Part 2

OVERHAUL





50. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length: 161.3 - 162.7 mm (6.350 - 6.406 inch)
Maximum bolt length: 164.2 mm (6.465 inch)
b. If the length is greater than maximum, replace the bolt.





51. INSPECT CHAIN TENSIONER ASSEMBLY NO. 1
a. Check the plunger moves smoothly when the ratchet pawl is raised, and when the ratchet pawl is released, the plunger is locked in place.
b. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with finger.





52. INSPECT CHAIN SUB-ASSEMBLY
a. Using a vernier calipers, measure the length of 15 links with the chain dully stretched.
Maximum chain elongation: 115.4 mm (4.543 inch)
b. If the elongation is greater than maximum, replace the chain.

NOTICE: Make the same measurements pulling at 3 or more places selected at random, and average the length.





53. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing sprocket.
b. Using a vernier calipers, measure the timing sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 97.3 mm (3.831 inch)

NOTICE: Vernier calipers must contact the chain rollers for the measuring.

54. INSPECT CAMSHAFT





a. Inspect the 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)
b. If the circle runout is greater than maximum, replace the camshaft.





c. Inspect cam lobe height.
1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 46.495 - 46.595 mm (1.8305 - 1.8345 inch)
Minimum cam lobe height: 46.385 mm (1.8262 inch)
d. If the cam lobe height is less than minimum, replace the camshaft.





e. Inspect camshaft journal diameter.
1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 - 35.985 mm (1.4162 - 1.4167 inch)
Other journal diameter: 22.959 - 22.975 mm (0.9039 - 0.9045 inch)
f. If the journal diameter is not as specified, check the oil clearance.
55. INSPECT NO. 2 CAMSHAFT
a. Place the camshaft on V-blocks.





b. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
c. If the circle runout is greater than maximum, replace the camshaft.





d. Inspect cam lobe height.
1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 45.983 - 46.083 mm (1.8104 - 1.8143 inch)
Minimum cam lobe height: 45.873 mm (1.8060 inch)
e. If the cam lobe height is less than minimum, replace the camshaft.





f. Inspect camshaft journal diameter.
1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 - 35.985 mm (1.4162 - 1.4167 inch)
Other journal diameter: 22.959 - 22.975 mm (0.9039 - 0.9045 inch)
g. If the journal diameter is not as specified, check the oil clearance.
56. INSTALL ENGINE REAR OIL SEAL
a. Apply MP grease to a new oil seal lip.

NOTICE: Keep the lip off the foreign materials.





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

NOTICE: Wipe Off extra crease on the crankshaft.

57. INSTALL BALANCE SHAFT BEARING NO. 1
a. Install the bearings in the crankcase and balance shaft housing.
b. Apply a light coat of engine oil on the bearings.
58. INSTALL BALANCE SHAFT No. 1 AND No. 2





a. Rotate driven gear No. 1 of balance shaft No. 1 for the rotating direction until it hits the stopper.
b. Confirm the matchmarks on driven gear No. 1 and No. 2 are matched.





c. Align the timing marks of the No. 1 and No. 2 balance shaft as shown in the illustration.
d. Place the No. 1 and No. 2 balance shaft on the crankcase.
e. Apply a light coat of engine oil under the heads of the balance shaft housing bolts.





f. Temporarily tighten 8 bolts in the several passes as 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.





g. Mark the front side of each balance shaft housing bolt head with paint.
h. Retighten the bolts by 90° as the sequence shown.
i. Check that the painted marks are now at a 90° angle to the front.
59. INSTALL STIFFENING CRANKCASE ASSEMBLY





a. Apply seal packing in the shape of bead (Diameter 2.5 mm - 3 mm (0.098 - 0.118 inch)) the places shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes after applying seal packing.
- Do not start the engine within 2 hours after installing.





b. Install a new O-ring the place shown in the illustration.





c. With the crank pin of the balance shaft, at 6 o'clock position, install the No. 1 and No. 2 balance shaft and the adjusting hole as shown in the illustration.





d. Install the 11 bolts in the several passes as sequence shown in the illustration.
Torque: 33 Nm (332 kgf-cm, 24 ft. lbs.)





e. Confirm that timing marks of the balance shaft are matched as shown in the illustration when the key groove is at 6 o'clock position.





60. INSTALL W/ HEAD TAPER SCREW PLUG NO. 1
a. Apply adhesive to the threads of the plug and install.
Adhesive:
Part No. 08833-00070, THREE BOND 1324 or equivalent.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)





61. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign substance on the mesh part of the filter.
b. Using a 6 mm socket hexagon wrench, install the oil control valve filter with a new gasket.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





62. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Install the water drain cock sub assembly within the range shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





63. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
- Remove any oil from contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.

64. INSTALL CYLINDER HEAD SUB-ASSEMBLY

HINT: 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 bolts and plate washers to the cylinder head.

NOTICE: Do not drop the washers into the cylinder head.





c. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)
d. Mark the front side of each cylinder head bolt with paint.





e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted marks are now at a 90° angle to the front.
65. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





66. INSTALL CAMSHAFT BEARING NO. 2





67. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY
a. Put the camshaft timing gear assembly and the camshaft together with the straight pin of 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, 49 ft. lbs.)
e. Check that the camshaft timing gear assembly can move to the retard angle side (the right direction), and is locked at the most retarded position.





68. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Fix the camshaft No. 2 to the vise, and install camshaft No. 2 timing gear.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
69. INSTALL CAMSHAFT BEARING NO. 1





70. INSTALL CAMSHAFT
a. Tighten camshaft bearing cap No. 1 and No. 3 as the sequence shown in the illustration.
Torque:
Bearing cap No. 1 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
- Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 1.
- Install the camshaft with its timing mark of camshaft timing gear on top.





71. INSTALL NO. 2 CAMSHAFT
a. Tighten camshaft bearing cap No. 2 and No. 3 as the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
- Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 2.
- Camshaft with its timing mark of camshaft timing gear on top.





72. INSTALL OIL PUMP ASSEMBLY
a. Install oil pump assembly with 3 bolts and a new gaskets.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
73. INSTALL NO. 2 CHAIN SUB-ASSEMBLY





a. Set the crankshaft key into the left horizontal position.
b. Turn the cutout of the drive shaft to the top.





c. Align the mark links (yellow colored links) with the timing marks of gear as shown in the illustration.
d. Insert the gear with chain to the crankshaft and oil pump shaft.
e. Temporarily tighten the oil pump drive shaft gear by a nut.





f. Insert the damper spring into the adjusting hole, and install the chain tensioner plate by a bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)





g. Align an adjusting hole of the sprocket with the groove of the oil pump.
h. Put a bar (4 mm) into the adjusting hole of the sprocket to lock in position, and assemble a nut.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.)





i. Rotate the crankshaft clockwise 90°, and align the crankshaft key with the top.
74. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
75. INSTALL CHAIN VIBRATION DAMPER NO. 1
a. Install the chain vibration damper with the 2 bolts.
Torque: 9 Nm (92 kg-cm, 80 inch lbs.)
76. INSTALL CHAIN SUB-ASSEMBLY
a. Set No. 1 cylinder to TDC/compression.





1) Align the timing marks of the camshaft timing sprockets and No. 1 bearing caps.





2) Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.





b. Align the mark plate (blue or orange colored link) with the timing mark of the crankshaft timing gear.





c. Using SST, install the sprocket.
SST 09309-37010





d. Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear, and install the chain.
77. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
78. INSTALL TIMING CHAIN GUIDE
Torque: 9 Nm (92 kgf-cm, 80 inch lbs.)





79. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
a. Install crank angle sensor plate with the "F" mark facing forward.
80. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL





a. Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010
b. Apply a light coat of MP grease to the lip of a new oil seal.

NOTICE: Keep the lip off foreign materials.

81. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes after applying seal packing.
- Do not start the engine within 2 hours after installing.





a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
b. Apply seal packing in the shape of bead (Diameter 2 mm (0.09 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent





c. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.118 - 0.157 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent





d. Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
Bolt A 9.0 Nm (92 kgf-cm, 80 inch lbs.)
Bolt B 21 Nm (214 kgf-cm, 15 ft. lbs.)
Bolt C 43 Nm (438 kgf-cm, 32 ft. lbs.)
Nut 9.0 Nm (92 kgf-cm, 80 inch lbs.)
82. INSTALL OIL PAN SUB-ASSEMBLY

NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes after applying seal packing.
- Do not start the engine within 2 hours after Installing.





a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
b. Apply seal packing in the shape of bead (Diameter 3 mm - 4 mm (0.157 inch)) as shown in the illustration, and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent





c. Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
83. INSTALL OIL PAN DRAIN PLUG
a. Install an oil pan drain plug with a new gasket.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
84. INSTALL WATER PUMP ASSEMBLY
a. Clean the contact surface of the cylinder block.





b. Apply seal packing in the shape of bead (Diameter 2.2 - 2.5 mm) to the outside edge of the water pump.
Seal packing: Part No. 08826-0100 or equivalent

NOTICE:
- Remove any oil from the contact surface.
- Install the water pump within 5 minutes after applying seal packing.
- Do not start the engine within 2 hours after installing.





c. Install the water pump assembly with 4 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: Tighten the outside bolts and nuts with the clamp.

85. INSTALL WATER PUMP PULLEY





a. Using SST, install the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00700)
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)





86. INSTALL CRANK POSITION SENSOR
a. Install the bolt and crankshaft position sensor.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Confirm the wire harness of the crank position sensor is placed as shown in the illustration.
87. INSTALL CRANKSHAFT PULLEY





a. Using SST, tighten the set bolt (TMC made).
SST 09213-54015 (91651-60855), 09330-00021
Torque: 170 Nm (1,733 kgf-cm, 125 ft. lbs.)





b. Using SST, tighten the set bolt (TMMK made).
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 170 Nm (1,733 kgf-cm, 125 ft. lbs.)
88. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1





a. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger can not spring out.





b. Install a new gasket chain tensioner with 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: If the hook is released wile inserting, apply the hook again, and insert the chain tensioner.





c. Turn the crankshaft counterclockwise, and check the plunger knock pin is disconnected from the hook.





d. Turn the crankshaft clockwise, and check the plunger is pushed by the plunger.
89. INSPECT VALVE CLEARANCE
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. Check only the valve indicated.
1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
Valve clearance (cold):
Intake 0.19 - 0.29 mm (0.007 - 0.011 inch)
Exhaust 0.30 - 0.40 mm (0.012 - 0.016 inch)
d. Turn the crankshaft 1 revolution (360°) clockwise, and set No. 4 cylinder to TDC/compression.





e. Check only the valve indicated.
1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
2) Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
Valve clearance (cold):
Intake 0.19 - 0.29 mm (0.007 - 0.011 inch)
Exhaust 0.30 - 0.40 mm (0.012 - 0.016 inch)