Part 2

OVERHAUL (CONTINUED)

37. REMOVE CAMSHAFT
a. Remove the camshaft.
38. REMOVE NO.2 CAMSHAFT
a. Remove the No.2 camshaft.





39. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
a. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft housing sub-assembly RH with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT: Tape the screwdriver tip before use.

40. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)





a. While pushing down the chain tensioner No.3, insert a pin of diameter 1.0 mm (0.039 inch) into the hole to fix it.





b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gears.

NOTICE:
- Be careful not to damage the cylinder head with the wrench.
- Do not disassemble the camshaft timing gear assembly.
c. Remove the No.2 chain.





41. REMOVE CHAIN TENSIONER ASSEMBLY NO.3
a. Remove the bolt and chain tensioner No.3.
42. REMOVE CAMSHAFT BEARING CAP





a. Remove the 3 gaskets.





b. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.





c. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.





d. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.

NOTICE: Uniformly loosen the bolts while keeping the camshaft level.

e. Remove the 5 bearing caps.
43. REMOVE NO.4 CAMSHAFT SUB-ASSEMBLY
a. Remove the No.4 camshaft sub-assembly.
44. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY
a. Remove the No.3 camshaft sub-assembly.





45. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
a. Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft housing sub-assembly LH with a screwdriver.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and camshaft housing.

HINT: Tape the screwdriver tip before use.

46. REMOVE VALVE ROCKER ARM SUB-ASSEMBLY NO.1
a. Remove the 24 valve rocker arms.

HINT: Arrange the removed parts in the correct order.

47. REMOVE VALVE LASH ADJUSTER ASSEMBLY
a. Remove the 24 valve lash adjusters from the cylinder head.

HINT: Arrange the removed parts in the correct order.

48. REMOVE CYLINDER HEAD LH





a. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.





b. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from not removing the bolts in the correct order.

HINT: Be sure to keep the removed parts separate for each installation position.

c. Remove the cylinder head and gasket.





49. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from not removing the bolts in the correct order.

HINT: Be sure to keep the removed parts separate for each installation position.

b. Remove the cylinder head and gasket.





50. REMOVE WATER INLET PIPE
a. Separate the knock sensor wire.
b. Remove the 2 bolts, and water inlet pipe.
c. Separate the water by-pass hose No.1.





51. INSPECT VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.

a. Place the lash adjuster into a container full of engine oil.
b. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
SST 09276-75010
c. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
d. Check the movement of the plunger and bleed the air. OK: Plunger moves up and down.

NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

e. After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger. OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
52. INSPECT CAMSHAFTS





a. Inspect 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: 0.04 mm (0.0016 inch)

If the circle runout is greater than the maximum, replace the camshaft.

HINT: Check the oil clearance after replacing the camshaft.





b. Using a micrometer, measure the cam lobe height.




Standard cam lobe height




Maximum cam lobe height





c. Using a micrometer, measure the journal diameter.





Standard journal diameter:
If the journal diameter is not as specified, check the oil clearance.
53. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Clamp the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft in the vise.





b. Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
c. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.

CAUTION: Be sure not to turn the camshaft timing gear in the retard direction (the right angle).

d. Check that there is no clearance between the gear's fringe and the camshaft.





e. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
f. Check the lock of the camshaft timing gear.
1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.

NOTICE: Be careful not to damage the camshaft.





g. Release the lock pin.
1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT: 2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

2. Break through the tape of the advance side path and the retard side path on the opposite side to the hole of the advance side path, as shown in the illustration.





3. Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the two broken paths.

CAUTION: Cover the paths with a shop rag or piece of cloth when applying pressure to keep oil from splashing.





4. Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.

HINT: This operation releases the lock pin for the most retarded position.

5. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path, in that order.

NOTICE: Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

h. Check for smooth rotation.
1. Turn the camshaft timing gear within its movable range (21 °) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

CAUTION: Do not use air pressure to perform the smooth operation check.

i. Check the lock in the most retarded position.
1. Confirm that the camshaft timing gear is locked at the most retarded position.





j. Remove the fringe bolt and camshaft timing gear.

NOTICE:
- Be sure not to remove the other 3 bolts.
- If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

54. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
a. Clamp the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft in the vise.





b. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight pin.
c. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the pin enters the groove.

CAUTION: Be sure not to turn the camshaft timing exhaust gear in the retard direction (the right angle).

d. Check that there is no clearance between the gear's fringe and the camshaft.





e. Tighten the fringe bolt with the camshaft timing exhaust gear fixed.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
f. Check the camshaft timing exhaust gear lock.
1. Make sure that the camshaft timing exhaust gear is locked.





g. Release the lock pin.
1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

HINT: 4 oil paths are provided in the groove. Plug 2 paths with rubber pieces.

2. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.





3. Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the two broken paths (the advance side path and the retard side path).

NOTICE: Cover the paths with a shop rag or piece of cloth when applying pressure to keep oil from splashing.





4. Make sure that the camshaft timing exhaust gear turns in the retard direction when reducing the air pressure applied to the advance side path.

HINT: The lock pin is released and the camshaft timing exhaust gear turns in the retard direction.

5. When the camshaft timing exhaust gear comes to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

NOTICE: Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear may abruptly shift in the advance direction and break the lock pin or other parts.

h. Check for smooth rotation.
1. Turn the camshaft timing exhaust gear within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear turns smoothly.

NOTICE: When the air pressure is released from the advance side path and then from the retard side path, the gear automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

i. Check the lock at the most advanced position.
1. Make sure that the camshaft timing exhaust gear is locked at the most advanced position.





j. Remove the fringe bolt and camshaft timing exhaust gear.

NOTICE:
- Be sure not to remove the other 3 bolts.
- If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.





55. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 inch)
Minimum outside diameter: 10.70 mm (0.4213 inch)

HINT:
- If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.
- If the diameter is less than the minimum, replace the cylinder head bolt.





56. INSPECT CHAIN SUB-ASSEMBLY
a. Pull the chain with a force of 147 N (15 kgf, 33 ft. lbs.) as shown in the illustration.
b. Using vernier calipers, measure the length of 15 links.
Maximum chain elongation: 136.9 mm (5.390 inch)
If the elongation is greater than the maximum, replace the chain.

NOTICE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.





57. INSPECT NO.2 CHAIN SUB-ASSEMBLY
a. Pull the chain with a force of 147 N (15 kgf, 33 ft. lbs.) as shown in the illustration.
b. Using vernier calipers, measure the length of 15 links.
Maximum chain elongation: 137.6 mm (5.417 inch)
If the elongation is greater than the maximum, replace the chain.

NOTICE: Perform the same measurement by pulling at random in 3 or more places to obtain an average.





58. INSPECT CRANKSHAFT TIMING GEAR
a. Wrap the chain around the sprocket.
b. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 61.4 mm (2.417 inch)

HINT:
- The vernier calipers must contact the chain rollers for the measurement.
- If the diameter is less than the minimum, replace the chain and sprocket.





59. INSPECT IDLE SPROCKET ASSEMBLY
a. Wrap the chain around the sprocket.
b. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 61.4 mm (2.417 inch)

HINT:
- The vernier calipers must contact the chain rollers for the measurement.
- If the diameter is less than the minimum, replace the chain and sprocket.





60. INSPECT IDLE GEAR SHAFT OIL CLEARANCE
a. Using a micrometer, measure the idle gear shaft diameter.
Idle gear shaft diameter: 30.000 to 30.013 mm (1.1811 to 1.1816 inch)





b. Using a caliper gauge, measure the inside diameter of the idle gear.
Idle gear inside diameter: 30.020 to 30.033 mm (1.1819 to 1.1824 inch)
c. Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.
Standard oil clearance: 0.007 to 0.033 mm (0.0003 to 0.0013 inch)
Maximum oil clearance: 0.083 mm (0.0033 inch)
If the thrust oil clearance is greater than the maximum, replace the idle gear shaft and idle gear.





61. INSPECT CHAIN TENSIONER ASSEMBLY NO.1
a. Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.
If necessary, replace the chain tensioner assembly No.1.





62. INSPECT CHAIN TENSIONER ASSEMBLY NO.2
a. Check that the plunger moves smoothly.
b. Measure the worn depth of the chain tensioner slipper.
Maximum depth: 0.9 mm (0.035 inch)
If the depth is greater than the maximum, replace the chain tensioner No.2.





63. INSPECT CHAIN TENSIONER ASSEMBLY NO.3
a. Check that the plunger moves smoothly.
b. Measure the worn depth of the chain tensioner slipper.
Maximum depth: 0.9 mm (0.035 inch)
If the depth is greater than the maximum, replace the chain tensioner No.3.





64. INSPECT CHAIN TENSIONER SLIPPER
a. Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain tensioner slipper.





65. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Measure the worn depth of the chain vibration damper No.1.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain vibration damper No.1.





66. INSPECT CHAIN VIBRATION DAMPER NO.2
a. Measure the worn depth of the chain vibration damper No.2.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain vibration damper No.2.





67. INSTALL ENGINE REAR OIL SEAL
a. Place the oil seal retainer on wooden blocks.
b. Using SST, tap in a new oil seal until its surface is flush with the oil seal retainer edge.
SST 09223-15030

NOTICE:
- Keep the lip free from foreign matter.
- Do not tap on the oil seal at an angle.

68. INSTALL ENGINE REAR OIL SEAL RETAINER





a. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent
Seal diameter: 2.0 to 3.0 mm (0.079 to 0.118 inch)

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





b. Install the oil seal retainer with the 6 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

NOTICE: Be sure to apply adhesive 1324 to the bolts in the places indicated by * before installing them.

Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent.





69. INSTALL WATER INLET PIPE
a. Install the water inlet pipe with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
b. Install the water by-pass hose No.1.





70. INSTALL CYLINDER HEAD SUB-ASSEMBLY
a. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE:
- Be careful of the installation direction.
- Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

b. Place the cylinder head on the cylinder block.

NOTICE: Ensure that no oil is on the mounting surface of the cylinder head.

HINT: The cylinder head bolts are tightened in 3 progressive steps.

c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





d. Step 1
1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)





e. Step 2
1. Mark the cylinder head bolt head with paint as shown in the illustration.
2. Tighten the cylinder head bolts another 90°.
f. Step 3
1. Tighten the cylinder head bolts by an additional 90°.
2. Check that the painted mark is now facing rearward.





g. Seal packing will seep out on the engine's front side.
Thoroughly wipe clean any seal packing.





71. INSTALL CYLINDER HEAD LH
a. Place the cylinder head gasket on the cylinder block surface with the front face of the Lot No. stamp upward.

NOTICE:
- Be careful of the installation direction.
- Gently place the cylinder head in order not to damage the gasket with the bottom part of the head.

b. Place the cylinder head on the cylinder block.

NOTICE: Ensure that no oil is on the mounting surface of the cylinder head.

HINT: The cylinder head bolts are tightened in 3 progressive steps.

c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





d. Step 1
1. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 8 cylinder head bolts with the plate washers in several steps and in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)





e. Step 2
1. Mark the cylinder head bolt head with paint as shown in the illustration.
2. Tighten the cylinder head bolts another 90°.
f. Step 3
1. Tighten the cylinder head bolts by an additional 90°.
2. Check that the painted mark is now facing rearward.





g. Tighten the 2 bolts in the order shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)

NOTICE: Only use the specifications stated above when lightning the bolts 1 and 2 shown in the illustration.





h. Seal packing will seep out on the engine's front side.
Thoroughly wipe clean any seal packing.





72. INSTALL VALVE LASH ADJUSTER ASSEMBLY

NOTICE:
- Keep the lash adjuster free from dirt and foreign objects.
- Only use clean engine oil.

a. Place the lash adjuster into a container full of engine oil.
b. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the checkball inside the plunger.
SST 09276-75010
c. Squeeze the SST and lash adjuster together to move the plunger up and down 5 to 6 times.
d. Check the movement of the plunger and bleed the air.
OK: Plunger moves up and down.

NOTICE: When bleeding high-pressure air from the compression chamber, make sure that the tip of the SST is actually pressing the checkball as shown in the illustration. If the checkball is not pressed, air will not bleed.

e. After bleeding the air, remove the SST. Then quickly and firmly press the plunger with a finger.
OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster. Install the lash adjusters.

NOTICE: Install the lash adjuster at the same place it was removed from.





73. INSTALL VALVE ROCKER ARM SUB-ASSEMBLY NO.1
a. Apply engine oil to the lash adjuster tips and valve stem cap ends.
b. Make sure that the valve rocker arms are installed as shown in the illustration.





74. INSTALL CAMSHAFT BEARING CAP
a. Apply engine oil to the camshaft journals, camshaft housings and bearing caps.
b. Install the camshaft and camshaft No.2 to the camshaft housing RH.
c. Make sure of the marks and numbers on the camshaft bearing caps and place them in each proper position and direction.





d. Temporarily tighten the 8 bolts in the order shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
75. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY RH





a. Apply seal packing in a continuous bead as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent Seal diameter: 3.5 to 4.5 mm (0.138 to 0.177 inch)

NOTICE:
- Remove any oil from the contact surface.
- Install the camshaft housing sub-assembly RH within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.
- Do not start the engine for at least 2 hours after installation.





b. Install the camshaft housing RH, and tighten the 12 bolts in the order shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)

NOTICE: Make sure that the knock pin of the camshaft is positioned as shown in the illustration before installing the camshaft housing RH.





c. Tighten the 8 bolts in the order shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)

NOTICE: Thoroughly wipe clean any seal packing.





d. Install 3 new gaskets.