Part 2

OVERHAUL (CONTINUED)
26. REMOVE CYLINDER HEAD SUB-ASSEMBLY





a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.

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





b) Remove the cylinder head from the cylinder block.
27. REMOVE CYLINDER HEAD GASKET





a) Remove the cylinder head gasket from the cylinder block.

28. REMOVE OIL FILTER SUB-ASSEMBLY





a) Using SST, remove the oil filter.
SST 09228-06501
29. REMOVE OIL FILTER UNION





a) Using a socket hexagon wrench 12, remove the oil filter union.
30. REMOVE ENGINE REAR OIL SEAL





a) Using a knife, cut off the oil seal lip.
b) Using a screwdriver with its tip wrapped with tape, pry out the oil seal.

NOTICE: After removing, check the crankshaft for damage. If damaged, smooth the surface with 400-grit sandpaper.

31. REMOVE OIL PAN DRAIN PLUG





a) Remove the oil pan drain plug and gasket from the oil pan.
32. REMOVE OIL PAN SUB-ASSEMBLY





a) Remove the 14 bolts and 2 nuts.





b) Insert the blade of SST between the bearing cap and oil pan, then cut off the applied sealer and remove the oil pan.
SST 09032-00100

NOTICE: Be careful not to damage the oil pan contact surface of the bearing cap and oil pan.

33. REMOVE OIL STRAINER SUB-ASSEMBLY





a) Remove the bolt and 2 nuts, then remove the oil strainer.
34. REMOVE OIL STRAINER FLANGE GASKET





a) Remove the gasket from the cylinder block.
35. INSPECT CHAIN TENSIONER ASSEMBLY NO. 1





a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
b) Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
36. INSPECT CHAIN SUB-ASSEMBLY





a) Using a spring tension gauge and vernier calipers, pull the timing chain with 140 N (14.3 kgf, 31.5 lbs.), then measure its length.
Maximum chain elongation: 115.3 mm (4.539 inch)
If the chain elongation is greater than maximum, replace the chain.

HINT: Take the same measurements by pulling at 3 or more places selected at random.

37. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a) Wrap the chain around the camshaft timing gear.





b) Using vernier calipers, measure the diameter of the timing gear with the chain wrapped.
Minimum gear diameter (w/ chain): 96.8 mm (3.811 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than minimum, replace the chain and camshaft timing gear.
38. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a) Wrap the chain around the crankshaft timing gear.





b) Using vernier calipers, measure the crankshaft timing gear diameter with the chain.
Minimum gear diameter (w/ chain): 51.0 mm (2.008 inch)

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

If the diameter is less than minimum, replace the chain and crankshaft timing gear.
39. INSPECT CHAIN TENSIONER SLIPPER





a) Using verniers calipers, measure the chain tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the chain tensioner slipper.
40. INSPECT CHAIN VIBRATION DAMPER NO. 1





a) Using vernier calipers, measure the vibration damper wears.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the chain vibration damper.
41. INSPECT CYLINDER HEAD SET BOLT





a) Using vernier calipers, measure the length of the cylinder head bolts from the seat to the end.
Standard bolt length: 146.8 to 148.2 mm (5.780 to 5.835 inch)
Maximum bolt length: 148.5 mm (5.846 inch)
If the bolt length is greater than maximum, replace the cylinder head set bolt.
42. INSPECT CAMSHAFT
a) Check 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)
If the circle runout is greater than maximum, replace the camshaft.
b) Inspect the cam lobes.





1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
44.333 to 44.433 mm (1.7454 to 1.7493 inch) for intake
43.761 to 43.861 mm (1.7229 to 1.7268 inch) for exhaust
Minimum cam lobe height:
44.18 mm (1.7394 inch) for intake
43.61 mm (1.7169 inch) for exhaust
If the cam lobe height is less than minimum, replace the camshaft.
c) Inspect the camshaft journals.





1) Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 34.449 to 34.465 mm (1.3563 to 1.3569 inch)
Other journal diameters: 22.949 to 22.965 mm (0.9035 to 0.9041 inch)
If the journal diameter is not as specified, check the oil clearance.
43. INSTALL OIL STRAINER FLANGE GASKET





a) Install a new gasket onto the cylinder block.
44. INSTALL OIL STRAINER SUB-ASSEMBLY





a) Install the oil strainer with the 2 nuts and bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
45. INSTALL OIL PAN SUB-ASSEMBLY
a) Remove any old packing material from the contact surface and thread holes.





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

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes of applying seal packing.
^ Do not put in engine oil for at least 2 hours after installing the oil pan.





c) Install the oil pan with the 14 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
^ Tighten the bolts and nuts to the specified torque in two passes.
^ Tighten the bolts and nuts within 15 minutes of applying sealant (if possible within 3 minutes).

46. INSTALL OIL PAN DRAIN PLUG





a) Place a new gasket on the oil pan drain plug, then install it onto the oil pan.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
47. INSTALL ENGINE REAR OIL SEAL
a) Apply a light coat of multi-purpose grease to a new oil seal lip.

NOTICE: Keep the lip free of foreign objects.





b) Using SST and a hammer, tap the new oil seal in until its surface is flush with the rear oil seal retainer edge.
SST 09223-15020, 09950-70010 (09951-07100)

NOTICE:
^ Tap the oil seal in a vertical position.
^ Wipe any extra grease off the crankshaft.

48. INSTALL OIL FILTER UNION





a) Using a socket hexagon wrench 12, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
49. 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, then tighten it until the gasket comes into contact with the seat.





d) Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
50. INSTALL CYLINDER HEAD GASKET





a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
^ Make sure that the cylinder head gasket is mounted in the correct direction.
^ Place the cylinder head gently in order to avoid damaging the gasket.