Part 1

OVERHAUL

HINT:
^ Thoroughly clean all parts to be assembled.
^ Before installing the parts, apply new engine oil to all sliding and rotating surfaces.
^ Replace all gaskets, O-rings and oil seals with new ones.





1. REMOVE ENGINE HANGER NO.1
a. Remove the 4 bolts and engine hangers.
2. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the 2 water drain cocks.
3. REMOVE SPARK PLUG
4. REMOVE OIL FILLER CAP SUB-ASSEMBLY





5. REMOVE OIL FILLER CAP HOUSING
a. Remove the 2 nuts and oil filler cap housing.





6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.





7. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.





8. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
a. Remove the pulley bolt, cover plate and idler pulley.





9. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and timing belt cover.





10. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, 2 nuts and belt tensioner.





11. REMOVE FAN BRACKET SUB-ASSEMBLY
a. Remove the 2 bolts, 2 nuts and fan bracket.
12. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY





a. Using SST, remove the pulley bolt.
SST 09213-70011 (90105-08076), 09330-00021





b. Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)





13. REMOVE TIMING BELT NO.1 COVER
a. Remove the 4 bolts and timing belt cover.





14. REMOVE TIMING GEAR COVER SPACER
a. Remove the cover spacer and gasket.





15. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
16. SET NO. 1 CYLINDER TO TDC/COMPRESSION





a. If reusing the timing belt, check the installation marks on the timing belt.
1 Check that there are 3 installation marks on the timing belt by turning the crankshaft as shown in the illustration.
If the installation marks have disappeared, put a new installation mark on the timing belt before removing each part.





b. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.





c. Check that the timing marks of the camshaft timing pulleys and timing belt plates are aligned.
If not, turn the crankshaft 1 complete revolution (360°).
17. REMOVE TIMING BELT
a. Set the No.1 cylinder to approx. 45° BTDC/compression.





1 Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approx. 45°.

NOTICE: If the timing belt is disengaged, having the crankshaft pulley at a wrong angle can cause the piston head and valve head to come into contact with each other when removing the camshaft timing pulley and camshaft, causing damage. So always set the crankshaft pulley at the correct angle.





b. Alternately loosen the 2 bolts, then remove the bolts, chain tensioner and dust boot.





c. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley (RH bank) counterclockwise
SST 09960-10010 (09962-01000, 09963-00350)
d. Disconnect the timing belt from the timing belt idler No.1 and remove the timing belt.





18. INSPECT TIMING BELT

NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or removing the mount bolt of the camshaft timing pulley.

If there are any defects as shown in the illustration, check the following points:
a. If premature parting occurs, check the following:
^ Check for proper installation.
^ Check the timing cover gasket for damage and proper installation.
b. If the belt teeth are cracked or damaged, inspect the camshaft.
c. If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.
d. If there is wear or damage on only one side of the belt, check the belt guide and alignment of each pulley.
e. If there is noticeable wear on the belt teeth, check for damage on the timing belt or foreign objects on the pulley teeth. Check if the gasket is installed correctly.
If necessary, replace the timing belt.





19. INSPECT CHAIN TENSIONER ASSEMBLY NO.1
a. Visually check the seal portion of the tensioner for oil leakage.

HINT: If there is a faint trace of oil on the seal on the push rod side, the tensioner is all right.

If leakage is found, replace the tensioner.





b. Hold the tensioner by hands and push the push rod strongly as shown in the illustration to check that it does not move.

If the push rod moves, replace the tensioner.

NOTICE: Do not face the tensioner push rod downward.





c. Measure the protrusion of the push rod from the housing end.
Protrusion: 11.2 to 12.2 mm (0.440 to 0.480 inch)
If the protrusion is not as specified, replace the tensioner.





20. REMOVE CAMSHAFT TIMING PULLEYS
a. Hold the crankshaft with a wrench, and remove the 8 bolts and 2 timing pulleys.





21. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.1
a. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.





22. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2
a. Remove the bolt and idler.