attach a hoist. 9. Remove all bolts that fasten flywheel housing (4) to the engine block.
Dowel pins are used for the correct alignment and positioning of flywheel housing (4) to the engine block. Removal of the locating dowel pins may help to free flywheel housing (4) from the engine block.
10. Remove flywheel housing (4) from the engine. The weight of the flywheel housing is 210 kg (454 lb). Use the following steps to install the flywheel housing. Also refer to Specifications Manual SENR5189 for additional information.11. Use 6V1541 Quick Cure Primer to clean the mating surfaces of the flywheel housing and the cylinder block. Put 6V6640 Gasket Maker on the mating surfaces of the flywheel housing and cylinder block.12. Use a hoist and tooling (B) to position flywheel housing (4) onto the cylinder block.13. If the locating dowel pins were removed from flywheel housing (4) and the cylinder block, install the dowel pins. Make sure the dowel pins are properly seated. 14. Install the bolts for flywheel housing (4) in their respective locations. See the Installation Chart. Tighten the 1/2" - NC bolts to a torque of 135 15 N m (100 11 lb. ft.). Tighten the 5/8" NC bolts to a torque of 270 25 N m (200 18 lb. ft.).15. Remove tooling (B).16. Put the camshaft timing pins in position and put the timing bolt in the flywheel with number 1 piston at the compression stroke. See the topic, Install Camshafts in this module. Be sure gear backlash is removed.17. Install two camshaft drive gears (3).18. Install the bolt and plate (5).19. Position timing ring (2) onto the camshaft and locating dowel. Install the washer and bolt for timing ring (2).20. Use the following steps to seat the camshaft gears onto the tapered ends of the camshafts:a. Tighten the bolt holding timing ring (2) to a torque of 360 50 N m (265 35 lb. ft.).b. Use a soft hammer to hit the head of the bolt holding timing ring (2). This will help seat camshaft drive gear (3) the gear on the camshaft.c. Again tighten the bolt holding timing ring (2) to a torque of 360 50 N m (265 35 lb. ft.). Put a mark on the bolt and timing ring (2).d. Repeat Steps b and c until the bolt holding timing ring (2) no longer moves (the marks stay aligned) after reaching the proper torque.e. Repeat Steps a through d to seat the remaining camshaft drive gear (3) located beneath the bolt and plate (5).21. Remove the timing pins from the camshafts and the flywheel.22. Install the covers (1) in their respective positions.End By:a. install crankshaft rear seal and wear sleeveb. install oil pan, (rear half only)c. install electric starting motorsd. install enginee. install speed/timing sensor **Refer to the topic "Installation/Removal Of The Speed/Timing Sensor" in the Testing & Adjusting manual for this procedure.