Part 3

RH Bank:

LH Bank:

OVERHAUL





51. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.
52. REMOVE SPARK PLUG TUBE GASKET





a. Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.

NOTICE: Be careful not to damage the baffle plate of the cylinder head cover.

b. Using a screwdriver and a hammer, tap out the gasket.





c. Using needle-nose pliers, pry out the gasket.

NOTICE: Be careful not to damage the cylinder head cover.





53. 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 re moving the mounting bolt of the camshaft timing pulley.

Check the belt for any defects, as shown in the illustrations.
Also, check these points.
a. If there is 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, check to see if either camshaft is locked.
c. If there is noticeable wear or cracks on the belt face, check to 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 the timing cover for damage.
^ Check that the gasket has been installed correctly.
^ Check for foreign object on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.
54. INSPECT CAMSHAFT





a. Inspect camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the runout is greater than maximum, replace the camshaft.





b. Inspect cam lobes.
1. Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 43.132 to 43.232 mm (1.6981 to 1.7020 inch)
Exhaust 43.010 to 43.110 mm (1.6933 to 1.6972 inch)
Minimum cam lobe height:
Intake 42.98 mm (1.6921 inch)
Exhaust 42.86 mm (1.6874 inch)
If the cam lobe height is less than minimum, replace the camshaft.





c. Inspect camshaft journals.
1. Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 to 26.975 mm (1.0614 to 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.





55. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than minimum, replace the bolt.





56. INSTALL SPARK PLUG TUBE GASKET
a. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
b. Return the ventilation plate tab to its original position.
c. Apply a light coat of MP grease to the gasket lip.
57. INSTALL ENGINE REAR OIL SEAL





a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects.





b. Apply MP grease to the oil seal lip.
58. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing material from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal retainer within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





59. INSTALL OIL PUMP SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects

b. Apply MP grease to the oil seal lip.
60. INSTALL OIL PUMP ASSEMBLY
a. Remove any old packing material from the contact surface.





b. Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.





c. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.





d. Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.





e. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
Bolt A 8.0 Nm (82 kgf-cm, 71 inch lbs.)
Bolt B 20 Nm (199 kgf-cm, 14 ft. lbs.)
Bolt C 43 Nm (439 kgf-cm, 32 ft. lbs.)
61. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
62. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
63. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old seal packing from the contact surface.





b. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt holes in the region "X".
^ Apply seal packing to the inner side of the bolt holes in the region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing

c. Install the oil pan No. 1 with the 15 bolts and 2 nuts Tighten the bolts uniformly in, several steps.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf cm, 14 ft. lbs.)
64. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the bolt and 2 nuts
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
65. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Remove any old seal packing from the contact surface.





b. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil within 2 hours after installing.

c. Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
66. INSTALL OIL PAN DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
67. INSTALL WATER INLET HOUSING
a. Remove any old packing material from the contact surface.





b. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the water inlet housing within 3 minutes after applying seal packing.
^ Do not expose the seal to coolant within 2 hours after installing.





c. Install the water inlet housing with the 8 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





68. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

69. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.





c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step c.
f. Check that each painted mark is now at a 90° angle to the front.





g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





70. INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket on the cylinder block with the L mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

71. INSTALL CYLINDER HEAD LH

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.





c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step c.
f. Check that each painted mark is now at a 90° angle to the front.





g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)





72. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign object is on the mesh part of the filter.
b. Assemble the valve filter and the plug.
c. Install the plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
73. INSTALL CYLINDER HEAD COVER REAR
a. Install the rear cover and a new gasket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
74. INSTALL CAMSHAFT SUB GEAR





a. Clamp the camshaft in a vise on the hexagonal lobe.

NOTICE: Be careful not to damage the camshaft.





b. Install the camshaft gear bolt washer and the camshaft sub-gear.

HINT: Attach the pins on the gears to the gear bolt washer ends.

c. Install the wave washer.





d. Using snap ring pliers, install the snap ring.





e. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
f. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

NOTICE: Be careful not to damage the camshaft journals.

HINT: When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installation of the service bolt.