Part 2

OVERHAUL (CONTINUED)
25. REMOVE OIL CONTROL VALVE FILTER





a) Remove the plug and oil control valve filter. (Front side)





b) Remove the oil control valve filter. (Rear side)
26. REMOVE VALVE ROCKER SHAFT SUB-ASSEMBLY NO. 1





a) Remove the bolt, then remove the rocker shaft No. 1.
b) Remove the valve rocker arm.
27. REMOVE VALVE ROCKER SHAFT SUB-ASSEMBLY NO.2





a) Remove the bolt, then remove the rocker shaft No. 2.
b) Remove the valve rocker arm.
28. REMOVE HEAD SUB-ASSEMBLY, CYLINDER





a) Using a bi-hexagon wrench 10, uniformly loosen the 10 cylinder head bolts, in several passes in the sequence shown.
b) 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 bolts in the wrong order.

c) Remove the cylinder head from the cylinder block.
29. REMOVE CYLINDER HEAD GASKET
30. REMOVE OIL FILTER SUB-ASSEMBLY





a) Using SST, remove the oil filter.
SST 09228-06501
31. REMOVE OIL FILTER UNION
a) Using a socket hexagon wrench 12, remove the oil filter union.
32. 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 removing, check the crankshaft for damage. If damaged, smooth the surface with a 400-grit sandpaper.

33. REMOVE OIL PAN DRAIN PLUG
a) Remove the oil pan drain plug and gasket from the oil pan.
34. REMOVE OIL PAN SUB-ASSEMBLY





a) Remove the 12 bolts and 4 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 surface which is in contact with the bearing cap and oil pan flange.

35. REMOVE OIL STRAINER SUB-ASSEMBLY
a) Remove the bolt and 2 nuts, then remove the oil strainer.
b) Remove the gasket.
36. REMOVE OIL PAN BAFFLE PLATE
a) Remove the 4 bolts, then remove the oil pan baffle plate.
37. 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.
38. 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 elongation is greater than maximum, replace the chain.

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

39. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET





a) Wrap the chain around the timing sprocket.
b) Using vernier calipers, measure the timing sprocket diameter with the chain.
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 gear diameter is less than minimum, replace the chain and camshaft timing gear.
40. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET





a) Wrap the chain around the timing sprocket.
b) Using vernier calipers, measure the timing sprocket 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 gear diameter is less than minimum, replace the chain and crankshaft timing gear.
41. INSPECT CHAIN TENSIONER SLIPPER





a) Using vernier 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.
42. INSPECT CHAIN VIBRATION DAMPER NO. 1





a) Using vernier calipers, measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than maximum, replace the chain vibration damper.
43. 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.
44. INSPECT VALVE ROCKER SHAFT SUB-ASSEMBLY NO. 1





a) Using a micrometer, measure the rocker shaft No.1 diameter.
Standard diameter: 15.965 to 15.985 mm (0.6285 to 0.6293 inch)
If the diameter is less than minimum, replace the valve rocker shaft No. 1.
45. INSPECT VALVE ROCKER SHAFT SUB-ASSEMBLY NO.2





a) Using a micrometer, measure the rocker shaft No.2 diameter.
Standard diameter: 15.965 to 15.985 mm (0.6285 to 0.6293 inch)
If the diameter is less than minimum, replace the valve rocker shaft No. 2.
46. INSPECT VALVE ROCKER ARM





a) Cover the oil paths of the rocker arm shaft except 2 paths with vinyl type.
b) Align the oil path of the rocker arm shaft with the oil path of the rocker arm.
c) Check that the piston inside of the rocker arm moves when 180 kPa (1.8 kgf/cm2, 25.6 psi) of air is applied to the oil paths.
47. INSPECT CAMSHAFT SUB-ASSEMBLY, NO. 1





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 of the 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:




Minimum cam lobe height:
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: 27.949 to 27.965 mm (1.1004 to 1.1010 inch)
If the journal diameter is not as specified, check the oil clearance.
48. INSPECT CAMSHAFT SUB-ASSEMBLY, NO.2





a) Inspect the cam lobes.
1) Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
40.019 to 40.119 mm (1.5755 to 1.5795 inch) for No. 1
38.863 to 38.963 mm (1.5300 to 1.5340 inch) for No. 2
Minimum cam lobe height:
39.86 mm (1.5693 inch) for No. 1
38.71 mm (1.5240 inch) for No. 2
If the cam lobe height is less than minimum, replace the camshaft.





b) 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: 27.949 to 27.965 mm (1.1004 to 1.1010 inch)
If the journal diameter is not as specified, check the oil clearance.
49. INSTALL OIL PAN BAFFLE PLATE
a) Install the oil pan baffle plate with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
50. INSTALL OIL STRAINER SUB-ASSEMBLY
a) Install a new gasket onto the oil pan baffle plate.
b) Install the oil strainer with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)