Part 2

OVERHAUL (CONTINUED)
26. REMOVE REAR TIMING BELT PLATE LH NO. 2
a. Remove the 2 bolts and timing belt plate.
27. REMOVE REAR TIMING BELT PLATE LH
a. Remove the bolt and timing belt plate.

28. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown in the illustration.

NOTICE:
^ Cylinder head warpage or cracking could result from removing bolts in incorrect order.
^ Be careful not to drop the plate washer for the 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.

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 in the illustration.

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 cannot be removed, 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 ASSEMBLY
a. Remove the 5 bolts, 2 stud bolts and nut, water pump and gasket.
31. REMOVE OIL PAN SUB-ASSEMBLY NO.2
32. REMOVE OIL PAN BAFFLE PLATE
a. Remove the 3 bolts, 2 nuts and baffle plate.
33. REMOVE OIL PAN SUB-ASSEMBLY
34. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt, 2 nuts, oil strainer and gasket.
35. REMOVE OIL PUMP ASSEMBLY

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.

HINT: Tape the screwdriver tip before use.

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

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

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

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 into the timing tube.

NOTICE: Be careful of the installation direction.

41. INSTALL CAMSHAFT TIMING TUBE ASSEMBLY
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 (76 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 it touches the bottom.
e. Using a 10 mm hexagon wrench, install the bolt.
Torque: 78 Nm (795 kgf-cm, 58 ft. lbs.)
f. Install the seal washer and screw plug.
Torque: 15 Nm (152 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 plier, remove the snap ring.
d. Remove the wave washer, sub gear and bolt washer.

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

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

44. INSTALL CAMSHAFT SUB GEAR
a. Install the 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 holes of the driven main gear and sub gear by turning the sub gear clockwise. Temporarily install a service bolt.
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 and wooden block, pry out the oil seal.

HINT: Tape the screwdriver tip before use.

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

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.
b. Apply seal packing to the oil seal retainer as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
Seal width: 3 to 4 mm (0.12 to 0.16 inch)

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.

c. Install a new O-ring to the cylinder block.
d. Install the oil seal retainer with the 7 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
50. INSTALL OIL PUMP ASSEMBLY