Part 3
OVERHAUL90. ADJUST VALVE CLEARANCE
NOTICE: Do not turn the crankshaft without the chain tensioner.
a. Turn the crankshaft 1 revolution (360°) clockwise, and set No. 1 cylinder to TDC/compression.
b. Place matchmarks on the timing chain and camshaft timing gear.
c. Remove the 2 bolts and chain tensioner.
d. Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set bolt.
NOTICE: Be careful not to damage the valve lifter.
e. Loosen the camshaft bearing cap bolts on No. 2 camshaft in the sequence shown in the illustration in several passes, and remove the caps.
f. Raising the camshaft, remove the set bolt.
g. Remove the timing chain sprocket from the camshaft with timing chain.
h. Remove the timing chain sprocket from the timing chain.
i. Loosen the camshaft bearing cap bolts on camshaft in the sequence shown in the illustration, in several passes, and remove the caps.
j. Remove the intake camshaft.
k. Tie the timing chain with a string.
l. Using a micrometer, measure the thickness of the removed lifter.
m. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
Valve clearance:
Intake A = B + (C - 0.24 mm (0.0094 inch))
Exhaust A = B + (C - 0.35 mm (0.0138 inch))
HINT:
- Select a new lifter with a thickness as close as possible to the calculated values.
- Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch).
n. Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing sprockets.
o. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9.0 Nm (92 kgf-cm, 80 inch lbs.)
p. Put the camshaft No. 2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets.
q. Raising the camshaft, tighten the set bolt temporarily.
r. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No.2 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No.3 9.0 Nm (92 kgf-cm, 80 inch lbs.)
s. Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
NOTICE: Be careful not to damage the valve lifter.
t. As shown in the illustration, check the matchmarks on the timing chain and camshaft timing sprockets and the alignment of the pulley groove with timing mark of the chain cover.
HINT: There are 7 links between the timing marks.
u. Install chain tensioner.
1) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
2) Install a new gasket and chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger.
3) Turn the crankshaft counterclockwise, and disconnect the plunger knock pin form the hook.
4) Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
91. INSTALL CAMSHAFT POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
92. INSTALL CYLINDER HEAD COVER GASKET
a. Install the gasket to the cylinder head cover.
93. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove any old packing (FIPG) material.
b. Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 5 minutes after applying seal packing.
- Do not put into engine oil 2 hours after installing.
c. Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8 ft. lbs.)
94. INSTALL OIL FILTER UNION
a. Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
95. INSTALL OIL FILTER SUB-ASSEMBLY
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.
d. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
96. INSTALL SPARK PLUG
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
97. INSTALL VENTILATION VALVE SUB-ASSEMBLY
a. Apply adhesive on the threads of the ventilation valve.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
98. INSTALL OIL FILLER CAP GASKET
a. Install the gasket to the oil filter cap.
99. INSTALL OIL FILLER CAP