Part 3

OVERHAUL (CONTINUED)
51. INSTALL OIL PAN SUB-ASSEMBLY
a) Remove any old packing material from the contact surface.





b) Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.15748 to 0.19685 inch)) to the oil pan mating surface 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 installation.





c) Install the oil pan with the 12 bolts and 4 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
52. INSTALL OIL PAN DRAIN PLUG
a) Place a new gasket on the drain plug, then install it onto the oil pan.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)





53. INSTALL ENGINE REAR OIL SEAL
a) Apply multi-purpose grease to a new oil seal lip.

NOTICE: Keep the lip free of foreign materials.

b) Using SST and a hammer, then tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE: Wipe any extra grease off the crankshaft.

54. 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.)
55. 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
Reference torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
56. 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 not 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 reinstall the cap.

57. INSTALL HEAD SUB-ASSEMBLY, CYLINDER





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 by 180° in the sequence order shown.
f) Check that the paint mark on each bolt is at a 180° angle to the original position.
58. INSTALL VALVE ROCKER SHAFT SUB-ASSEMBLY NO.2





a) Put the valve rocker shaft through the cylinder head and the hole of the valve rocker arm, then check that the groove of the shaft is in the correct direction.
b) Install the bolt to fix the rocker shaft No. 2.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
59. INSTALL VALVE ROCKER SHAFT SUB-ASSEMBLY NO. 1





a) Put the valve rocker shaft through the cylinder head and the hole of the valve rocker arm, then check that the groove of the shaft is in the correct direction.
b) Install the bolt to fix the rocker shaft No. 1.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
60. 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. (Front side)
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c) Install the oil control valve filter into the cylinder head. (Rear side)
61. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
62. INSTALL CAM TIMING CONTROL VALVE HOUSING





a) Install a new gasket and the control valve housing with the 3 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
63. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY





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 lightly 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 assembly can move to the retard angle side (the right angle), and is locked in the most retarded position.
64. 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.

65. 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.)
66. INSTALL OIL PUMP ASSEMBLY





a) Place a new gasket onto the cylinder block.





b) Align the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, then slide on the oil pump.





c) Install the oil pump with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
67. 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.)

68. INSTALL CHAIN SUB-ASSEMBLY
a) Set the No. 1 cylinder to the TDC/compression.





1) Turn the hexagonal wrench head portion of the camshafts so as to align the point marks of the camshaft timing sprockets.





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 timing chain onto the crankshaft timing sprocket with the yellow mark link aligned with the timing mark on the crankshaft timing sprocket.

HINT: A yellow color link and 2 orange color links are on the chain.





c) Using SST, then install the sprocket.
SST 09223-22010





d) Install the timing chain on the camshaft timing sprockets with the orange mark link aligned with the timing marks on the camshaft timing sprockets.
69. INSTALL CHAIN TENSIONER SLIPPER
a) Install the chain tensioner slipper with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
70. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1





a) Install the crankshaft position sensor plate with the "F" mark facing forward.
71. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL





a) Apply a light coat of multi-purpose grease to a new oil seal lip.
b) Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010

NOTICE: Keep the lip free of foreign objects.

72. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
a) Remove any old packing (FIPG) material. Be careful not to drop any oil on the contact surface of the timing chain cover, cylinder head and cylinder block.

HINT:
^ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.





b) Apply a continuous bead of seal packing (Diameter 3 mm (0.118 inch)) as shown in the illustration.
Seal packing: THREE BOND 1280 B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Do not put in engine oil for at least 2 hours after installation.
^ Install a nozzle that has been cut to a 1.5 mm opening.

c) Install the 2 gaskets onto the timing chain cover as shown in the illustration.





d) Apply a continuous bead of seal packing (Diameter 3 mm (0.118 inch)) as shown in the illustration. Seal packing: THREE BOND 1280 B or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Do not put in engine oil for at least 2 hours after installation.
^ Install the chain cover, engine mounting bracket and water pump within 15 minutes of applying seal packing.

e) Install the timing chain cover with the 13 bolts.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) for (M8) bolt
11 Nm (112 kgf-cm, 8 ft. lbs.) for (M6) bolt
73. INSTALL CHAIN TENSIONER ASSEMBLY NO. 1





a) Check that the O-ring is clean, then set the hook as shown in the illustration.





b) Apply engine oil to the chain tensioner, then install it.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: When installing the chain tensioner, set the hook again if the hook releases the plunger.

74. INSTALL CRANKSHAFT PULLEY





a) Align the pulley set key with the key groove of the pulley, then slide on the pulley.
b) Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 120 Nm (1,224 kgf-cm, 89 ft. lbs.)





c) Turn the crankshaft counterclockwise so as to disconnect the plunger knock pin from the hook.





d) Turn the crankshaft clockwise, then check that the slipper is pushed by the plunger.

HINT: If the plunger is not extended, push the slipper into the chain tensioner using a screw driver so that the hook is released from the knock pin and the plunger can be extends.

75. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET





a) Install the engine mounting bracket with the 4 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
76. INSTALL WATER PUMP ASSEMBLY





a) Place a new O-ring onto the timing chain cover.
b) Install the water pump with the 6 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





HINT: Each bolt length is indicated in the table.

77. INSTALL WATER PUMP PULLEY





a) Using SST, install the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
78. INSPECT VALVE CLEARANCE
a) Set the No. 1 cylinder to the TDC/compression.





1) Turn the crankshaft pulley until its groove and the timing mark "O" of the timing chain cover are aligned.
2) Check that the point marks of the camshaft timing gears are as shown in the illustration.

HINT: If not, turn the crankshaft 1 revolution (360°) so as to align the marks as above.

b) Check only the valves indicated.





1) Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





Valve clearance (Cold)

c) Turn the crankshaft 1 revolution (360°) so as to set the No. 4 cylinder to the TDC/compression.
d) Check only the valves indicated.





1) Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
2) Record any out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





Valve clearance (Cold)

79. ADJUST VALVE CLEARANCE
a) Set the SST.





1) Turn the crankshaft so that the related rocker arm, where the valve clearance is adjusted, is fully pushed down.

NOTICE: Remove the spark plug and take off the compression.





2) Insert SST into the plug tube.
SST 09248-77010 (09248-07010)

NOTICE:
^ SST cannot be inserted unless the set screw is loosened.
^ Make sure that the camshaft is in the same condition as step (1).





3) Operate the lever so that the SST seat surface comes into contact with the valve retainer, then lock them with the set screw.

NOTICE:
^ There must be no clearance between the valve rotation and SST seat.
^ Make sure that there is no clearance when inserting the SST, as any clearance may unlock the keeper.

4) Lock the set screw on the plug tube side of SST.





5) Rotate the crankshaft so that the camshaft is positioned as shown in the illustration.

NOTICE:
^ Take care of the rotation direction to prevent the camshaft lobe from interfering with the SST shaft.
^ Do not rotate the crankshaft excessively.

b) Remove the adjusting shim.





1) Lift the rocker arm to make room, then remove the adjusting shim using SST.
SST 09248-77010 (09248-07010)

NOTICE: Do not remove SST with the adjusting shim removed.

HINT:
^ Setting SST from the upper right makes the removal easier.
^ If there is not enough room, reset SST.








2) Determine the size of the replaced shim according to the formulas or charts:
^ Using a dial indicator, measure the thickness of the removed shim.
^ Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
Intake: A = B + (C - 0.13 mm (0.005 inch)) x 1.5
Exhaust: A = B + (C - 0.27 mm (0.011 inch)) x 1.5

HINT: Shims are available in 41 sizes in increments of 0.020 mm (0.0008 inch), from 2.000 mm (0.0787 inch) to 2.800 mm (0.1102 inch).





Valve Shim Selection Chart (Intake)





Valve Shim Selection Chart (Exhaust)





c) Using SST, lift the rocker arm to make room, then install the adjusting shim.

HINT:
^ Setting SST from the upper right makes the removal easier.
^ To remove SST from the adjusting shim, it is advisable to push down the rocker arm.





d) Turn the crankshaft so that the related rocker arm, where the valve clearance is adjusted, is fully pushed down.

NOTICE:
^ Take care of rotation direction to prevent the camshaft lobe from interfering with the SST shaft.
^ Do not turn the crankshaft excessively.

e) After loosening the 2 set screws of SST, remove SST itself.
SST 09248-77010 (09248-07010)
80. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
a) Remove any old packing (FIPG) material.
b) Install the cylinder head cover gasket to the cylinder head cover.





c) Install the new spark plug tube gasket and 4 new O-ring to the cylinder head cover.





d) Apply seal packing to 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 seal packing.
^ Do not put in engine oil for at least 2 hours after installation.





e) Install the cylinder head cover and bracket with the 9 bolts. Uniformly tighten the bolts, in the several passes in the sequence shown.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
81. INSTALL SPARK PLUG
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
82. INSTALL VENTILATION VALVE SUB-ASSEMBLY
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)