Part 3
OVERHAUL70. INSTALL CYLINDER BLOCK SIDE COVER
a. Install a new gasket and the cylinder block side cover with the 3 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
71. INSTALL CYLINDER BLOCK SIDE COVER DRAIN COCK PLUG
a. Install the drain cock plug with a new O-ring.
Torque 7.0 Nm (71 kgf-cm, 62 inch lbs.)
72. INSTALL WATER INLET HOUSING
a. Remove any old packing material form the contact surface.
b. Apply seal packing in the shape of bead (Diameter 3 - 5 mm (0.12 - 0.20 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the water inlet housing within 3 minutes after applying seal packing.
- Do not put into coolant within 2 hours after installing.
c. Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes, in the sequence shown.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
73. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the R mark upward.
NOTICE: Remove any oil from the contact surface. Be careful of the installation direction. Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.
74. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.
c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.
g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
75. INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket on the cylinder block surface with the L mark upward.
NOTICE:
- Remove any oil from the contact surface. Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.
76. INSTALL CYLINDER HEAD LH
NOTICE: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.
c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.
g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
77. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign substance is on the mesh part of the filter.
b. Assemble the valve filter and plug.
c. Install the plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
78. INSTALL CYLINDER HEAD COVER REAR
a. Install the rear cover and a new gasket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
79. INSTALL CAMSHAFT SUB GEAR
a. Fix the hexagonal wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Install the camshaft gear spring and camshaft sub-gear.
HINT: Attach the pins on the gears to the gear spring ends.
c. Install the wave washer.
d. Using snap ring pliers, install the snap ring.
e. Using SST, align the holes of the camshaft main gear and sub-gear by turning camshaft sub-gear counterclockwise, and temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
f. Align the gear teeth of the main gear and sub-gear, and tighten the service bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
NOTICE: Be careful not to damage the camshaft journals.
HINT: When installing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by the operation.
80. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Align the knock pin with knock pin groove and install VVT-i on the camshaft.
NOTICE: Install it under the condition that the lock pin is operated and locked at the maximum delay angle position.
b. Apply the engine oil on the nut, the placing surface of VVT-i and the screw portion.
NOTICE:
- Be sure to apply the oil, otherwise the specified torque cannot be obtained.
- The nuts must be changed to the new one when changing VVT-i.
c. Using a 46 mm socket wrench, install and tighten a new lock nut by turning it counterclockwise.
Torque: 150.5 Nm (1,530 ± 50 kgf-cm, 111 ± 4 ft. lbs.)
NOTICE:
- The lock nut has LH threads.
- Never use any tool other than the socket wrench, otherwise that may result in deforming the cam angle rotor portion.
81. INSTALL NO.2 CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving 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. Apply new engine oil to the thrust portion and journal of the camshaft.
b. Place the No. 2 camshaft at a 90° angle of timing mark (2 dot marks) on the cylinder head.
c. Apply MP grease to a new oil seal lip.
d. Install the oil seal to the camshaft.
NOTICE: Do not turn over the oil seal lip. Insert the oil seal until it stops.
e. Remove any old packing material from the contact surface.
f. Apply seal packing to the No. 1 bearing cap as shown.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Install the No. 1 bearing cap within 5 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.
g. Install the 5 bearing caps in their proper locations.
h. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
i. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
82. INSTALL CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving 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. Apply new engine oil to the thrust portion and journal of the camshaft.
b. Align the timing marks (2 dot marks) of the camshaft drive with driven gears.
c. Place the camshaft on the cylinder head.
d. Install the 5 bearing caps in their proper locations.
e. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
f. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g. Remove the service bolt.
83. INSTALL NO.4 CAMSHAFT SUB-ASSY
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving 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. Apply new engine oil to the thrust portion and journal of the camshaft.
b. Place the No. 4 camshaft at a 90° angle of timing mark (2 dot marks) on the cylinder head.
c. Apply MP grease to a new oil seal lip.
d. Install the oil seal to the camshaft.
NOTICE: Do not turn over the oil seal lip. Insert the oil seal until it stops.
e. Remove any old packing material from the contact surface.
f. Apply seal packing to the No 1 bearing cap as shown.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Install the No. 1 bearing cap within 5 minutes after applying seal packing.
- Do not put into engine oil within 2 hours after installing.
g. Install the 5 bearing caps in their proper locations.
h. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
i. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
84. INSTALL NO.3 CAMSHAFT SUB-ASSY
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be held level while it is being installed. If the camshaft is not level, the portion of the cylinder head receiving 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. Apply new engine oil to the thrust portion and journal of the camshaft.
b. Align the timing marks (2 dot marks) of the camshaft drive with driven gears. Place the camshaft on the cylinder head.
c. Install the 5 bearing caps in their proper locations.
d. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.
e. Install and uniformly tighten the 10 bearing cap bolts, in several passes, in the sequence shown.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
f. Remove the service bolt.
85. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the pulley set key with the key groove of the timing pulley, and slide on the timing pulley.
NOTICE: Do not scratch the sensor part of the crankshaft timing pulley.
b. Install the timing belt plate with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
86. INSTALL WATER PUMP ASSY
a. Install a new gasket and the water pump with the 4 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
87. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of engine oil to a new O-ring and install it to the level gage guide.
b. Install the level gage guide.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
88. INSTALL OIL FILTER SUB-ASSY
a. Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
b. Check and clean the oil filter installation surface.
c. Apply clean engine oil to the gasket of a new oil filter.
d. Lightly screw the oil filter into place, and tighten it until gasket contacts the seat.
e. Using SST, tighten it an additional 3/4 turn.
SST 09228-07501
89. INSTALL TIMING BELT IDLER BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
90. INSTALL TIMING BELT NO.3 COVER
a. Visually check the crack and break in the gasket of the timing belt cover.
NOTICE: If it is judged that water is entering at the visual check, repair it with seal packing when the crack length is within 2 - 3 cm (0.79 - 1.18 inch). Change the gasket when the crack length is 3 - 4 cm (1.18 - 1.57 inch) and more.
b. In case of repairing the timing belt cover gasket, follow the procedure.
1. Repair the crack and break portion applying the seal packing.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: In case of applying the seal packing, apply it as wide and high as the gasket.
c. In case of replacing the timing belt cover gasket, follow the procedure. Using a screwdriver and gasket scraper, remove the remained gasket.
NOTICE: Be careful not to damage the timing belt cover.
2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.
NOTICE:
- Affix the gasket in the center of the groove.
- At the corner, affix it without making the thickness of the gasket less.
HINT:
3. In case of having clearance at the joining portion of the gasket, apply the seal packing.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: In case of applying the seal packing, apply it as wide and high as the gasket.
d. Install the timing belt cover with the 6 bolts.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)
91. INSTALL CAMSHAFT TIMING PULLEY
a. Pay attention to the direction of the belt guide, install the camshaft timing pulley and tighten the bolt temporally.
HINT:
- Face the belt guide of the RH timing pulley toward the engine front.
- Face the belt guide of the LH timing pulley toward the engine rear.
b. Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)
c. Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)
92. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
93. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
a. Using a 10 mm socket hexagon wrench, install the plate washer and idler pulley.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
94. INSTALL TIMING BELT
a. Remove any oil or water on the pulleys, and keep them clean.
NOTICE:
- If adherence of water and/or oil to the timing belt is found, restore the leakage and install a new timing belt.
- Wipe only the pulleys; do not use any cleansing agent.
b. Inspect the idler pulleys.
1. Check that the idler pulley turns smoothly.
2. Visually check the seal portion of the idler pulley for grease leakage.
c. Inspect the water pump.
1. Turn the pulley, and check that water pump bearing moves smoothly and quietly.
2. Visually check the drain hole for coolant leakage.
d. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
e. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body.
f. Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No. 3 timing belt cover.
SST 09960-10010 (09962-01000, 09963-01000)
g. Face the front mark on the timing belt forward.
h. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
i. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
HINT: The installation marks are placed when the timing belt is removed, or printed originally are used as match marks.
j. Install the timing belt in this order.
95. INSTALL CHAIN TENSIONER ASSY NO.1
a. Set the timing belt tensioner upright on the press.
b. Slowly press in the push rod.
NOTICE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbs) to the rod.
c. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
d. Release the press.
e. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)
NOTICE: Be sure to tighten the bolts equally. Installing the tensioner slantingly may cause failure of its proper operation.
f. Remove the 1.5 mm hexagon wrench from the tensioner.
g. Slowly turn the crankshaft 2 revolutions, and align the timing marks of the crankshaft timing pulley with oil pump body.
NOTICE: Always turn the crankshaft clockwise.
h. Check the timing marks of the RH and LH timing pulleys with the timing marks of the No. 3 timing belt cover as shown in the illustration. If the marks do not align, remove the timing belt and reinstall it.
i. Remove the crankshaft pulley bolt.
96. INSTALL TIMING BELT GUIDE NO.2
a. Install the timing belt guide, facing the cup side toward the engine front.
97. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
98. INSTALL TIMING BELT NO.2 COVER
a. Visually check the crack and break in the gasket of the timing belt cover.
HINT: If it is judged that water is entering at the visual check, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)
99. INSTALL TIMING BELT NO.1 COVER
a. Visually check the crack and break in the gasket of the timing belt cover.
HINT: If it is judged that water is entering at the visual check, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)
100. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 215 Nm (2,192 kgf-cm, 159 ft. lbs.)
101. INSTALL CRANK POSITION SENSOR NO.1
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
102. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
103. INSTALL ENGINE HANGER NO.2
Torque: 20 Nm (199 kgf-cm. 14 ft. lbs.)
104. INSPECT VALVE CLEARANCE
a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No. 1 timing belt cover.
b. Check that the valve lifters on the No. 1 (IN and EX) are loose. If not, turn the crankshaft 1 revolution (360°) and align the mark.
c. Check only those valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.15 - 0.25 mm (0.006 - 0.010 inch)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
d. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.15 - 0.25 mm (0.006 - 0.010 inch)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
e. Turn the crankshaft 2/3 of a revolution (240°), and check only the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.15 - 0.25 mm (0.006 - 0.010 inch)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
105. ADJUST VALVE CLEARANCE
a. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up.
b. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.
c. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A)
SST 09248-55040 (09248-05410, 09248-05420)
HINT:
- Apply SST (B) at a slight angle on the side marked with "9" or "7", at the position shown in the illustration.
- When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle.
d. Using a small screwdriver and magnetic finger, remove the adjusting shim.
e. Using a micrometer, measure the thickness of the removed shim.
f. Calculate the thickness of a new shim so the valve clearance comes within the specified value.
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.008 inch))
Exhaust A = B + (C - 0.30 mm (0.012 inch))
g. Select a new shim with a thickness as close as possible to the calculated values.
HINT: Shims are available in 17 sizes in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch).
h. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down.
i. Press down the valve lifter with SST (A), and remove SST (B).
SST 09248-55040 (09248-05410, 09248-05420)
j. Recheck the valve clearance.
106. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Install the gasket to the cylinder head cover.
b. Apply seal packing to the cylinder head 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 after applying seal packing.
- Do not start the engine within 2 hours after installing.
c. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts, in several passes.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
107. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
a. Install the gasket to the cylinder head cover.
b. Apply seal packing to the cylinder head 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 after applying seal packing.
- Do not start the engine within 2 hours after installing.
c. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts in several passes.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
108. INSTALL SPARK PLUG
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)