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OVERHAUL
26. REMOVE NO.2 CHAIN SUB-ASSY
a. Turn the crankshaft counterclockwise by 90°, and align an adjusting hole of the oil pump drive shaft gear with the groove of the oil pump.
b. Put a bar (4 mm) in the adjusting hole of the oil pump drive shaft gear to lock in position, and remove a nut.
c. Remove bolt and a chain tensioner plate.
d. Remove the oil pump drive gear, oil pump drive shaft gear and No. 2 chain sub assembly.
27. REMOVE OIL PUMP ASSY
a. Remove 3 bolts and the oil pump assembly.
28. REMOVE NO.2 CAMSHAFT
a. Remove No. 1 and No. 2 camshaft bearing caps as the sequence shown in the illustration.
b. Remove No. 2 camshaft.
29. REMOVE CAMSHAFT
a. Remove No. 1 and No. 3 camshaft bearing caps as the sequence shown in the illustration.
b. Remove No. 1 camshaft.
30. REMOVE CAMSHAFT BEARING NO.1
31. REMOVE CAMSHAFT TIMING GEAR OR SPROCKET
a. Fix the No. 2 camshaft with a vise, and remove the camshaft timing gear.
NOTICE: Be careful not to damage the camshaft.
32. REMOVE CAMSHAFT TIMING GEAR ASSY
a. Fix the No. 1 camshaft with a vise, and make sure that the camshaft timing gear assembly does not move.
b. Cover all the paths with vinyl tape except an advanced side path as shown in the illustration.
c. Put air pressure into the oil path with 150 kPa (1.5 kgf/cm2, 21 psi), and turn the camshaft timing gear assembly to the advance direction (counter-clockwise) by force.
NOTICE: Cover the paths with shop rag to avoid oil splashing.
HINT: Depending on the air pressure, the VVT timing sprocket will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage form the port, there may be the case that the lock pin could be hardly released.
d. Remove a fringe bolt of camshaft timing gear assembly.
NOTICE:
- Be sure not to remove the other 4 bolts.
- In case of reusing the camshaft timing gear assembly, release the straight pin lock first, and then install the gear.
33. REMOVE CAMSHAFT BEARING NO.2
34. REMOVE CYLINDER HEAD SUB-ASSY
a. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. 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 and incorrect order.
35. REMOVE CYLINDER HEAD GASKET
36. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
37. REMOVE UNION (W/OIL COOLER)
38. REMOVE OIL CONTROL VALVE FILTER
a. Using a 6 mm socket hexagon wrench, remove a plug and oil control valve filter.
39. REMOVE W/HEAD TAPER SCREW PLUG NO.1
40. INSPECT BALANCE SHAFT THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Standard thrust clearance: 0.050 - 0.090 mm (0.0020 - 0.0035 inch)
Maximum thrust clearance: 0.090 mm (0.0035 inch)
41. 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 by 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.
If the clearance is greater than maximum, replace the bearing. If necessary, replace the balance shaft. 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 a 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)
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)
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)
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)
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)
If the length is greater than maximum, replace the bolt.