Part 2
Part 1 Of 10:
Part 2 Of 10:
Part 3 Of 10:
Part 4 Of 10:
Part 5 Of 10:
Part 6 Of 10:
Part 7 Of 10:
Part 8 Of 10:
Part 9 Of 10:
Part 10 Of 10:
PARTIAL ENGINE ASSY
OVERHAUL
26. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Clamp the camshaft in a vise.
b. Remove the fringe bolt and camshaft timing sprocket.
NOTICE: Be careful not to damage the camshaft.
27. REMOVE CAMSHAFT
a. Using several steps, loosen and remove the 8 bearing cap bolts uniformly in the sequence shown in the illustration, then remove the 4 bearing caps and camshaft.
NOTICE: Loosen each bolt uniformly keeping the camshaft level.
28. INSPECT CAMSHAFT TIMING GEAR ASSY
a. Check the lock of the camshaft timing gear.
1. Clamp the camshaft in a vise, and check that the camshaft timing gear is locked.
NOTICE: Be careful not to damage the camshaft.
b. Release the lock pin.
1. Cover the 4 oil paths of the cam journal with tape as shown in the illustration.
HINT: One of the 2 grooves located on the cam journal is for retarding cam timing (upper) and the other is for advancing cam timing (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with rubber pieces before wrapping the cam journal with the tape.
2. Punctuate the tape for the advance oil path and for the retard oil path on the opposite side from the advance oil path.
3. Put air pressure into two broken paths (the advance side path and the retard side path) with about 150 kPa (1.5 kgf/cm2).
NOTICE: Cover the paths with shop rag prevent oil splashing.
4. Confirm if the camshaft timing gear assembly revolves in the timing advance direction when reducing the air pressure of the timing retard path.
HINT: The lock pin is released, and the camshaft timing gear revolves in the timing advance direction.
5. When the camshaft timing gear reaches the most advanced position, remove the air pressure of the timing retard side path, and then release the air pressure of the timing advance side path.
NOTICE: Camshaft timing assembly gear occasionally shifts to the retard side abruptly, if the air compression of the advanced side path is released first. It often results in the breakage of the lock pin.
c. Check smooth revolution.
1. Except the position where the lock pin meets at the most retarded angle, let the valve timing controller assembly turn back and forth and check the movable range and that there is no disturbance.
Standard: Smooth movable range is about 22.5°
NOTICE: Be sure to perform this check by hand, instead of air pressure.
d. Check the lock is at the most retarded position.
1. Confirm that the camshaft timing gear assembly is locked at the most retarded position.
29. REMOVE CAMSHAFT TIMING GEAR ASSY
a. Turn the valve timing controller assembly at the most advanced angle.
b. Remove the fringe bolt and camshaft timing gear assembly.
NOTICE:
^ Be careful not to remove the other 4 bolts.
^ If reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.
30. REMOVE CYLINDER HEAD SUB-ASSY
a. Using several steps, loosen and remove the 10 cylinder head bolts uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.
NOTICE:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.
31. REMOVE CYLINDER HEAD GASKET
32. REMOVE OIL FILTER SUB-ASSY
a. Using SST, remove the oil filter.
SST 09228-06501
33. REMOVE OIL FILTER UNION
a. Using a 12 mm hexagon wrench, remove the oil filter union.
34. REMOVE ENGINE REAR OIL SEAL
a. Using a knife, cut off the oil seal lip.
b. Using a screwdriver with the tip wrapped in tape, pry out the oil seal.
NOTICE: After removal, check if the crankshaft is not damaged. If it is damaged, smooth the surface with 400-grit sandpaper.
35. REMOVE OIL PAN SUB-ASSY NO.2
a. Remove the oil pan drain plug and gasket.
b. Remove the 9 bolts and 2 nuts.
c. Insert the blade of SST between the oil pan No. 1 and oil pan No. 2, and cut off the applied sealer and remove the oil pan No. 2.
SST 09032-00100
NOTICE: Be careful not to damage the oil pan No. 1 and oil pan No. 2.
36. REMOVE OIL STRAINER SUB-ASSY
a. Remove the bolt and 2 nuts.
b. Remove the oil strainer and gasket.
37. REMOVE OIL PAN SUB-ASSY
a. Loosen and remove the 13 bolts uniformly in several steps.
b. Using screwdriver, remove the oil pan No. 1 by prying between the cylinder block and oil pan No. 1.
NOTICE: Be careful not to damage the contact surfaces of the oil pan No. 1 and cylinder block.
c. Remove the 2 O-rings from the cylinder block.
d. Remove the 4 stud bolts.
38. INSPECT CHAIN TENSIONER ASSY NO.1
a. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
b. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushing with your finger.
39. INSPECT CAMSHAFT TIMING GEAR ASSY
a. Wrap the chain around the timing sprocket.
b. Using vernier calipers, measure a diameter of the timing gear with the chain wrapped.
Minimum gear diameter (w/chain): 96.2 mm (3.787 in.)
If the diameter is less than minimum, replace the sprocket.
NOTICE: Vernier calipers must contact the chain link for measuring.
40. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing sprocket.
b. Using vernier calipers, measure the diameter of the timing gear with the chain wrapped.
Minimum gear diameter (w/chain): 96.2 mm (3.787 in.)
If the diameter is less than minimum, replace the sprocket.
NOTICE: Vernier calipers must contact the chain link for measuring.
41. INSPECT CHAIN TENSIONER SLIPPER
a. Measure the chain tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the slipper.
42. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 in.)
If the wear is greater than maximum, replace the damper.
43. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length: 142.8 to 144.2 mm (5.622 to 5.677 in.)
Maximum bolt length: 147.1 mm (5.791 in.)
If the length exceeds the maximum, replace the bolt.
44. INSTALL OIL PAN SUB-ASSY
a. Using a torx socket wrench E57 install the 4 stud bolts.
Torque: 5.0 Nm (50 kgf-cm, 44 in. lbs.)
b. Remove any old packing material from the contact surface.
c. Apply a continuous bead of seal packing (Diameter 2.0 mm to 3.0 mm (0.079 to 0.118 in.) to the oil pan mating surface as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying the seal packing.
^ Do not expose the seal to engine oil within 2 hours of installation.
d. Install 2 new O-rings to the cylinder block.
e. Using several steps, install and tighten the 13 bolts uniformly in the sequence shown in the illustration.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
HINT: Each bolt length as follows.
Bolt A 49 mm (1.93 in.)
Bolt B 88 mm (3.47 in.)
Bolt C 144 mm (5.67 in.)
45. INSTALL OIL STRAINER SUB-ASSY
a. Install a new gasket and the oil strainer with the 2 nuts and bolt.
Torque: 11 Nm (112 kgf-cm, 8.1 ft. lbs.)
46. INSTALL OIL PAN SUB-ASSY NO.2
a. Remove any old packing material from the contact surface.
b. Apply a continuous bead of seal packing (Diameter 2.5 to 3.5 mm (0.0984 to 0.1378 in.) to the oil pan mating surface as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying the seal packing.
^ Do not expose the seal to engine oil within 2 hours of installation.
^ Do not start the engine within 2 hours of installation.
c. Install the oil pan No. 2 with the 9 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in. lbs.)
d. Install the drain plug with a new gasket.
Torque: 38 Nm (382 kgf-cm, 28 ft. lbs.)
47. INSTALL OIL FILTER UNION
a. Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
48. INSTALL OIL FILTER SUB-ASSY
a. Check and clean the oil filter installation surface.
b. Apply clean engine oil to the gasket of a new oil filter.
c. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
d. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
49. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.
NOTICE:
^ Remove any oil from the contact surface.
^ Pay attention to the mounting orientation of the cylinder head gasket.
^ Place the cylinder head on the cylinder head gently in order not to damage the gasket at the bottom part of the head.
50. INSTALL CYLINDER HEAD SUB-ASSY
HINT: The cylinder head bolts are tightened in 2 successive steps.
a. Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.138 to 0.177 in.) as shown in the illustration.
NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
b. Apply a light coat of engine oil on the threads of the cylinder head bolts.
c. Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi hexagon wrench in the sequence shown in the illustration.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
d. Mark the front of the cylinder head bolt with paint.
e. Using the same sequence as step (c), retighten the cylinder head bolts by additional 90° and one more additional 90° as shown in the illustration.
f. Check that each paint mark is now at the 180° angle to the front.