Removal and Replacement

REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DRAIN COOLANT
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE CYLINDER HEAD COVER NO.2
a) Remove the 3 bolts and nut, then remove the cylinder head cover No. 2.
6. DISCONNECT BATTERY NEGATIVE TERMINAL





7. SEPARATE ACCELERATOR CONTROL CABLE ASSEMBLY
8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
9. DISCONNECT UNION TO CONNECTOR TUBE HOSE





a) Disconnect the union to connector tube hose from the brake booster.
10. REMOVE EFI FUEL PIPE CLAMP
11. DISCONNECT FUEL TUBE SUB-ASSEMBLY
12. DISCONNECT RADIATOR HOSE INLET
13. DISCONNECT HEATER INLET WATER HOSE
14. DISCONNECT HEATER OUTLET WATER HOSE
15. DISCONNECT WATER BY-PASS HOSE NO.2
16. DISCONNECT WATER BY-PASS HOSE NO.3
17. REMOVE WIRE HARNESS PROTECTOR
18. SEPARATE SUCTION HOSE SUB-ASSEMBLY
19. REMOVE AIR SWITCHING VALVE ASSEMBLY
20. REMOVE FAN AND GENERATOR V BELT
21. REMOVE GENERATOR BRACKET NO. 1
22. REMOVE GENERATOR ASSEMBLY
23. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)

HINT: Hang up the hoses instead of detaching.

24. REMOVE EXHAUST PIPE ASSEMBLY FRONT
25. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
26. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

HINT: Jack the engine up and down to remove the bolt.

27. REMOVE IGNITION COIL ASSEMBLY
28. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
29. REMOVE MANIFOLD STAY
30. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
31. REMOVE EXHAUST MANIFOLD
32. REMOVE WATER PUMP PULLEY
SST 09960-10010 (09962-01000, 09963-00600)
33. REMOVE WATER PUMP ASSEMBLY
34. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
35. REMOVE CRANKSHAFT POSITION SENSOR
36. SET NO. 1 CYLINDER TO TDC/COMPRESSION
37. REMOVE CRANKSHAFT PULLEY
SST 09213-70011 (09213-70020), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010)
38. REMOVE CHAIN TENSIONER ASSEMBLY NO. 1
39. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
40. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
41. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
42. REMOVE CHAIN TENSIONER SLIPPER
a) Remove the bolt and chain tensioner slipper.
43. REMOVE CHAIN VIBRATION DAMPER NO. 1
a) Remove the 2 bolts and chain vibration damper No. 1.
44. REMOVE CHAIN SUB-ASSEMBLY
45. REMOVE OIL LEVEL GAGE GUIDE
46. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
47. REMOVE SURGE TANK STAY NO. 1





a) Remove the 2 bolts and nut, then remove the surge tank stay.
48. REMOVE INTAKE MANIFOLD





a) Remove the 4 bolts and 2 nuts, then remove the intake manifold and gasket.
49. REMOVE CAMSHAFT





a) Uniformly loosen and remove the 20 bearing cap bolts, in several passes in the sequence shown, then remove the 9 bearing caps of the intake and exhaust camshafts.
50. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a) Disconnect the water by-pass pipe from the cylinder head.





b) Using a bi-hexagon wrench 10, uniformly loosen the 10 cylinder head bolts, in several passes in the sequence shown.
c) Remove the 10 cylinder head bolts and plate washers.

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

d) Remove the cylinder head from the cylinder block.
51. REMOVE CYLINDER HEAD GASKET
52. 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 when installing.
- Place the cylinder head gently in order to avoid damaging the gasket.





b) Apply seal packing to the cylinder head gasket as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

HINT: Avoid applying an excessive amount of seal packing to the surface.

- The parts must be assembled within 3 minutes of applying. Otherwise, the seal packing must be removed and reapplied.
- Immediately remove the nozzle from the tube, then rein stall the cap.

53. INSPECT CYLINDER HEAD SET BOLT





a) Using vernier calipers, measure the length of the 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.
54. INSTALL CYLINDER HEAD SUB-ASSEMBLY





a) Place the cylinder head on the cylinder block.

HINT: The cylinder head bolts are tightened in 2 progressive steps.

b) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
c) Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with the plate washers, in several passes in the sequence shown.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)





d) Mark the front of each cylinder head bolt with paint.
e) Retighten the cylinder head bolts 180° in the sequence shown.
f) Check that the paint marks on each bolts are at a 180° angle from the original position.
g) Install the water by-pass pipe.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)
55. INSTALL CAMSHAFT
a) Apply a light coat of engine oil to the camshaft journals.





b) Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing 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 tighten the bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
56. INSTALL INTAKE MANIFOLD





a) Install a new gasket and the intake manifold with the 4 bolts and 2 nuts.
Torque:
34 Nm (347 kgf-cm, 25 ft. lbs.) for bolt A and nut A
46 Nm (469 kgf-cm, 34 ft. lbs.) for bolt B
57. INSTALL SURGE TANK STAY NO. 1





a) Install the surge tank stay with the 2 bolts and nut.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
58. INSTALL OIL LEVEL GAGE GUIDE
a) Apply a light coat of engine oil to the new O-ring, then install it onto the oil level gage guide.
b) Install the oil level gage guide with the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
59. INSTALL CHAIN VIBRATION DAMPER NO. 1
a) Install the chain vibration damper No. 1 with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
60. INSTALL CHAIN SUB-ASSEMBLY
SST 09223-22010
61. INSTALL CHAIN TENSIONER SLIPPER
62. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
63. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
SST 09223-22010
64. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
65. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1
66. INSTALL CRANKSHAFT PULLEY
SST 09213-70011 (09213-70020), 09330-00021
67. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
68. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
69. INSTALL WATER PUMP ASSEMBLY
70. INSTALL WATER PUMP PULLEY
SST 09960-10010 (09962-01000, 09963-00600)
71. INSTALL EXHAUST MANIFOLD
72. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
73. INSTALL MANIFOLD STAY
74. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
75. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
76. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
Torque:
29 Nm (296 kgf-cm, 21 ft. lbs.) for nut
100 Nm (1,020 kgf-cm, 74 ft. lbs.) for bolt
77. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
78. INSTALL EXHAUST PIPE ASSEMBLY FRONT
79. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONING)
80. INSTALL GENERATOR ASSEMBLY
81. INSTALL GENERATOR BRACKET NO. 1
82. INSTALL AIR SWITCHING VALVE ASSEMBLY
83. INSTALL SUCTION HOSE SUB-ASSEMBLY
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
84. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 3.5 Nm (36 kgf-cm, 31 inch lbs.)
85. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
86. ADD COOLANT
87. CHECK FOR ENGINE COOLANT LEAKAGE
88. CHECK FOR ENGINE OIL LEAKAGE
89. CHECK FOR EXHAUST GAS LEAKAGE
90. INSPECT IGNITION TIMING
SST 09843-18040
91. INSPECT ENGINE IDLING SPEED
92. INSPECT COMPRESSION
SST 09992-00500
93. INSPECT CO/HC
94. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)