Part 3
OVERHAUL67. INSTALL WATER INLET HOUSING
a. Remove any old packing material from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 3 to 5 mm (0.12 to 0.20 inch)) 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 expose the seal packing to coolant within 2 hours after installing.
c. Install the water inlet housing with the 8 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
68. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upward.
NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
69. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE: The cylinder head bolts are tightened in 2 successive steps.
a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.
c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
f. Check that each painted mark is now at a 90° angle to the front.
g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
70. INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket on the cylinder block with the L mark upward.
NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.
71. INSTALL CYLINDER HEAD LH
NOTICE: The cylinder head bolts are tightened in 2 successive steps.
a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.
c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
f. Check that each painted mark is now at a 90° angle to the front.
g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
72. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign object 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.)
73. INSTALL CYLINDER HEAD COVER REAR
a. Install the rear cover and a new gasket.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
74. INSTALL CAMSHAFT SUB GEAR
a. Clamp the camshaft in a vise on the hexagonal lobe.
NOTICE: Be careful not to damage the camshaft.
b. Install the camshaft gear bolt washer and camshaft sub gear.
HINT: Attach the pins on the gears to the gear bolt washer 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 the camshaft sub gear counterclockwise, then temporarily install a service bolt.
SST 09960-10010 (09962-01000, 09963-00500)
f. Align the gear teeth of the main gear and sub gear, then 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 installation of the service bolt.
75. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Align the alignment pin with the alignment pin groove, then install the VVT-i into the camshaft.
NOTICE: Install it with the lock pin engaged and locked at the most retard angle position.
b. Apply engine oil to the nut, mounting surface of the VVT-i and screw threads.
NOTICE:
^ Be sure to apply the oil, otherwise the specified torque cannot be obtained.
^ New nuts must be used when replacing the VVT-i unit.
c. Using a 46 mm socket wrench, install and tighten a lock nut by turning it counterclockwise.
Torque: 150 Nm (1,530 kgf-cm, 111 ft. lbs.)
NOTICE:
^ The lock nut has LH threads.
^ Never use any tools other than the socket wrench. Other tools will deform the cam angle rotor.
76. INSTALL NO.2 CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must 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 the timing mark (2 dot marks) on the cylinder head.
c. Apply multi-purpose 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 bearing cap No. 1 as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Install the bearing cap No. 1 within 5 minutes after applying seal packing.
^ Do not expose the seal packing to 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 to the threads of the bearing cap bolts.
i. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
77. INSTALL CAMSHAFT
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must 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 and 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 to the threads of the bearing cap bolts.
f. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g. Remove the service bolt.
78. INSTALL NO.1 CAMSHAFT SUB-ASSY
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must 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 the timing mark (1 dot marks) on the cylinder head.
c. Apply multi-purpose 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 bearing cap No. 1 as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Install the bearing cap No. 1 within 5 minutes after applying seal packing.
^ Do not expose the seal packing to 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 to the threads of the bearing cap bolts.
i. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
79. INSTALL NO.3 CAMSHAFT SUB-ASSY
NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while being installed. If the camshaft is not kept level, the cylinder head or camshaft may be damaged. To avoid this, the following steps must be carried out.
a. Apply new engine oil to the thrust portion and journal of the camshaft.
b. Align the timing marks (1 dot marks) of the camshaft drive and 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 to the threads of the bearing cap bolts.
f. Using several steps, tighten the 10 bearing cap bolts uniformly in the sequence shown in the illustration.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
g. Remove the service bolt.
80. INSTALL CRANKSHAFT TIMING PULLEY
a. Align the keyway of the timing pulley with the key located on the crankshaft, then slide the timing pulley into place.
NOTICE: Do not scratch the sensor area of the crankshaft timing pulley.
b. Install the timing belt plate with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
81. INSTALL WATER PUMP ASSY
a. Install a new gasket and the water pump with the 3 bolts and 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
82. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of engine oil to a new O-ring, then install it to the level gage guide.
b. Install the level gage guide.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
83. INSTALL OIL FILTER SUB-ASSY
a. Using a socket hexagon wrench 12, 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, then tighten it until the gasket contacts the seat.
e. Using SST, tighten it by an additional 3/4 turn.
SST 09228-07501
84. INSTALL TIMING BELT IDLER BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
85. INSTALL TIMING BELT NO.3 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.
HINT: If there is a trace of water intrusion when checking visually, re pair the gasket with seal packing when the crack length is within 2 to 3 cm (0.79 to 1.18 inch). Replace the gasket when the crack length is 3 to 4 cm (1.18 to 1.57 inch)or longer.
b. If the timing belt cover gasket is needed to repair, follow the procedure.
1. Repair the cracks and breaks by applying seal packing to the damaged area.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: When applying the seal packing, apply it as wide and high as the gasket.
c. If the timing belt cover gasket is needed to replace, follow the procedure.
1. Using a screwdriver and gasket scraper, remove the remaining gasket.
NOTICE: Be careful not to damage the timing belt cover.
2. Remove the backing paper from a new gasket, then 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 corners, try to keep the gasket thickness uniform.
HINT
3. If there is a gap between the ends of the gasket, apply seal packing to close the gap.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE: When 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, 75 inch lbs.)
86. INSTALL CAMSHAFT TIMING PULLEY
a. Pay attention to the orientation of the belt guide. Install the camshaft timing pulley with the belt guide properly oriented, then tighten the bolt temporarily.
HINT:
^ Align the belt guide of the RH timing pulley so it faces the front of the engine as illustrated.
^ Align the belt guide of the LH timing pulley so it faces the rear of the engine as illustrated.
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.)
87. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
88. INSTALL TIMING BELT IDLER SUB-ASSY NO.1
a. Using a socket hexagon wrench 10, install the plate washer and timing belt idler No. 1 with the pivot bolt.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
89. INSTALL TIMING BELT
a. Remove any oil or water on the pulleys, then keep them clean.
NOTICE:
^ If there is a trace of water and/or oil on the timing belt, repair the leakage and install a new timing belt.
^ Only wipe the pulleys; do not use any cleaning agent.
b. Check the idler pulleys.
1. Check that the idler pulley turns smoothly.
2. Visually check the seal portion of the idler pulley for oil leakage.
c. Check the water pump.
1. Turn the pulley, then check that water pump bearing moves smoothly and does not make a noise.
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 counterclockwise by approximately 60°.
NOTICE: To prevent contact of the piston head with the valve head, set the crankshaft pulley at the 60° BTDC/compression position.
f. Using SST, turn the crankshaft pulley, then align the timing marks of the timing pulley with the timing belt No. 3 cover.
SST 09960-10010 (09962-01000, 09963-01000)
g. Turn the crankshaft, then align the timing mark of the crankshaft timing pulley with the oil pump body.
h. Align the front mark on the timing belt so it faces forward.
i. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
j. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.
k. Install the timing belt in this order.
90. INSTALL TIMING BELT TENSIONER ASSY
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, then 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 uniformly. Installing the tensioner at an angle may cause failure of its proper operation.
f. Remove the 1.5 mm hexagon wrench from the tensioner.
g. Turn the crankshaft 2 revolutions slowly, then align the timing mark of the crankshaft timing pulley with the oil pump body.
NOTICE: Always turn the crankshaft clockwise.
h. Check that the timing marks of the RH and LH timing pulleys are aligned with the timing marks of the timing belt No. 3 cover as shown in the illustration.
If the marks are not aligned, remove the timing belt and reinstall it.
i. Remove the crankshaft pulley bolt.
91. INSTALL TIMING BELT GUIDE NO.2
a. Install the timing belt guide with the cup side facing the engine front.
92. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
93. INSTALL TIMING BELT NO.2 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
94. INSTALL TIMING BELT NO.1 COVER
a. Visually check for cracks and breaks on the gasket of the timing belt cover.
If there is a trace of water intrusion when checking visually, replace the timing belt cover.
b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
95. INSTALL CRANKSHAFT PULLEY
a. Align the keyway of the pulley with the key located on the crankshaft, then slide the pulley into place.
b. Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 220 Nm (2,250 kgf-cm, 162 ft. lbs.)
96. INSTALL VVT SENSOR
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
97. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
98. INSTALL ENGINE HANGER NO.2
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
99. INSPECT VALVE CLEARANCE
a. Turn the crankshaft pulley, then align the timing notch with the timing mark "0" of the timing belt No. 1 cover.
b. Check that the valve lifters on the intake side of the No. 1 cylinder are not pushed by the cam.
If the valve lifters are pushed, turn the crankshaft 1 revolution (360°) and align the marks as above.
c. Inspect the valves indicated in the illustration on the left.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 inch) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 inch) for exhaust
2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
d. Turn the crankshaft by 2/3 of a revolution (240°), then inspect the valves indicated in the illustration on the left.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 inch) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 inch) for exhaust
2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
e. Turn the crankshaft by 2/3 of a revolution (240°), then inspect the valves indicated in the illustration on the left.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
0.15 to 0.25 mm (0.0059 to 0.0098 inch) for intake
0.25 to 0.35 mm (0.0098 to 0.0138 inch) for exhaust
2. Record the out-of-specification valve clearance measurements. They will be used later to select an adjusting shim to replace.
100. ADJUST VALVE CLEARANCE
a. Turn the camshaft so that the cam lobe faces upward.
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 SST (B) from getting 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 that the valve clearance comes within the specified value.
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.0079 inch))
Exhaust A = B + (C - 0.30 mm (0.0118 inch))
g. Select a new shim with a thickness which is as close to the calculated values as possible.
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).
^ Refer to New Shim Thickness table on the next 2 pages.
Adjusting Shim Selection Chart (intake)
Adjusting Shim Selection Chart (Exhaust)
h. Place a new adjusting shim on the valve lifter with the imprinted number facing down.
i. Press down the valve lifter with SST (A), then remove SST (B).
SST 09248-55040 (09248-05410, 09248-05420)
j. Recheck the valve clearance.
101. 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. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
102. 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. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
103. INSTALL SPARK PLUG
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)