Part 1
OVERHAUL1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
2. REMOVE OIL FILLER CAP GASKET
3. REMOVE VENTILATION VALVE SUB-ASSEMBLY
4. REMOVE SPARK PLUG
5. REMOVE OIL FILTER SUB-ASSEMBLY
a. Using SST, remove the oil filter.
SST 09228-06501
6. REMOVE OIL FILTER UNION
a. Using a 12 mm hexagon wrench, remove the oil filter union.
7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove 8 bolts, 2 nuts, and cylinder head cover sub assembly.
8. REMOVE CYLINDER HEAD COVER GASKET
9. REMOVE CAMSHAFT POSITION SENSOR
10. REMOVE CRANKSHAFT PULLEY
a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the timing chain cover.
b. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap as shown in the illustration.
c. Remove the crankshaft pulley (TMC made).
1) Using SST, fix the crankshaft pulley and loosen a 3 pulley set bolt.
SST 09213-54015 (91651-60855), 09330-00021
2) Using a pulley set bolt and SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09950-05021)
d. Remove the crankshaft pulley (TMMK made).
1) Using SST, fix the crankshaft pulley and loosen a pulley set bolt.
SST 09960-10010 (09962-01000, 09960-01000)
2) Using SST, remove the crankshaft pulley.
SST 09950-40011 (09951-04010, 09952-04010, 09953-04030, 09954-04010, 09955-04041, 09957-04010, 91111-51014)
11. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1
a. Remove the 2 nuts, timing chain tensioner and gasket.
NOTICE: Be sure not to turn the crankshaft without the chain tensioner.
12. REMOVE WATER PUMP PULLEY
a. Using SST, remove the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
13. REMOVE WATER PUMP ASSEMBLY
a. Remove the 4 bolts, 2 nuts, bracket and water pump.
14. REMOVE CRANK POSITION SENSOR
15. REMOVE OIL PAN DRAIN PLUG
16. REMOVE OIL PAN SUB-ASSEMBLY Z
a. Remove the 12 bolts and 2 nuts.
b. Insert the blade of SST between the crank case and oil pan, cut off applied sealer and remove the oil pan.
SST 09032-0100
NOTICE: Be careful not to damage the contact surface of the cylinder block and oil pan.
17. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a. Remove the 14 bolts and 2 nuts.
b. Remove the timing chain cover by prying the portions between the timing chain cover and cylinder head or cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of the timing chain cover, cylinder block and cylinder head.
18. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
a. Using a screwdriver, remove the oil seal.
19. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
20. REMOVE TIMING CHAIN GUIDE
21. REMOVE CHAIN TENSIONER SLIPPER
22. REMOVE CHAIN VIBRATION DAMPER NO. 1
23. REMOVE CHAIN SUB-ASSEMBLY
24. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET
25. REMOVE NO. 2 CHAIN SUB-ASSEMBLY
a. Turn the crankshaft counterclockwise 90°, and align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
b. Put a bar ([diameter] 4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove a nut.
c. Remove bolt and a chain tensioner plate.
d. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub assembly.
26. REMOVE OIL PUMP ASSEMBLY
a. Remove 3 bolts and the oil pump assembly.
27. REMOVE NO. 2 CAMSHAFT
a. Remove No. 1 and No. 2 camshaft bearing caps as the sequence shown in the illustration.
b. Remove No. 2 camshaft.
28. REMOVE CAMSHAFT
a. Remove No. 1 and No. 3 camshaft bearing caps as the sequence shown in the illustration.
b. Remove No. 1 camshaft.
29. REMOVE CAMSHAFT BEARING NO. 1
30. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Fix the No. 2 camshaft with a vise, and remove the camshaft timing gear.
NOTICE: Be careful not to damage the camshaft.
31. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
a. Fix the No. 1 camshaft with a vise, and make sure the camshaft timing gear assembly does not move.
b. Cover all the paths with vinyl tape except an advanced side path as shown in the illustration.
c. Put air pressure into the oil path with 150 kPa (1.5 kg/cm2, 21 psi), and turn the camshaft timing gear assembly to the advance direction (counterclockwise) by force.
NOTICE: Cover the paths with shop rag to avoid oil splashing.
HINT: Depending on the air pressure, the VVT timing sprocket will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage form the port, there may be the case that the lock pin could be hardly released.
d. Remove a fringe bolt of camshaft timing gear assembly.
NOTICE:
- Be sure not to remove the other 4 bolts.
- In case of reusing the camshaft timing gear assembly, release the straight pin lock first, and then install the gear.
32. REMOVE CAMSHAFT BEARING NO. 2
33. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
34. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers.
NOTICE:
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in and incorrect order.
35. REMOVE CYLINDER HEAD GASKET
36. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
37. REMOVE OIL CONTROL VALVE FILTER
a. Using a 6 mm socket hexagon wrench, remove a plug and oil control valve filter.
38. REMOVE W/ HEAD TAPER SCREW PLUG NO. 1
39. INSPECT BALANCE SHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.050 - 0.090 mm (0.0020 - 0.0035 inch)
Maximum thrust clearance: 0.090 mm (0.0035 inch)
40. INSPECT BALANCE SHAFT OIL CLEARANCE
a. Uniformly loosen and remove the 8 bolts in several passes, in the sequence shown.
b. Lay a strip of plastigage across each journal, and install the balance shaft housing.
c. Apply light coat of engine oil on the threads and under the heads of the balance shaft housing bolts.
d. Temporarily tighten 8 bolts in the several passes, in the sequence shown, and fully tighten with specified torque.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)
HINT: The balance shaft housing bolts are tightened in 2 progressive steps.
e. Mark the front side of each balance shaft housing bolt head with paint.
f. Retighten the bolts 90° as the sequence shown.
g. Check that the paint marks are now at a 90° angle to the front.
h. Remove the balance shaft housing, and measure the plastigage at its widest point.
Standard oil clearance: 0.004 - 0.031 mm (0.0002 - 0.0012 inch)
Maximum oil clearance: 0.031 mm (0.0012 inch)
NOTICE: Completely remove the plastigage after the inspection.
i. If the clearance is greater than maximum, replace the bearing. If necessary, replace the balance shaft.
j. If using a standard bearing, replace it with one having the same number.
Balance shaft housing journal bore diameter:
Balance shaft journal diameter:
Standard bearing center wall thickness:
41. REMOVE BALANCE SHAFT No. 1 AND No. 2
42. REMOVE BALANCE SHAFT BEARING NO. 1
43. REMOVE ENGINE REAR OIL SEAL
a. Using a knife, cut off the oil seal lip.
b. Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE: After the removal, check the crankshaft is not damaged. If there is, mend it with a sandpaper (#400).
44. REMOVE STIFFENING CRANKCASE ASSEMBLY
a. Uniformly loosen and remove the 11 bolts, in several passes, in the sequence shown.
b. Using a screwdriver, remove the crankcase by prying the portions between the crankcase and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the crank case and cylinder block.
c. Remove the O-ring from the cylinder block.
45. INSPECT OIL PUMP DRIVE GEAR
a. Wrap the chain around the drive gear.
b. Using vernier calipers, measure the drive gear diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
Minimum gear diameter (w/ chain): 48.2 mm (1.898 inch)
c. If the diameter is less than minimum, replace the chain and drive gear.
46. INSPECT OIL PUMP DRIVE SHAFT GEAR
a. Wrap the chain around the drive shaft gear.
b. Using vernier calipers, measure the drive shaft gear diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
Minimum gear diameter (w/ chain): 48.2 mm (1.898 inch)
c. If the diameter is less than minimum, replace the chain and drive shaft gear.
47. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing gear.
b. Using vernier calipers, measure the timing gear diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
Minimum gear diameter (w/ chain): 51.6 mm (2.031 inch)
c. If the diameter is less than minimum, replace the chain and timing gear.
48. INSPECT CHAIN TENSIONER SLIPPER
a. Measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 inch)
b. If the wear is greater than maximum, replace the chain tensioner slipper.
49. INSPECT CHAIN VIBRATION DAMPER NO. 1
a. Measure the chain vibration damper No. 1 wears.
Maximum wear: 1.0 mm (0.039 inch)
b. If the wear is greater than maximum, replace the chain vibration damper No. 1.