Part 2
OVERHAUL41. INSPECT BALANCE SHAFT OIL CLEARANCE
a. Uniformly loosen and remove the 8 bolts in several passes, in the sequence shown.
b. Lay a strip of plastigage across each journal, and install the balance shaft housing.
c. Apply light coat of engine oil on the threads and under the heads of the balance shaft housing bolts.
d. Temporarily tighten 8 bolts in the several passes, in the sequence shown, and fully tighten with specified torque.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)
HINT: The balance shaft housing bolts are tightened in 2 progressive steps.
e. Mark the front side of each balance shaft housing bolt head with paint.
f. Retighten the bolts 90° as the sequence shown.
g. Check that the paint marks are now at a 90° angle to the front.
h. Remove the balance shaft housing, and measure the plastigage at its widest point.
Standard oil clearance: 0.004 - 0.031 mm (0.0002 - 0.0012 inch)
Maximum oil clearance: 0.031 mm (0.0012 inch)
NOTICE: Completely remove the plastigage after the inspection.
i. If the clearance is greater than maximum, replace the bearing. If necessary, replace the balance shaft.
j. If using a standard bearing, replace it with one having the same number.
Balance shaft housing journal bore diameter
Balance shaft journal diameter
Standard bearing center wall thickness
42. REMOVE BALANCE SHAFT No. 1 AND No. 2
43. REMOVE BALANCE SHAFT BEARING NO. 1
44. REMOVE ENGINE REAR OIL SEAL
a. Using a knife, cut off the oil seal lip.
b. Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE: After the removal, check the crankshaft is not damaged. If there is, mend it with sandpaper (#400).
45. REMOVE STIFFENING CRANKCASE ASSY
a. Uniformly loosen and remove the 11 bolts, in several passes, in the sequence shown.
b. Using a screwdriver, remove the crankcase by prying the portions between the crankcase and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the crankcase and cylinder block.
c. Remove the O-ring from the cylinder block.
46. INSPECT OIL PUMP DRIVE GEAR
a. Wrap the chain around the drive gear.
b. Using vernier calipers, measure the drive gear diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
Minimum gear diameter (w/chain): 48.2 mm (1.898 inch)
c. If the diameter is less than minimum, replace the chain and drive gear.
47. INSPECT OIL PUMP DRIVE SHAFT GEAR
a. Wrap the chain around the drive shaft gear.
b. Using vernier calipers, measure the drive shaft gear diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
Minimum gear diameter (w/chain): 48.2 mm (1.898 inch)
c. If the diameter is less than minimum, replace the chain and drive shaft gear.
48. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing gear.
b. Using vernier calipers, measure the timing gear diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
Minimum gear diameter (w/chain): 51.6 mm (2.031 inch)
c. If the diameter is less than minimum, replace the chain and timing gear.
49. INSPECT CHAIN TENSIONER SLIPPER
a. Measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 inch)
b. If the wear is greater than maximum, replace the chain tensioner slipper.
50. INSPECT CHAIN VIBRATION DAMPER NO. 1
a. Measure the chain vibration damper No. 1 wears.
Maximum wear: 1.0 mm (0.039 inch)
b. If the wear is greater than maximum, replace the chain vibration damper No. 1.
51. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length: 161.3 - 162.7 mm (6.350 - 6.406 inch)
Maximum bolt length: 164.2 mm (6.465 inch)
b. If the length is greater than maximum, replace the bolt.
52. INSPECT CHAIN TENSIONER ASSY NO. 1
a. Check the plunger moves smoothly when the ratchet pawl is raised, and when the ratchet pawl is released, the plunger is locked in place.
b. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with finger.
53. INSPECT CHAIN SUB-ASSY
a. Using a spring scale, pull the chain sub assembly with 140 N (14.3 kgf, 315 lbs.) and measure the length of the chain sub assembly by vernier calipers.
Maximum chain elongation: 115.4 mm (4.543 inch)
b. If the elongation is greater than maximum, replace the chain.
NOTICE: Make the same measurements pulling at 3 or more places selected at random, and average the length.
54. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing sprocket.
b. Using vernier calipers, measure the timing sprocket diameter with the chain.
Minimum sprocket diameter (w/chain): 97.3 mm (3.831 inch)
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
55. INSPECT CAMSHAFT
a. Inspect the camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
b. If the circle runout is greater than maximum, replace the camshaft.
c. Inspect cam lobe height.
1. Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 46.495 - 46.595 mm (1.8305 - 1.8345 inch)
Minimum cam lobe height: 46.385 mm (1.8262 inch)
d. If the cam lobe height is less than minimum, replace the camshaft.
e. Inspect camshaft journal diameter.
1. Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 - 35.985 mm (1.4165 - 1.4167 inch)
Other journal diameter: 22.959 - 22.975 mm (0.9039 - 0.9045 inch)
f. If the journal diameter is not as specified, check the oil clearance.
56. INSPECT NO. 2 CAMSHAFT
a. Place the camshaft on V-blocks.
b. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
c. If the circle runout is greater than maximum, replace the camshaft.
d. Inspect cam lobe height.
1. Using a micrometer, measure the cam lobe height.
Standard cam lobe height: 45.983 - 46.083 mm (1.8104 - 1.8143 inch)
Minimum cam lobe height: 45.873 mm (1.8060 inch)
e. If the cam lobe height is less than minimum, replace the camshaft.
f. Inspect camshaft journal diameter.
1. Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 - 35.985 mm (1.4165 - 1.4167 inch)
Other journal diameter: 22.959 - 22.975 mm (0.9039 - 0.9045 inch)
g. If the journal diameter is not as specified, check the oil clearance.
57. INSTALL ENGINE REAR OIL SEAL
a. Apply MP grease to a new oil seal lip.
NOTICE: Keep the lip off the foreign materials.
b. Using SST and a hammer, evenly tap the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)
NOTICE: Wipe off extra grease on the crank shaft.
58. INSTALL BALANCE SHAFT BEARING NO. 1
a. Install the bearings in the crankcase and balance shaft housing.
b. Apply a light coat of engine oil on the bearings.
59. INSTALL BALANCE SHAFT No. 1 AND No. 2
a. Rotate driven gear No. 1 of balance shaft No. 1 for the rotating direction until it hits the stopper.
b. Confirm the matchmarks on driven gear No. 1 and No. 2 are matched.
c. Align the timing marks of the No. 1 and No. 2 balance shaft as shown in the illustration.
d. Place the No. 1 and No. 2 balance shaft on the crankcase.
e. Apply a light coat of engine oil under the heads of the balance shaft housing bolts.
f. Temporarily tighten 8 bolts in the several passes as the sequence shown, and fully tighten with specified torque.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)
HINT: The balance shaft housing bolts are tightened in 2 progressive steps.
g. Mark the front side of each balance shaft housing bolt head with paint.
h. Retighten the bolts by 90° as the sequence shown.
i. Check that the painted marks are now at a 90° angle to the front.
60. INSTALL STIFFENING CRANKCASE ASSY
a. Apply seal packing in the shape of bead (Diameter 2.5 mm - 3 mm (0.098 - 0.118 inch)) the places shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the crankcase within 3 minutes after applying seal packing.
- Do not start the engine within 2 hours after installing.
b. Install a new O-ring the place shown in the illustration.
c. With the crank pin of the balance shaft, at 6 o'clock position, install the No. 1 and No. 2 balance shaft and the adjusting hole as shown in the illustration.
d. Install the 11 bolts in the several passes as sequence shown in the illustration.
Torque: 33 Nm (332 kgf-cm, 24 ft. lbs.)
e. Confirm that timing marks of the balance shaft are matched as shown in the illustration when the key groove is at 6 o'clock position.
61. INSTALL W/ HEAD TAPER SCREW PLUG NO. 1
a. Apply adhesive to the threads of the plug and install.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
62. INSTALL OIL CONTROL VALVE FILTER
a. Check that no foreign substance on the mesh part of the filter.
b. Using a 6 mm socket hexagon wrench, install the oil control valve filter with a new gasket.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
63. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a. Install the water drain cock sub assembly within the range shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
64. INSTALL UNION (W/ OIL COOLER)
Torque: 40 Nm (408 kgf-cm, 29 ft. lbs.)
65. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE:
- Remove any oil from contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
66. INSTALL CYLINDER HEAD SUB-ASSY
HINT: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply seal packing in the shape of bead (Diameter 2.5 - 3 mm (0.098 - 0.118 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Remove any oil from contact surface.
- Install the cylinder head within 3 minutes after applying seal packing.
- After installing the cylinder head, cylinder head bolts must be tightened within 15 minutes.
b. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
c. Install bolts and plate washers to the cylinder head.
NOTICE: Do not drop the washers into the cylinder head.
d. Using a 10 mm bi-hexagon wrench, temporarily tighten each bolts in the several passes, as the sequence shown in the illustration, and fully tighten with specified torque.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)
e. Mark the front side of each cylinder head bolt with paint.
f. Retighten the cylinder head bolts by 90° in the sequence shown.
g. Check that the painted marks are now at a 90° angle to the front.
67. INSTALL CAMSHAFT BEARING NO. 2
68. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Put the camshaft timing gear assembly and the camshaft together with the straight pin of the key groove.
b. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove.
CAUTION: Be sure not to turn the camshaft timing gear to the retard angle side (to the right angle).
c. Check that there is no clearance between the gear's fringe and the camshaft.
d. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 49 ft. lbs.)
e. Check that the camshaft timing gear assembly can move to the retard angle side (the right direction), and is locked at the most retarded position.
69. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Fix the camshaft No. 2 to the vise, and install camshaft No. 2 timing gear.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
70. INSTALL CAMSHAFT BEARING NO. 1
71. INSTALL CAMSHAFT
a. Tighten camshaft bearing cap No. 1 and No. 3 as the sequence shown in the illustration.
Torque:
Bearing cap No. 1 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE:
- Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 1.
- Install the camshaft with its timing mark of camshaft timing gear on top.
72. INSTALL NO. 2 CAMSHAFT
a. Tighten camshaft bearing cap No. 2 and No. 3 as the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE:
- Tighten the bolts after deciding the position for the thrust direction of the camshaft by bearing cap No. 2.
- Install the camshaft with its timing mark of camshaft timing gear on top.
73. INSTALL OIL PUMP ASSY
a. Install oil pump assembly with 3 bolts and a new gaskets.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
74. INSTALL NO. 2 CHAIN SUB-ASSY
a. Set the crankshaft key into the left horizontal position.
b. Turn the cutout of the drive shaft to the top.
c. Align the mark links (yellow colored links) with the timing marks of gear as shown in the illustration.
d. Insert the gear with chain to the crankshaft and oil pump shaft.
e. Temporarily tighten the oil pump drive shaft gear by a nut.
f. Insert the damper spring into the adjusting hole, and install the chain tensioner plate by a bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
g. Align an adjusting hole of the sprocket with the groove of the oil pump.
h. Put a bar ([diameter] 4 mm) into the adjusting hole of the sprocket to lock in position, and assemble a nut.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.)
i. Rotate the crankshaft clockwise 90°, and align the crankshaft key with the top.
75. INSTALL CRANKSHAFT TIMING GEAR OR SPROCKET
76. INSTALL CHAIN VIBRATION DAMPER NO. 1
a. Install the chain vibration damper with the 2 bolts.
Torque: 9 Nm (92 kgf-cm, 80 inch lbs.)
77. INSTALL CHAIN SUB-ASSY
a. Set No. 1 cylinder to TDC/compression.
1. Align the timing marks of the camshaft timing sprockets and No. 1 bearing caps.
2. Using the crankshaft pulley bolt, turn the crankshaft and set the set key on the crankshaft upward.
b. Align the mark plate (blue or orange colored link) with the timing mark of the crankshaft timing gear.
c. Using SST, install the sprocket.
SST 09309-37010
d. Align the mark links (gold or yellow colored links) with the timing marks of the camshaft timing gear, and install the chain.
78. INSTALL CHAIN TENSIONER SLIPPER
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
79. INSTALL TIMING CHAIN GUIDE
Torque: 9 Nm (92 kgf-cm, 80 inch lbs.)