Part 3
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OVERHAUL
51. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 6 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and main bearing cap.
52. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and a hammer, tap out the oil seal.
53. REMOVE OIL PUMP ASSY
a. Remove the 9 bolts.
b. Remove the oil pump by prying a screwdriver between the oil pump and main bearing cap.
c. Remove the O-ring.
54. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.
55. REMOVE SPARK PLUG TUBE GASKET
a. Bend up the tab on the ventilation baffle plate which prevents the gasket from the 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.
56. 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. 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 timing cover for damage.
- Check gasket has been installed correctly.
- Check for foreign material on the pulley teeth.
If necessary, replace the timing belt.
57. 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: 0.06 mm (0.0024 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 42.932 - 43.032 mm (1.6902 - 1.6942 inch)
Exhaust 42.764 - 42.864 mm (1.6836 - 1.6876 inch)
Minimum cam lobe height:
Intake 42.78 mm (1.6842 inch)
Exhaust 42.61 mm (1.6776 inch)
If the cam lobe height is less than minimum, replace the cam shaft.
c. Inspect camshaft journals.
1 Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 - 26.975 mm (1.0614 - 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.
58. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 - 9.05 mm (0.3524 - 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3775 inch)
If the diameter is less than minimum, replace the bolt.
59. 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.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE:
- Be careful not to tap the oil seal slantingly.
- Keep the lip off foreign materials.
d. Apply MP grease to the oil seal lip.
60. 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 slantingly.
- Keep the lip off foreign materials.
b. Apply MP grease to the oil seal lip.
61. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 2 - 3 mm (0.08 - 0.12 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 seal retainer within 3 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.
c. Install the oil seal retainer with the 6 bolts, uniformly tighten the bolt in several passes.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
62. 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 slantingly.
- Keep the lip off foreign materials.
b. Apply MP grease to the oil seal lip.
63. INSTALL OIL PUMP ASSY
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 seal packing in the shape of bead (Diameter 2 - 3 mm (0.08 - 0.12 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Apply seal packing to the inner side of the bolt hole.
- Remove any oil from contact surface.
- Install the oil pump within 3 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.
d. Engage the spline teeth of the oil pump drive gear with the large teeth of the crankshaft, and slide the oil pump on the crankshaft.
e. Install the oil pump with the 9 bolts. Uniformly tighten the bolts in several passes.
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 CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
65. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
66. INSTALL OIL PAN SUB-ASSY
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.12 - 0.16 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Apply seal packing to the outer side of the bolt hole in the region "X".
- Apply seal packing to the inner side of the bolt hole in the region "Y".
- Remove any oil from the contact surface.
- Install the No.1 oil pan within 3 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.
c. Install the No. 1 oil pan with the 15 bolts and 2 nuts. Uniformly tighten the bolts in several passes.
Torque:
10 mm head 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12 mm head 20 Nm (199 kgf-cm, 14 ft. lbs.)
67. INSTALL OIL STRAINER SUB-ASSY
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.)
68. INSTALL OIL PAN SUB-ASSY NO.2
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 4 - 5 mm (0.16 - 0.20 inch)) consequently 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 hole.
- 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 No. 2 oil pan with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
69. INSTALL OIL PAN DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
70. INSTALL CYLINDER BLOCK SIDE COVER (2WD DRIVE TYPE)
a. Install a new gasket and the cylinder block side cover with the 3 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
71. INSTALL CYLINDER BLOCK SIDE COVER DRAIN COCK PLUG (2WD DRIVE TYPE)
a. Install the drain cock plug with a new O-ring.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
72. INSTALL WATER INLET HOUSING
a. Remove any old packing material form the contact surface.
b. Apply seal packing in the shape of bead (Diameter 3 - 5 mm (0.12 - 0.20 inch)) consequently 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 put into coolant within 2 hours after installing.
c. Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes, in the sequence shown.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
73. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the R mark upward.
NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.
74. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.
c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.
g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
75. INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket on the cylinder block surface with the L mark upward.
NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.