Part 4
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OVERHAUL
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 finks (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.)
80. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install crank angle sensor plate with the "F" mark facing forward.
81. INSTALL ENGINE REAR OIL SEAL
a. Using SST, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010
b. Apply a light coat of MP grease to the lip of a new oil seal.
NOTICE: Keep the lip off foreign materials.
82. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
NOTICE:
- Remove any oil from the contact surface.
- Install the chain cover within 3 minutes after applying seal packing.
- Do not start the engine within 2 hours after installing.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the timing chain cover, cylinder head and cylinder block.
b. Apply seal packing in the shape of bead (Diameter 2 mm (0.09 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
c. Apply seal packing in the shape of bead (Diameter 3 - 4 mm (0.118 - 0.157 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
d. Install the timing chain cover with the 14 bolts and 2 nuts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for Bolt A
21 Nm (214 kgf-cm, 15 ft. lbs.) for Bolt B
43 Nm (438 kgf-cm, 32 ft. lbs.) for Bolt C
9.0 Nm (92 kgf-cm, 80 inch lbs.) for Nut
83. INSTALL OIL PAN SUB-ASSY
NOTICE:
- Remove any oil from the contact surface.
- Install the oil pan within 3 minutes after applying seal packing.
- Do not start the engine within 2 hours after installing.
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the cylinder block and oil pan.
b. Apply seal packing in the shape of bead (Diameter 3 mm - 4 mm (0.157 inch)) as shown in the illustration, and install the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
c. Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
84. INSTALL OIL PAN DRAIN PLUG
a. Install an oil pan drain plug with a new gasket.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
85. INSTALL WATER PUMP ASSY
a. Clean the contact surface of the cylinder block.
b. Apply seal packing in the shape of bead (Diameter 2.2 - 2.5 mm) to the outside edge of the water pump.
Seal packing: Part No. 08826-00100 or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the water pump within 5 minutes after applying seal packing.
- Do not start the engine within 2 hours after installing.
c. Install the water pump assembly with 4 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: Tighten the outside bolts and nuts with the clamp.
86. INSTALL WATER PUMP PULLEY
a. Using SST, install the water pump pulley.
SST 09960-10010 (09962-0100O, 0996-00700)
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
87. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the bolt and crankshaft position sensor.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Confirm the wire harness of the crank position sensor is placed as shown in the illustration.
88. INSTALL CRANKSHAFT PULLEY
a. Using SST, tighten the set bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 170 Nm (1,733 kgf-cm, 125 ft. lbs.)
89. INSTALL CHAIN TENSIONER ASSY NO.1
a. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
b. Install a new gasket chain tensioner with 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: If the hook is released wile inserting, apply the hook again, and insert the chain tensioner.
c. Turn the crankshaft counterclockwise, and check the plunger knock pin is disconnected from the hook.
d. Turn the crankshaft clockwise, and check the plunger is pushed by the plunger.
90. INSPECT VALVE CLEARANCE
a. Turn the crankshaft pulley, and align its groove with the timing mark "O" of the timing chain cover.
b. Check that the timing marks of the camshaft timing sprockets are aligned with the timing marks of the No. 1 bearing cap as shown in the illustration.
c. Check only the valve indicated.
1 Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
2 Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
Valve clearance (cold):
Intake 0.19 - 0.29 mm (0.007 - 0.011 inch)
Exhaust 0.30 - 0.40 mm (0.012 - 0.016 inch)
d. Turn the crankshaft 1 revolution (360°) clockwise, and set No.4 cylinder to TDC/compression.
e. Check only the valve indicated.
1 Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
2 Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement valve lifter.
Valve clearance (cold):
Intake 0.19 - 0.29 mm (0.007 - 0.011 inch)
Exhaust 0.30 - 0.40 mm (0.012 - 0.016 inch)
91. ADJUST VALVE CLEARANCE
NOTICE: Do not turn the crankshaft without the chain tensioner.
a. Turn the crankshaft 1 revolution (360°) clockwise, and set No.1 cylinder to TDC/compression.
b. Place matchmarks on the timing chain and camshaft timing gear.
c. Remove the 2 bolts and chain tensioner.
d. Fix the camshaft with a spanner and so on, then loosen the camshaft timing gear set bolt.
NOTICE: Be careful not to damage the valve lifter.
e. Loosen the camshaft bearing cap bolts on No. 2 camshaft in the sequence shown in the illustration in several passes, and remove the caps.
f. Raising the camshaft, remove the set bolt.
g. Remove the timing chain sprocket from the camshaft with timing chain.
h. Remove the timing chain sprocket from the timing chain.
i. Loosen the camshaft bearing cap bolts on camshaft in the sequence shown in the illustration, in several passes, and remove the caps.
j. Remove the intake camshaft.
k. Tie the timing chain with a string.
l. Using a micrometer, measure the thickness of the removed lifter.
m. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
Valve clearance:
Intake A = B + (C - 0.24 mm (0.0094 inch))
Exhaust A = B - (C - 0.35 mm (0.0138 inch))
HINT:
- Select a new lifter with a thickness as close as possible to the calculated values.
- Lifter are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch).
n. Install the timing chain on the camshaft timing gear, with the painted links aligned with the timing marks on the camshaft timing sprockets.
o. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque:
Bearing cap No. 1 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9.0 Nm (92 kgf-cm, 80 inch lbs.)
p. Put the camshaft No. 2 on the cylinder head with the painted links of chain aligned with the timing mark on the camshaft timing sprockets.
q. Raising the camshaft, tighten the set bolt temporarily.
r. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque:
Bearing cap No. 2 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No. 3 9.0 Nm (92 kgf-cm, 80 inch lbs.)
s. Fix the camshaft with a spanner and so on, then tighten the camshaft timing gear set bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
NOTICE: Be careful not to damage the valve lifter.
t. As shown in the illustration, check the matchmarks on the timing chain and camshaft timing sprockets and the alignment of the pulley groove with timing mark of the chain cover.
HINT: There are 7 links between the timing marks.
u. Install chain tensioner.
1 Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.
2 Install a new gasket and chain tensioner with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger.
3 Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.
4 Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
92. INSTALL CAMSHAFT POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
93. INSTALL CYLINDER HEAD COVER GASKET
a. Install the gasket to the cylinder head cover.
94. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Remove any old packing (FIPG) material.
b. Apply seal packing to 2 locations 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 5 minutes after applying seal packing.
- Do not put into engine oil 2 hours after installing.
c. Install the cylinder head cover with the 8 bolts and 2 nuts.
Torque:
Bolt A 11 Nm(112 kgf-cm, 8 ft. lbs.)
Bolt B 14 Nm (143 kgf-cm, 10 ft. lbs.)
Nut 11 Nm (112 kgf-cm, 8 ft. lbs.)
95. INSTALL OIL FILTER UNION (W/O OIL COOLER)
a. Using a 12 mm hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
96. INSTALL OIL COOLER ASSY (W./ OIL COOLER)
a. Install a new O-ring to the oil cooler.
b. Apply a light coat of engine oil on the threads and under the head of the union bolt.
c. Install the oil cooler and union bolt.
Torque: 78.5 Nm (800 kgf-cm, 58 ft. lbs.)
d. Install the flange nut.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
97. 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. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
98. INSTALL SPARK PLUG
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
99. INSTALL VENTILATION VALVE SUB-ASSY
a. Apply adhesive on the threads of the ventilation valve.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
Adhesive: Part No. 08833-00070 THREE BOND 1324 or equivalent
100. INSTALL OIL FILLER CAP GASKET
a. Install the gasket to the oil filter cap.
101. INSTALL OIL FILLER CAP SUB-ASSY