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OVERHAUL
39. INSPECT CHAIN TENSIONER SLIPPER
a. Using a vernier calipers, measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the chain tensioner slipper.
40. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Using a vernier calipers, measure the vibration damper wears.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the chain vibration damper.
41. INSPECT CYLINDER HEAD SET BOLT
a. Using a vernier calipers, measure the length of cylinder head bolts from the seat to the end.
Standard bolt length: 146.8 - 148.2 mm (5.780 - 5.835 inch)
Maximum bolt length: 148.5 mm (5.846 inch)
If the bolt length is greater than maximum, replace the cylinder head set bolt.
42. INSPECT CAMSHAFT
a. Inspect camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle 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 44.333 - 44.433 mm (1.7454 - 1.7493 inch)
Exhaust 43.761 - 43.861 mm (1.7229 - 1.7268 inch)
Minimum cam lobe height:
Intake 44.18 mm (1.7394 inch)
Exhaust 43.61 mm (1.7169 inch)
If the cam lob height is less than minimum, replace the camshaft.
c. Inspect camshaft journals.
1. Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 34.449 - 34.465 mm (1.3563 - 1.3569 inch)
Others journal diameter: 22.949 - 22.965 mm (0.9035 - 0.9041 inch)
If the journal diameter is not as specified, check the oil clearance.
43. INSTALL OIL STRAINER FLANGE GASKET
a. Install a new gasket to the bearing cap.
44. INSTALL OIL STRAINER SUB-ASSY
a. Install the oil strainer with the 2 nuts and bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
45. INSTALL OIL PAN SUB-ASSY
a. Remove any old packing material from the contact surface and thread holes.
b. Apply seal packing in the shape of bead (Diameter 3.5 mm - 4.5 mm - (0.138 - 0.177 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.
c. Install the oil pan with the 14 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
46. INSTALL OIL PAN DRAIN PLUG
a. Place a new gasket on the oil pan drain plug, and install it.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
47. INSTALL ENGINE REAR OIL SEAL
a. Apply a light coat of MP grease to a new oil seal lip.
NOTICE: Keep the lip off foreign materials.
b. Using SST, tap in the oil seal until its surface is flush with the oil seal retainer edge.
SST 09223-1502O, 09950-70010 (09951-07100)
NOTICE: Wipe off extra grease on the crank shaft.
48. INSTALL OIL FILTER UNION
a. Using a socket hexagon wrench 12, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
49. INSTALL OIL FILTER SUB-ASSY
a. Check and clean the oil filter installation surface.
b. Apply clean engine oil to the gasket of a new oil filter.
c. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
50. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE: Pay attention to the installation direction. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
51. INSTALL CYLINDER HEAD SUB-ASSY
a. Place the cylinder head on the cylinder block.
b. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
c. Using a bi-hexagon wrench 10, install and uniformly tighten the 10 cylinder head bolts with plate washers, in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
d. Mark the front of the cylinder head bolt with paint.
e. Retighten the cylinder head bolts 90° in the numerical order shown.
f. Check that the point marked bolts are moved at 90° angle.
52. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
b. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove.
CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle).
c. Check that there is no clearance between the gear's fringe and the camshaft.
d. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm 40 ft. lbs.)
e. Check that the camshaft timing gear assembly can move to the retard angle side (the right angle), and is locked at the most retarded position.
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Grip the camshaft with a vice, and install the camshaft timing gear with bolt.
Torque: 54 Nm (551 kgf-cm 40 ft. lbs.)
NOTICE: Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT
a. Apply a light coat of engine oil on the camshaft journals.
b. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.
c. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 23 Nm (235 kgf-cm, 17 ft. lbs.)
Bearing cap No. 3 13 Nm (133 kgf-cm, 10 ft. lbs.)
55. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign substance on the mesh part of the oil control valve filter.
b. Install a new gasket and the oil control valve filter on the bolt, and install it.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
a. Apply a light coat of a new O-ring, and install it to the camshaft timing oil control valve.
b. Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: Be careful not twist an O-ring.
57. INSTALL OIL PUMP GASKET
a. Install a new gasket to the cylinder block.
58. INSTALL OIL PUMP ASSY
a. Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, and side the oil pump.
b. Install the oil pump with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
59. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
60. INSTALL CHAIN SUB-ASSY
a. Set No. 1 cylinder to TDC/compression.
1. Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing gears.
2. Using a crankshaft pulley bolt, turn the crankshaft, and the timing gear key aligned with the point mark on the oil pump.
b. Install the chain on the crankshaft timing gear with the yellow color mark link aligned with the timing mark on the crankshaft timing gear.
c. Using SST, install the crankshaft timing gear.
SST 09223-22010
d. Install the chain on the camshaft timing gears with the yellow color mark links aligned with the timing marks on the camshaft timing gears.