Part 3
OVERHAUL (CONTINUED)51. INSTALL CYLINDER HEAD SUB-ASSY
a) Place the cylinder head on the cylinder block.
b) Apply a light coat of engine oil to the threads and the bottom of the heads of the cylinder head bolts.
c) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
d) Mark the front of the cylinder head bolts with paint.
e) Retighten the cylinder head bolts by 90° in the sequence order shown.
f) Check that the paint mark of each bolt is at 90° angle to the front.
52. INSTALL CAMSHAFT TIMING GEAR ASSY
a) Put the camshaft timing gear together with the camshaft with the straight pin off the key groove.
b) Turn the camshaft timing gear in the left as shown in the illustration while pushing it gently against the camshaft. Push further at the position where the pin fits into the groove.
CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (the right angle).
c) Check that there is no clearance between the gear fringe and camshaft.
d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
e) Check that the camshaft timing gear can move to the retard angle side (the right angle), and is locked in the most retarded position.
53. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a) Clamp the camshaft in a vise, then install the camshaft timing gear with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
NOTICE: Be careful not to damage the camshaft.
54. INSTALL CAMSHAFT
a) Apply a light coat of engine oil to the camshaft journals.
b) Place the 2 camshafts on the cylinder head as shown in the illustration.
c) Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then tight en the bolts.
Torque:
23 Nm (235 kgf-cm, 17 ft. lbs.) for bearing cap No. 1
13 Nm (133 kgf-cm, 10 ft. lbs.) for bearing cap No. 3
55. INSTALL OIL CONTROL VALVE FILTER
a) Check that there is no foreign objects on the mesh part of the oil control valve filter.
b) Install a new gasket and the oil control valve filter onto the bolt, then install it.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
56. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
a) Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.
b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: Be careful not to twist the O-ring.
57. INSTALL OIL PUMP GASKET
a) Install a new gasket onto the cylinder block.
58. INSTALL OIL PUMP ASSY
a) Align the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, then slide on the oil pump.
b) Install the oil pump with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
59. INSTALL CHAIN VIBRATION DAMPER NO. 1
a) Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
60. INSTALL CHAIN SUB-ASSY
a) Set the No. 1 cylinder to the TDC/compression.
1) Turn the hexagonal wrench head portion of the camshafts until the point marks of the 2 camshaft timing gears are aligned.
2) Using a crankshaft pulley bolt, turn the crankshaft to align the timing gear key with the point mark on the oil pump.
b) Install the chain onto the crankshaft timing gear with the yellow mark link aligned with the timing mark on the crankshaft timing gear.
c) Using SST, install the crankshaft timing gear.
SST 09223-22010
d) Install the chain onto the camshaft timing gears with the yellow mark links aligned with the timing marks on the camshaft timing gears.
61. INSTALL CHAIN TENSIONER SLIPPER
a) Install the chain tensioner slipper with the bolt.
Torque: 18.5 Nm (189 kgf-cm, 14 ft. lbs.)
62. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
a) Install the crankshaft position sensor plate with the "F" mark facing forward.
63. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
a) Apply a light coat of multi-purpose grease to a new oil seal lip.
b) Place the timing chain cover on wooden blocks.
c) Using SST, tap the oil seal in until its surface is flush with the timing chain cover edge.
SST 09223-22010
NOTICE: Keep the lip free off foreign objects.
64. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
a) Remove any old packing material from the contact surface.
b) Using a torx socket wrench E5, install the 3 stud bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
c) Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 inch)) as shown in the illustration.
Seal packing:
Water pump part: Part No. 08826-00100 or equivalent
Other part: Part No. 08826-00080 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the chain cover within 3 minutes of applying seal packing.
^ Do not start the engine for at least 2 hours after installing the chain cover.
^ Be careful to only apply the specified thickness / volume of seal packing in area D.
d) Install the timing chain cover with the 10 bolts and 2 nuts.
Torque:
13 Nm (133 kgf-cm, 10 ft. lbs.) for bolt A and nut A
18.5 Nm (189 kgf-cm, 14 ft. lbs.) for bolt B
65. INSTALL CHAIN TENSIONER ASSY NO. 1
a) Check that the O-ring is clean, then set the hook as shown in the illustration.
b) Apply a light coat of engine oil to the O-ring.
c) Install the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE:
^ Be careful not to twist the O-ring.
^ When installing the chain tensioner, set the hook again if the hook releases the plunger.
66. INSTALL CRANKSHAFT PULLEY
a) Align the pulley set key with the key groove of the crankshaft pulley, then slide on the crankshaft pulley.
b) Using SST, install the crankshaft pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 138 Nm (1,407 kgf-cm, 102 ft. lbs.)
c) Turn the crankshaft counterclockwise to disconnect the plunger knock pin from the hook.
d) Turn the crankshaft clockwise, then check that the slipper is pushed by the plunger.
If the plunger is not extended, push the slipper into the chain tensioner using a screwdriver so that the hook is released from the knock pin and the plunger can be extended.
67. INSTALL WATER PUMP O-RING
a) Install a new O-ring onto the timing chain cover.
68. INSTALL WATER PUMP ASSY
a) Install the water pump with the 6 bolts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt A
11 Nm (112 kgf-cm, 8 ft. lbs.) for bolt B
69. INSTALL ENGINE MOUNTING BRACKET RH
a) Install the engine mounting bracket RH with the 3 bolts.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
70. CHECK VALVE CLEARANCE
a) Set the No. 1 cylinder to the TDC/compression.
1) Turn the crankshaft pulley until its groove and timing mark "0" of the timing chain cover are aligned.
2) Check that the point marks of the camshaft timing gears are in a straight line on the timing chain cover surface as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) to align the marks as above.
b) Check only the valves indicated.
1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 inch) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 inch) for exhaust
2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
c) Turn the crankshaft 1 revolution (360°) to set the No.4 the cylinder to the TDC/compression.
d) Check only the valves indicated.
1) Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 inch) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 inch) for exhaust
2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifters.
71. ADJUST VALVE CLEARANCE
NOTICE: Do not to turn the crankshaft without the chain tensioner.
a) Set the No. 1 cylinder to the TDC/compression.
b) Place painted marks on the chain and camshaft timing gears.
c) Remove the 2 nuts, then remove the chain tensioner.
d) While holding the camshaft with a wrench, loosen the camshaft timing gear set bolt.
NOTICE: Be careful not to damage the valve lifter.
e) Using several steps, uniformly loosen and remove the 11 bolts in the sequence shown, then remove the 5 bearing caps.
f) Remove the camshaft timing gear as shown in the illustration.
g) Using several steps, uniformly loosen and remove the 8 bolts in the sequence shown, then remove the 4 bearing caps.
h) Remove the camshaft and camshaft timing gear while holding the timing chain by hand.
i) Tie the timing chain with a string as shown in the illustration.
NOTICE: Be careful not to drop anything inside the timing chain cover.
j) Remove the valve lifters.
k) Using a micrometer, measure the thickness of the removed valve lifters.
l) Calculate the thickness of a new lifter so that the valve clearance comes within the specified values.
Valve clearance:
Intake A = B + (C - 0.20 mm (0.0079 inch))
Exhaust A = B + (C - 0.30 mm (0.0118 inch))
HINT:
^ Select a new lifter with a thickness as close to the calculated values as possible.
^ Lifters 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).
^ Refer to New Lifter Thickness table.
Valve Lifter Selection Chart (Intake)
Valve Lifter Selection Chart (Exhaust)
m) Install the timing chain onto the camshaft timing gear with the paint mark aligned with the timing mark on the camshaft timing gear as shown in the illustration.
n) Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then tighten the bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
o) Put the No. 2 camshaft on the cylinder head with the paint mark of the chain aligned with the timing mark on the camshaft timing gear.
p) Temporarily install the camshaft timing gear set bolt.
q) Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then tighten the bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
r) Install the bearing cap No. 1.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
s) While holding the camshaft with a wrench, 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) Check that each timing mark is aligned with its corresponding painted mark on the timing chain as shown in the illustration. Also, check that the groove is aligned with timing mark "0" of the timing chain cover.
u) Install the chain tensioner.
1) Check that the O-ring is clean, and set the hook as shown in the illustration.
2) Apply a light coat of engine oil to the O-ring.
3) Install the chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE:
^ Be careful not to twist the O-ring.
^ When installing the chain tensioner, set the hook again if the hook releases the plunger.
4) Turn the crankshaft counterclockwise to disconnect the plunger knock pin from the hook.
5) Turn the crankshaft clockwise, then check that the slipper is pushed by the plunger.
If the plunger is not extended, push the slipper into the chain tensioner using a screwdriver so that the hook is released from the knock pin and the plunger can be extended.
72. INSTALL CYLINDER HEAD COVER GASKET
a) Install the gasket onto the cylinder head cover.
73. INSTALL CYLINDER HEAD COVER SUB-ASSY
a) Remove any old packing material from the contact surface.
b) Apply seal packing to the 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 3 minutes of applying the seal packing.
^ Do not put in engine oil for at least 2 hours after installation.
c) Install the cylinder head cover with the 9 bolts, 2 seal washers and 2 nuts.
Torque:
11 Nm (112 kgf-cm, 8 ft. lbs.) for bolt A and nut A
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bolt B
74. INSTALL SPARK PLUG
a) Using a spark plug wrench, install the spark plugs.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
75. INSTALL VENTILATION VALVE SUB-ASSY
a) Install the ventilation valve onto the cylinder head cover.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
76. INSTALL OIL FILLER CAP GASKET
a) Install the gasket onto the oil filler cap.
77. INSTALL OIL FILLER CAP SUB-ASSY
a) Install the oil filler cap onto the cylinder head cover.