Part 2
OVERHAUL (CONTINUED)23. INSPECT TIMING BELT IDLER
a. Visually check the seal portion of the idler pulley for oil leakage.
If leakage is found, replace the idler pulley.
b. Check that the idler pulley turns smoothly.
If necessary, replace the idler.
24. REMOVE CRANKSHAFT TIMING PULLEY
a. Using SST, remove the timing pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)
NOTICE: Do not turn the timing pulley.
25. REMOVE REAR TIMING BELT PLATE RH NO. 2
a. Remove the 2 bolts and rear timing belt plate RH No.2.
26. REMOVE REAR TIMING BELT PLATE RH
a. Remove the bolt, stud bolt and rear timing belt plate RH.
27. REMOVE REAR TIMING BELT PLATE LH NO. 2
a. Remove the 2 bolts and rear timing belt plate LH No.2.
28. REMOVE REAR TIMING BELT PLATE LH
a. Remove the bolt and rear timing belt plate LH.
29. REMOVE CAMSHAFTS
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.
a. Remove the camshafts of the RH bank.
1 In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench.
2 Secure the sub-gear to the main gear with a service bolt.
HINT: When removing the camshafts, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.
3 Set the timing mark (1-dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagonal portion of the exhaust camshaft with a wrench.
4 Uniformly loosen the 22 bearing cap bolts in the order shown in the illustration, then remove all the bolts.
5 Remove the oil feed pipe, 9 bearing caps, oil control valve filter, camshaft housing plug and 2 camshafts.
b. Remove the camshafts on the LH bank.
1 In order to install a service bolt to the sub and main gears, turn the camshaft with a wrench. The hexagonal portion of the camshaft is used for turning the camshaft with the wrench.
2 Secure the sub-gear to the main gear with a service bolt.
Recommended service bolt
HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has eliminated by the above operation.
3 Align the timing marks (2-dot marks) of the camshaft drive and driven gears by turning the hexagonal portion of the exhaust camshaft with a wrench.
4 Uniformly loosen the 22 bearing cap bolts in the order shown in the illustration, then remove all the bolts.
5 Remove the oil feed pipe, 9 bearing caps, oil control valve filter, camshaft housing plug and 2 camshafts.
HINT: Arrange the bearing caps in correct order.
30. REMOVE SEMICIRCULAR PLUG
31. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several steps, in the order shown in the illustration. Likewise, loosen the 10 bolts on the other side. Remove the 20 cylinder head bolts and plate washers.
NOTICE:
^ Cylinder head warpage or cracking may result from removing bolts in incorrect order.
^ Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
b. Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.
NOTICE:
^ Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
^ The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
HINT: If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.
32. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the thread outside diameter of the bolt.
Standard outside diameter: 9.810 to 9.960 mm (0.3862 to 0.3921 inch)
Minimum outside diameter: 9.700 mm (0.3819 inch)
33. REMOVE WATER PUMP ASSEMBLY
a. Remove the 5 bolts, 2 stud bolts, nut, water pump and gasket.
34. REMOVE OIL PAN SUB-ASSEMBLY NO.2
a. Remove the 17 bolts and 2 nuts.
b. Insert the blade of SST between the oil pan and No.2 oil pan, and cut off applied sealer. Remove the No.2 oil pan.
SST 09032-00100
NOTICE:
^ Be careful not to damage the contact surface of the oil pan and the No.2 oil pan.
^ Be careful not to damage the No.2 oil pan flange.
35. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 2 bolts, 2 nuts and baffle plate.
36. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 18 bolts and 2 nuts.
b. Using a screwdriver, remove the oil pan by prying between the oil pan and cylinder block in the order shown in the illustration.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block or oil pan.
37. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the 2 bolts, 2 nuts, oil strainer and gasket.
38. REMOVE OIL PUMP ASSEMBLY
a. Remove the 7 bolts and stud bolt.
HINT: Use a 6 mm hexagon wrench to tighten the hexagon head bolt.
b. Using a screwdriver, remove the oil pump by prying the portions between the oil pump and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pump.
c. Remove the O-ring from the cylinder block.
39. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 7 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying the portions between the oil seal retainer and crankshaft bearing cap.
c. Remove the O-ring.
40. REMOVE SPARK PLUG TUBE GASKET
a. Bend the 4 ventilation case claws installed on the cylinder head cover to an angle of 90° or more.
b. Using a screwdriver, pry out the gasket.
NOTICE: Be careful not to damage the cylinder head cover. Tape the screwdriver tip.
41. INSTALL SPARK PLUG TUBE GASKET
a. Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09951-00240, 09951-00440, 09952-06010), 09950-70010 (09951-07100)
NOTICE: Be careful of the installation direction.
b. Apply a light coat of MP grease to the gasket lip.
c. Return the 4 ventilation case claws to the original positions.
42. REMOVE CAMSHAFT TIMING TUBE ASSEMBLY
a. Mount the hexagonal portion of the camshaft in a vise.
NOTICE:
^ Be careful not to damage the camshaft.
^ Do not remove the 4 bolts shown in the illustration. If any of them are loosened or removed, the backlash of the gear in the timing tube will go out of adjustment. In this case, replace the timing tube assembly with a new one.
b. Remove the screw plug and seal washer.
c. Using a 10 mm hexagon wrench, and remove the bolt.
d. Pull out the timing tube and drive gear assembly from the camshaft.
e. Using SST and a 5 mm hexagon wrench, remove the 4 bolts, drive gear and oil seal.
NOTICE: Be careful not to damage the timing tube.
43. INSTALL CAMSHAFT SETTING OIL SEAL
a. Insert a new oil seal into the camshaft timing tube until it reaches the stopper.
NOTICE:
^ Be careful of the installation direction.
^ Do not turn over the oil seal lip.
44. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY
a. Align the timing tube knock pin with the knock pin groove of the drive gear, and temporarily install the drive gear with the 4 bolts.
b. Using SST and a 5 mm hexagon wrench, uniformly tighten the 4 bolts in several steps.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
NOTICE: Be careful not to damage the timing tube.
c. Mount the hexagonal portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
d. Align the camshaft knock pin with the knock pin groove of the timing tube, and push the timing tube by hand until it touches the bottom.
e. Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft. lbs.)
f. Install the seal washer and screw plug.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)