Part 1
OVERHAULHINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new parts.
1. REMOVE ENGINE HANGER NO. 1
a. Remove the 4 bolts and engine hangers.
2. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a. Remove the 2 water drain cocks.
3. REMOVE SPARK PLUG
4. REMOVE OIL FILLER CAP SUB-ASSY
5. REMOVE OIL FILLER CAP HOUSING
a. Remove the 2 nuts and oil filler cap housing.
6. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
7. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
a. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
8. REMOVE IDLER PULLEY SUB-ASSY NO.2
a. Remove the pulley bolt, cover plate and idler pulley.
9. REMOVE TIMING BELT COVER SUB-ASSY NO.2
a. Remove the 2 bolts and timing belt cover.
10. REMOVE V-RIBBED BELT TENSIONER ASSY
a. Remove the bolt, 2 nuts and belt tensioner.
11. REMOVE FAN BRACKET SUB-ASSY
a. Remove the 2 bolts, 2 nuts and fan bracket.
12. REMOVE CRANKSHAFT DAMPER SUB-ASSY
a. Using a SST, loosen the pulley bolt.
SST 09213-70011 (90105-08076), 09330-00021
b. Using a SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)
13. REMOVE TIMING BELT NO.1 COVER
a. Remove the 4 bolts and timing belt cover.
14. REMOVE TIMING GEAR COVER SPACER
15. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
16. SET NO. 1 CYLINDER TO TDC/COMPRESSION
a. If reuse the timing belt, check the installation marks on the timing belt.
1. Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part.
b. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
c. Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.
If not, turn the crankshaft 1 complete revolution (360°).
17. REMOVE TIMING BELT
a. Set the No. 1 cylinder to at approximately 50° BTDC/compression.
1. Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approximately 50°.
NOTICE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.
b. Alternately loosen the 2 bolts, then remove the bolts, belt tensioner and dust boot.
c. Using a SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley counterclockwise.
SST 09960-10010 (09962-01000, 09963-00350)
d. Disconnect the timing belt from the timing belt idler No. 1, and remove the timing belt.
18. INSPECT TIMING BELT
NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley.
If there are any defects, as shown in the illustrations, check these points:
a. Premature parting
^ Check for proper installation.
^ Check the timing cover gasket for damage and proper installation.
b. If the belt teeth are cracked or damaged, inspect the camshaft.
c. If there is noticeable wear or cracks on the belt face, inspect see if there are nicks on the side of the idler pulley lock and water pump.
d. If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
e. If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign object on the pulley teeth.
If necessary, replace the timing belt.
19. INSPECT CHAIN TENSIONER ASSY NO.1
a. Visually check the seal portion of the tensioner for oil leakage.
HINT: If there is only the faintest trace of oil on the seal on the push rod side, the tensioner is all right.
If leakage is found, replace the tensioner.
b. Hold the tensioner by hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner.
NOTICE: Never hold the tensioner push rod facing downward.
c. Measure the protrusion of the push rod from the housing end.
Protrusion: 11.2 - 12.2 mm (0.440 - 0.480 inch)
If the protrusion is not as specified, replace the tensioner.
20. REMOVE CAMSHAFT TIMING PULLEYS
a. Using a SST, remove the 2 bolt and 2 timing pulleys.
SST 09960-10010 (09962-01000, 09963-01000)
21. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
a. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.
22. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
a. Remove the bolt and idler.
23. INSPECT TIMING BELT IDLER
a. Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler pulley.
b. Check that the idler pulley turns smoothly.
If necessary, replace the idler.
24. REMOVE CRANKSHAFT TIMING PULLEY
a. Using a SST, remove the timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)
NOTICE: Do not turn the timing pulley.
25. REMOVE TIMING BELT PLATE RR RH
a. Remove the 3 bolts, stud bolt and timing belt plate RR RH.
26. REMOVE TIMING BELT PLATE RR LH
a. Remove the 3 bolts and timing belt plate RR LH.
27. REMOVE CAMSHAFTS
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft seizes or breaks. To avoid this, the following steps should be carried out.
a. Remove the camshafts of the RH bank. In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench. Secure the sub gear to the main gear with the service bolt.
Recommended service bolt
HINT: When removing the camshafts. make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.
1. Set the timing mark (1 dot mark) of the camshaft main gear at approximately 10° angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
2. Uniformly loosen the 22 bearing cap bolts in the sequence as shown, then remove all the bolts.
3. Remove the oil feed pipe, 9 bearing caps, camshaft housing plug and 2 camshafts.
b. Remove the camshafts on the left bank.
1. In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench.
2. Secure the sub-gear to the main gear with a service bolt.
Recommended service bolt
HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has eliminated by the above operation.
3. Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
4. Uniformly loosen the 22 bearing cap bolts in the sequence as shown, then remove all the bolts.
5. Remove the oil feed pipe, 9 bearing caps, camshaft housing plug and 2 camshafts.
HINT: Arrange the bearing caps in correct order.
28. REMOVE SEMICIRCULAR PLUG
29. REMOVE CAMSHAFT SETTING OIL SEAL
30. REMOVE CYLINDER HEAD SUB-ASSY
a. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown Likewise, loosen the 10 bolts on the other side. Remove the 20 cylinder head bolts and plate washers
NOTICE:
^ Cylinder head warpage or cracking may result from removing bolts in incorrect order.
^ Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
b. Lift the cylinder head from the dowels on the cylinder block and place the 2 cylinder heads on wooden blocks on a bench
NOTICE:
^ Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
^ The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
HINT: If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver.