Part 1

OVERHAUL
1. 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 hot, 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 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09953-05020, 09954-05021)
9. REMOVE TIMING BELT NO.1 COVER
a. Remove the 4 bats and timing belt cover.
10. REMOVE TIMING GEAR COVER SPACER
11. REMOVE CRANKSHAFT POSITION SENSOR PLATE
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 09960-10010 (09962-1000, 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.
c. 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.

NOTICE: Do not turn the timing pulley.

SST 09950-50013 (09951-05010, 09952-05010, 09953-5010, 09953-05020, 09954-05010)





19. REMOVE CAMSHAFT TIMING PULLEY
a. Remove the 4 bolts and timing pulley.





20. REMOVE CAMSHAFT TIMING PULLEY SUB-ASSY
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 above 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 levels 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 above 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
a. 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.

30. REMOVE WATER PUMP ASSY
a. Remove the 5 bolts, 2 stud bolts and nut, water pump and gasket.
31. REMOVE OIL PAN SUB-ASSY NO.2
32. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 3 bolts, 2 nuts and baffle plate.
33. REMOVE OIL PAN SUB-ASSY
34. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt, 2 nuts, oil strainer and gasket.
35. REMOVE OIL PUMP ASSY





36. 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.





37. 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.





38. 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 (09551-00240, 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 its original position.
39. REMOVE CAMSHAFT TIMING TUBE ASSY





a. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE:
^ Be careful not to damage the camshaft.
^ The 4 bolts shown in the illustration determine the backlash of the gear in the timing tube, so do not remove them. If any of the 4 bolts are removed, install a new timing tube assy.





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, and remove the 4 bolts, drive gear and oil seal.
SST 09960-10010 (09962-01000, 09963-00500)

NOTICE: Be careful not to damage the timing tube.





40. INSTALL CAMSHAFT SETTING OIL SEAL
a. Place a new oil seal to the timing tube.

NOTICE: Be careful of the installation direction.

41. INSTALL CAMSHAFT TIMING TUBE ASSY





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 passes.
SST 09960-10010 (09962-01000, 09963-00500)
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)

NOTICE: Be careful not to damage the timing tube.





c. Mount the hexagon wrench head 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 you feel it touch the bottom.
e. Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (790 kgf-cm, 58 ft. lbs.)
f. Install the seal washer and screw plug.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
42. REMOVE CAMSHAFT SUB GEAR





a. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.





b. Using SST, turn the sub gear clockwise, and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00500)





c. Using snap ring pliers, remove the snap ring. Remove the wave washer, sub gear and gear bolt washer.

HINT: Arrange the driven sub gears and gear bolt washers (RH and LH sides).





43. INSPECT CAMSHAFT TIMING GEAR BOLT WASHER
a. Using vernier calipers, measure the free distance between the washer ends.
Free distance: 18.2 - 18.8 mm (0.712 - 0.740 inch)
If the free distance is not as specified, replace the washer.
44. INSTALL CAMSHAFT SUB GEAR





a. Install the gear bolt washer (1). sub gear (2) and wave washer (3)

HINT: Attach the pins on the gears to the gear bolt washer ends.





b. Using snap ring pliers, install the snap ring.





c. Mount the hexagon wrench head portion of the camshaft in a vise.

NOTICE: Be careful not to damage the camshaft.





d. Using SST, align the soles of the driven main gear and sub gear by turning the sub gear clockwise, and temporarily install a service bolts
SST 09960-10010 (09962-01000, 09963-00500)
e. Align the gear teeth of the driven main gear and sub gear, and tighten the service bolt.





45. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the oil pump body. Tape the screwdriver tip.

46. INSTALL OIL PUMP SEAL





a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09316-60011 (09316-00011)
b. Apply MP grease to the oil seal lip.





47. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and hammer, tap out the oil seal.





48. INSTALL ENGINE REAR OIL SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-56010
b. Apply MP grease to the oil seal lip.
49. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
1. Using a razor blade and gasket scraper, remove all the oil packing (FIPG) material from the gasket surfaces and sealing grooves.
2. Thoroughly clean all components to remove all the loose material.
3. Using a non-residue solvent, clean both sealing surfaces.





b. Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
1. Install a nozzle that has been cut to a 3 - 4 mm (0.12 - 0.16 inch) opening.
2. Parts must be assembled within 5 minutes of application. Otherwise the material must be removed and reapplied.
3. Immediately remove nozzle from the tube and reinstall cap.





c. Install a new O-ring to the cylinder block.
d. Install the oil seal retainer with the 7 bolts.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
50. INSTALL OIL PUMP ASSY