Part 2

OVERHAUL (CONTINUED)





26. REMOVE CHAIN TENSIONER ASSEMBLY NO.2
a. Remove the bolt and chain tensioner No. 2.
27. REMOVE CAMSHAFT TIMING GEARS AND NO.2 CHAIN (LH BANK)





a. While pushing down the chain tensioner No.3, insert a pin of [diameter]1.0 mm (0.039 inch) into the hole to fix it.





b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts, camshaft timing gear, camshaft timing gear assembly and timing chain No.2.

NOTICE:
^ Be careful not to damage the cylinder head and valve lifter with the wrench.
^ Do not disassemble the camshaft timing gear assembly.

28. REMOVE CHAIN TENSIONER ASSEMBLY NO.3





a. Remove the bolt and chain tensioner No.3.
29. REMOVE CAMSHAFTS

NOTICE: As the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head which receives the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.





a. Remove the camshafts of the RH bank.
1 Rotate the camshafts counterclockwise using a wrench so that the cam lobes of No. 1 cylinder face each direction as shown in the illustration.





2 Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.
3 Remove the 8 bearing caps and 2 camshafts.





b. Remove the camshafts of the LH bank.
1 Using several steps, loosen and remove the 16 bearing cap bolts uniformly in the sequence as shown in the illustration.
2 Remove the 8 bearing caps and 2 camshafts.
30. REMOVE CAMSHAFT BEARING NO.1
31. REMOVE CAMSHAFT BEARING NO.2
32. REMOVE CYLINDER HEADS





a. Using several steps, remove the 2 cylinder head bolts on the LH cylinder head in the sequence as shown in the illustration.





b. Using several steps, loosen the 8 cylinder head bolts on each cylinder head with a 10 mm bi-hexagon wrench in the sequence as shown in the illustration. Remove the 16 cylinder head bolts and plate washers.

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





c. Lift the cylinder head from the dowels on the cylinder block, and place the 2 cylinder heads on wooden blocks on a bench.

NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.

d. Remove the RH and LH cylinder head gaskets.





33. REMOVE WATER OUTLET PIPE NO.1
a. Separate the knock sensor wire.
b. Remove the 3 bolts and water outlet pipe.
34. REMOVE KNOCK SENSOR





a. Disconnect the knock sensor connectors.
b. Remove the 2 bolts and 2 knock sensors.





35. REMOVE ENGINE REAR OIL SEAL RETAINER
a. Remove the 5 bolts and 2 nuts.
b. Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and crankshaft bearing cap.





36. REMOVE ENGINE REAR OIL SEAL
a. Using a screwdriver and hammer, tap out the oil seal.
37. INSPECT CAMSHAFTS





a. Inspect the camshaft for runout.
1 Place the camshaft on V-blocks.
2 Using a dial indicator, measure the runout at the center journal.
Maximum runout: 0.06 mm (0.0024 inch)
If the runout is greater than the maximum, replace the camshaft.





b. Inspect the cam lobes.
1 Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
Intake 44.168 to 44.268 mm (1.7389 to 1.7428 inch)
Exhaust 44.580 to 44.680 mm (1.7551 to 1.7591 inch)
Minimum cam lobe height:
Intake 44.018 mm (1.7330 inch)
Exhaust 44.430 mm (1.7492 inch)
If the cam lobe height is less than the minimum, replace the camshaft.





c. Inspect the camshaft journals.
1 Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 inch)
Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 inch)
If the journal diameter is not as specified, check the oil clearance.
38. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Fix the intake camshaft with a vise.

NOTICE: Be careful not to damage the camshaft.





b. Align the knock pin hole in the camshaft timing gear assembly with the knock pin of the camshaft, and install the camshaft timing gear assembly with the bolt.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
c. Confirm the camshaft timing gear assembly is locked.





d. Release the lock pin.
1 Cover 4 oil paths of the cam journal with a masking tape as shown in the illustration.

HINT: One of the 2 grooves on the cam journal is for retards (upper) and the other is for advances (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 tape.

2 Prick a hole in the tape placed on the advance side path. Prick a hole in the retard side path, on the opposite side to that of the advance side path, as shown in the illustration.





3 Apply about 200 kPa (2.0 kgf/cm2) of air pressure to the two broken paths (the advance side path and the retard side path).

NOTICE: Cover the paths with a shop rag to avoid oil splashing.





4 Confirm that the camshaft timing gear assembly rotates in the advance direction when reducing the air pressure applied to the retard path.

HINT: When the lock pin is released, the camshaft timing gear rotates in the advance direction.

5 When the camshaft timing gear comes to the most advanced position, release the air pressure from the retard side path, and then release the air pressure from the advance side path.

NOTICE: The camshaft timing assembly gear occasionally shifts to the retard side abruptly, if air compression of the advanced side path is released first. It often results in the breakage of the lock pin.

e. Check for smooth revolution.
1 Except the position where the lock pin meets at the most retard angle, turn the camshaft timing gear assembly back and forth and check the movable range and that there is no disturbance.
Standard: Movable smoothly in the range about 31°

NOTICE: Be sure to perform this check by hand, instead of air pressure.

f. Check the lock in the most retarded position.
1 Confirm that the camshaft timing gear assembly is locked at the most retarded position.





g. Remove the set bolt and camshaft timing gear assembly.

NOTICE: Be sure not to remove the other 3 bolts.





39. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the outside thread diameter of the bolt.
Standard outside diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 inch)
Minimum outside diameter: 10.7 mm (0.421 inch)





40. INSPECT CHAIN SUB-ASSEMBLY
a. Using a spring scale, pull the chain sub assembly with a force of 147 N (15.0 kgf, 33.1 ft. lbs.) and measure the length of the chain sub assembly by vernier calipers.
Maximum chain elongation: 146.8 mm (5.780 inch)

NOTICE: Perform the same measurements by pulling at random in 3 or more places to obtain an average length.

If the elongation is greater than the maximum, replace the chain.





41. INSPECT NO.2CHAIN SUB-ASSEMBLY
a. Using a spring scale, pull the chain sub assembly with a force of 147 N (15.0 kgf, 33.1 ft. lbs.) and measure the length of the chain sub assembly by vernier calipers.
Maximum chain elongation: 146.8 mm (5.780 inch)

NOTICE: Perform the same measurements by pulling at random in 3 or more places to obtain an average length.

If the elongation is greater than the maximum, replace the chain.
42. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY





a. Put the No. 1 chain on the larger gear of the camshaft timing gear assembly.
b. Using vernier calipers, measure the timing gear with the chain.
Minimum gear diameter (w/ chain): 115.5 mm (4.547 inch)

NOTICE: The vernier calipers must contact the chain rollers for the measuring.

If the diameter is less than the minimum, replace the No.1 chain and camshaft timing gear assembly.





c. Put the No.2 chain on the smaller gear of the camshaft timing gear assembly.
d. Using vernier calipers, measure the timing gear with the chain.
Minimum gear diameter (w/ chain): 73.1 mm (2.878 inch)

NOTICE: The vernier calipers must contact the chain rollers for the measuring.

If the diameter is less than the minimum, replace the No.2 chain and camshaft timing gear assembly.





43. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Put the No.2 chain on the camshaft timing gear.
b. Using vernier calipers, measure the camshaft timing gear diameter with the chain.
Minimum gear diameter (w/ chain): 73.1 mm (2.878 inch)

NOTICE: The vernier calipers must contact the chain rollers for the measuring.

If the diameter is less than the minimum, replace the No.2 chain and the camshaft timing gear.





44. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Put the No.1 chain on the crankshaft timing gear.
b. Using vernier calipers, measure the crankshaft timing gear diameter with the chain.
Minimum gear diameter (w/ chain): 61.0 mm (2.402 inch)

NOTICE: The vernier calipers must contact the chain rollers for the measuring.

If the diameter is less than the minimum, replace the No.1 chain and crankshaft timing gear.





45. INSPECT IDLE GEAR NO.1
a. Put the No.1 chain on the idle gear.
b. Using vernier calipers, measure the idle gear with the chain.
Minimum gear diameter (w/ chain): 61.0 mm (2.402 inch)

NOTICE: The vernier calipers must contact the chain rollers for the measuring.

If the diameter is less than the minimum, replace the No.1 chain and idle gear.
46. INSPECT IDLE GEAR SHAFT OIL CLEARANCE





a. Using a micrometer, measure the idle gear shaft diameter.
Idle gear shaft diameter: 22.987 to 23.000 mm (0.9050 to 0.9055 inch)





b. Using a caliper gauge, measure the inside diameter of the idle gear.
Idle gear inside diameter: 23.02 to 23.03 mm (0.9063 to 0.9067 inch)
c. Subtract the idle gear shaft diameter measurement from the idle gear inside diameter measurement.
Standard oil clearance: 0.020 to 0.043 mm (0.0008 to 0.0017 inch)
Maximum oil clearance: 0.093 mm (0.0037 inch)





47. INSPECT CHAIN TENSIONER ASSEMBLY 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.





48. INSPECT CHAIN TENSIONER ASSEMBLY NO.2
a. Check that the plunger moves smoothly.
b. Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain tensioner No.2.





49. INSPECT CHAIN TENSIONER ASSEMBLY NO.3
a. Check that the plunger moves smoothly.
b. Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain tensioner No.3.





50. INSPECT CHAIN TENSIONER SLIPPER
a. Measure the worn depth of the chain tensioner slipper.
Maximum depth: 1.0 mm (0.039 inch)
If the depth is greater than the maximum, replace the chain tensioner slipper.