Part 1
OVERHAUL1. REMOVE SPARK PLUG
2. REMOVE OIL FILLER CAP SUB-ASSY
3. REMOVE CYLINDER HEAD COVER SUB-ASSY
a. Remove the 9 bolts, 9 seal washers, cylinder head cover and gasket.
4. REMOVE IDLER PULLEY SUB-ASSY NO.2
a. Remove the pulley bolt, cover plate and idler pulley.
5. REMOVE TIMING BELT COVER SUB-ASSY NO.2
a. Remove the 2 bolts and timing belt cover.
6. REMOVE V-RIBBED BELT TENSIONER ASSY
a. Remove the bat, 2 nuts and belt tensioner.
7. REMOVE IDLER PULLEY ASSY
a. Remove the 2 bolts, 2 nuts and idler pulley.
8. REMOVE CRANKSHAFT DAMPER SUB-ASSY
a. Using SST, remove the damper bolt.
SST 09213-70010, 09330-00021
b. Using SST, remove the crankshaft damper.
SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05020)
9. REMOVE TIMING BELT NO.1 COVER
a. Remove the 4 bolts and timing belt cover.
10. REMOVE TIMING GEAR COVER SPACER
11. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
12. REMOVE TIMING BELT
a. If re-using 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, place a new installation mark on the timing belt before removing each part.
b. Set the No. 1 cylinder to approximately 50° BTDC/compression.
1. Using the crankshaft damper bolt, turn the crankshaft to align the timing marks of the crankshaft timing pulley and oil pump body.
2. Check that the timing marks of the camshaft timing pulleys and timing belt plates aligned.
If not, turn the crankshaft 1 revolution (360°).
3. Using the crankshaft damper bolt, turn the crankshaft counterclockwise by approximately 50°.
NOTICE: If the timing belt is disengaged, having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley (steps 19 and 20) and camshaft (steps 21 and 22), causing damage. So always set the crankshaft pulley at the correct angle.
c. Alternately loosen the 2 bolts, and remove them, the belt tensioner and dust boot.
d. Using SST, loosen the tension between the camshaft timing pulley (RH bank) and crankshaft timing pulley by slightly turning the camshaft timing pulley counterclockwise.
SST 0996-10010 (09962-01000, 09963-00350)
e. Disconnect the timing belt from the timing belt idler No. 1, and remove the timing belt.
13. 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 illustrations, check these points:
a. Premature parting.
- Check for proper installation.
- Check the timing cover gasket for damage and proper installation.
b. If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
If there is noticeable wear or cracks on the belt face, check to see 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 the alignment of each pulley.
e. If there is noticeable wear on the belt teeth, check timing cover for damage and check gasket has been installed correctly and for foreign material on the pulley teeth.
If necessary, replace the timing belt.
14. INSPECT TIMING BELT TENSIONER
a. Visually check the seal portion of the tensioner for oil leakage.
HINT:
- If there is only the faintest 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 with both hands and push the push rod strongly as shown to check that it doesn't move. If the push rod moves, replace the tensioner.
NOTICE: Never hold the tensioner push rod facing downward.
c. Measure the protrusion of the push rod from the housing end.
Protrusion: 9.5 - 10.5 mm (0.374 - 0.413 inch)
If the protrusion is not as specified, replace the tensioner.
15. REMOVE TIMING BELT IDLER SUB-ASSY NO.1
a. Using a 10 mm hexagon wrench, remove the bolt, idler and plate washer.
16. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
a. Remove the bolt and idler.
17. 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.
18. REMOVE CRANKSHAFT TIMING PULLEY
a. Using SST, remove the timing pulley.
SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05010)
NOTICE: Do not turn the timing pulley.
19. REMOVE CAMSHAFT TIMING PULLEY
a. Remove the 4 bolts and timing pulley.
20. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSY LH
a. Remove the 4 bolts and timing pulley.
21. REMOVE CAMSHAFT
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 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. Remove the camshafts of the RH bank.
1. Boring the service bolt hole of the sub gear upward by turning the hexagon wrench head portion of the No. 2 camshaft with a wrench.
2. Secure the sub gear to the main gear with a service bolt.
Recommended service bolt
HINT: When removing the camshafts, make sure that the torsional spring force of the sub gear has been eliminated by the operation.
3. Set the timing mark (1 dot mark) of the camshaft main gear at approximately 10° angle by turning the hexagon wrench head portion of the No. 2 camshaft with a wrench.
4. Uniformly loosen the 22 bearing cap bolts in several passes, in the sequence shown.
5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.
22. REMOVE NO.3 CAMSHAFT SUB-ASSY
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 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. Remove the camshafts of the LH bank.
1. Boring the service bolt hole of the sub gear upward by turning the hexagon wrench head portion of the No. 4 camshaft with a 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 been eliminated by the operation.
3. Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the No. 4 camshaft with a wrench.
4. Uniformly loosen the 22 bearing cap bolts in several passes, in the sequence shown.
5. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.
23. REMOVE SEMICIRCULAR PLUG
24. REMOVE TIMING BELT PLATE RR RH NO.2
a. Remove the 2 bolts and timing belt plate.
25. REMOVE TIMING BELT PLATE RR RH
a. Remove the bolt, stud bolt and timing belt plate.
26. REMOVE TIMING BELT PLATE RR LH NO.2
a. Remove the 2 bolts and timing belt plate.
27. REMOVE TIMING BELT PLATE RR LH
Remove the bolt and timing belt plate.
28. REMOVE CYLINDER HEAD SUB-ASSY
a. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown.
NOTICE:
- Cylinder head warpage or cracking could 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 cylinder head on wooden blocks on a bench.
HINT: If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
29. REMOVE CYLINDER HEAD LH
a. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown.
NOTICE:
- Cylinder head warpage or cracking could 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 cylinder head on wooden blocks on a bench.
HINT: If the cylinder head is lift off, pry between the cylinder head and cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.