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OVERHAUL
33. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
34. REMOVE CYLINDER HEAD SUB-ASSY
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-ASSY
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 ASSY
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 crankcase 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.
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 ASSY 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-ASSY
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 grease 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 crank case.
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 ASSY
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 crank case 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-ASSY
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-ASSY
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 and tighten 90° more.
f. Check that the painted marks are now at a 90° angle to the front.
65. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)