Part 2

OVERHAUL
34. REMOVE ENGINE HANGER NO.2
35. REMOVE CYLINDER HEAD COVER REAR

36. REMOVE OIL CONTROL VALVE FILTER
a. Remove the plug, gasket and valve filter.
37. REMOVE CYLINDER HEAD SUB-ASSEMBLY

a. Using a socket hexagon wrench 8, remove the hexagon bolt.

b. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing the bolts in an incorrect order.

38. REMOVE CYLINDER HEAD GASKET
39. REMOVE CYLINDER HEAD LH

a. Using a socket hexagon wrench 8, remove the hexagon bolt.

41. REMOVE WATER INLET HOUSING
a. Remove the 8 bolts and 2 nuts, then remove the water inlet housing.

42. REMOVE OIL FILTER SUB-ASSEMBLY
a. Using SST, remove the oil filter.
SST 09228-07501
b. Using a socket hexagon wrench 12, remove the oil filter union.
43. REMOVE OIL PAN DRAIN PLUG
44. REMOVE OIL PAN SUB-ASSEMBLY NO.2

a. Remove the 10 bolts and 2 nuts.

b. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, then cut off the sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
^ Be careful not to damage the contact surface of the oil pan No. 1 where the oil pan No. 2 is mounted.
^ Do not damage the flange portion of the oil pan No. 2 when removing.

45. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
46. REMOVE OIL PAN SUB-ASSEMBLY

a. Loosen and remove the 15 bolts and 2 nuts uniformly.

b. Using a screwdriver, remove the oil pan by prying between the cylinder block and oil pan.

NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.

47. REMOVE OIL PAN BAFFLE PLATE

48. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 6 bolts.
b. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and bearing cap.

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

50. REMOVE OIL PUMP ASSEMBLY
a. Remove the 9 bolts.
b. Using a screwdriver, remove the oil pump by prying between the oil pump and bearing cap.
c. Remove the O-ring.

51. REMOVE OIL PUMP SEAL
a. Using a screwdriver, pry out the oil seal.
52. REMOVE SPARK PLUG TUBE GASKET

a. Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.

NOTICE: Be careful not to damage the baffle plate of the cylinder head cover.

b. Using a screwdriver and hammer, tap out the gasket.

c. Using needle-nose pliers, pry out the gasket.

NOTICE: Be careful not to damage the cylinder head cover.

53. INSPECT TIMING BELT

NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow contact of the timing belt with oil, water or steam.
^ Do not use the timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

Check the belt for any defects as shown in the illustrations.
Also, check these points.
a. If the belt tears in a short time:
^ Check if the belt is installed properly.
^Check if the timing cover gasket is damaged and if it is installed properly.
b. If the belt teeth are cracked or damaged, check if either camshaft is locked.
c. If there is noticeable wear or cracks on the belt face, check 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 alignment of each pulley.
e. If there is noticeable wear on the belt teeth:
^ Check the timing cover for damage.
^ Check that the gasket has been installed correctly.
^ Check for foreign objects on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.
54. INSPECT CAMSHAFT

a. Inspect the camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the runout is greater than maximum, replace the camshaft.

b. Inspect the cam lobes.
1. Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
43.132 to 43.232 mm (1.6981 to 1.7020 inch) for intake
43.010 to 43.110 mm (1.6933 to 1.6972 inch) for exhaust
Minimum cam lobe height:
42.98 mm (1.6921 inch) for intake
42.86 mm (1.6874 inch) for exhaust
If the cam lobe height is less than minimum, replace the camshaft.

c. Inspect the camshaft journals.
1. Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 to 26.975 mm (1.0614 to 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.

55. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than minimum, replace the bolt.

56. INSTALL SPARK PLUG TUBE GASKET
a. Using SST and a hammer, tap in the new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
b. Return the ventilation plate tab to its original position.
c. Apply a light coat of multi-purpose grease to the gasket lip.
57. INSTALL ENGINE REAR OIL SEAL

a. Using SST and a hammer, tap in the new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects.

b. Apply multi-purpose grease to the oil seal lip.
58. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing material from the contact surface.

b. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal retainer within 3 minutes after applying seal packing.
^ Do not expose the seal packing to engine oil within 2 hours after installing.

c. Install the oil seal retainer with the 6 bolts. Tighten the bolts uniformly in several steps.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

59. INSTALL OIL PUMP SEAL
a. Using SST and a hammer, tap in the new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects.

b. Apply multi-purpose grease to the oil seal lip.
60. INSTALL OIL PUMP ASSEMBLY
a. Remove any old packing material from the contact surface.

b. Apply a light coat of engine oil to a new O-ring, then place it on the cylinder block.

c. Apply a continuous bead of seal packing (Diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal packing to engine oil within 2 hours after installing.

d. Align the key of the oil pump drive gear with the keyway located on the crankshaft, then slide the oil pump into place.

e. Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
8.0 Nm (82 kgf-cm, 71 inch lbs.) for bolt A
20 Nm (199 kgf-cm, 14 ft. lbs.) for bolt B
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt C
61. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
62. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
63. INSTALL OIL PAN SUB-ASSEMBLY
a. Remove any old seal packing from the contact surface.

b. Apply a continuous bead of seal packing (Diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt holes in the region "X".
^ Apply seal packing to the inner side of the bolt holes in the region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal packing to engine oil within 2 hours after installing.

c. Install the oil pan with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque:
8.0 Nm (82 kgf-cm, 71 inch lbs.) for 10 mm head
20 Nm (199 kgf-cm, 14 ft. lbs.) for 12 mm head
64. INSTALL OIL STRAINER SUB-ASSEMBLY
a. Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
65. INSTALL OIL PAN SUB-ASSEMBLY NO.2
a. Remove any old seal packing from the contact surface.

b. Apply a continuous bead of seal packing (Diameter 4 to 5 mm (0.16 to 0.20 inch)) as shown in the illustration. Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal packing to engine oil within 2 hours after installing.

c. Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
66. INSTALL OIL PAN DRAIN PLUG
a. Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)