Part 2

OVERHAUL (CONTINUED)





39. REMOVE ENGINE REAR OIL SEAL
a. Place the oil seal retainer on wooden blocks.
b. Using a screwdriver with its tip taped and a hammer, tap out the oil seal.

HINT: Tape the screwdriver tip before use.





40. INSPECT CHAIN SUB-ASSEMBLY
a. Pull the chain with a force of 147 Nm (15 kgf, 33 ft. lbs.) as shown in the illustration.
b. Using vernier calipers, measure the length of 16 links.
Maximum chain elongation: 147.5 mm (5.807 inch)
If the elongation is greater than the maximum, replace the chain.

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





41. INSPECT NO.2 CHAIN SUB-ASSEMBLY
a. Pull the chain with a force of 147 Nm (15 kgf, 33 ft. lbs.) as shown in the illustration.
b. Using vernier calipers, measure the length of 16 links.
Maximum chain elongation: 123.6 mm (4.866 inch)
If the elongation is greater than the maximum, replace the chain.

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





42. INSPECT CHAIN TENSIONER ASSEMBLY NO.1
a. Move the stopper plate upward to release the lock. Push the plunger and check that it moves smoothly.





43. INSPECT CHAIN TENSIONER ASSEMBLY NO.2
a. Move the stopper plate downward to release the lock. Push the plunger and check that it moves smoothly.





44. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance: 1.0 mm (0.039 inch)
If the distance is less than the minimum, replace the sprocket.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

b. Wrap the chain around the sprocket.
c. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 113.8 mm (4.480 inch)

HINT:
- The vernier calipers must contact the chain rollers for the measurement.
- If the diameter is less than the minimum, replace the chain and sprocket.





45. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Measure the distance between the most worn out timing gear tip and the beginning of the worn area below the tip.
Minimum distance: 1.0 mm (0.039 inch)
If the distance is less than the minimum, replace the timing gear.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.
b. Wrap the chain around the timing gear.
c. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 113.8 mm (4.480 inch)

HINT:
- The vernier calipers must contact the chain rollers for the measurement.
- If the diameter is less than the minimum, replace the chain and timing gear.





46. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Measure the distance between the most worn out sprocket tip and the beginning of the worn area below the tip.
Minimum distance: 1.0 mm (0.039 inch)
If the distance is less than the minimum, replace the sprocket.

HINT: If the worn area is too small or difficult to distinguish from a normal area, perform steps (b) and (c) below.

b. Wrap the chain around the drive sprocket.
c. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 59.4 mm (2.338 inch)

HINT:
- The vernier calipers must contact the chain rollers for the measurement.
- If the diameter is less than the minimum, replace the chain and sprocket.





47. INSPECT CHAIN TENSIONER SLIPPER
a. Using vernier calipers, measure the tensioner slipper wear.
Maximum wear: 2.0 mm (0.079 inch)
If the wear is greater than the maximum, replace the tensioner slipper.





48. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Using vernier calipers, measure the vibration damper wear.
Maximum wear: 2.0 mm (0.079 inch)
If the wear is greater than the maximum, replace the vibration damper.





49. INSPECT TIMING CHAIN GUIDE
a. Using vernier calipers, measure the chain guide wear.
Maximum wear: 0.5 mm (0.020 inch)
If the wear is greater than the maximum, replace the timing chain guide.





50. INSPECT CRANKSHAFT TIMING SPROCKET NO.2
a. Wrap the chain around the sprocket.
b. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 96.7 mm (3.807 inch)

HINT:
- The vernier calipers must contact the chain rollers for the measurement.
- If the diameter is less than the minimum, replace the chain and sprocket.





51. INSPECT BALANCE SHAFT DRIVE GEAR SUB-ASSEMBLY
a. Wrap the chain around the sprocket.
b. Using vernier calipers, measure the sprocket diameter with the chain.
Minimum sprocket diameter (w/ chain): 75.9 mm (2.988 inch)

HINT: The vernier calipers must contact the chain rollers for the measurement.

If the diameter is less than the minimum, replace the chain and sprocket.





52. INSPECT CHAIN VIBRATION DAMPER NO.2
a. Using vernier calipers, measure the vibration damper No.2 wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the vibration damper.





53. INSPECT CHAIN VIBRATION DAMPER NO.3
a. Using vernier calipers, measure the vibration damper No.3 wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the vibration damper.





54. INSPECT CHAIN VIBRATION DAMPER NO.4
a. Using vernier calipers, measure the vibration damper No.4 wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the vibration damper.





55. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the minimum diameter of the elongated thread at the measuring point.
Standard outside diameter: 10.76 to 10.97 mm (0.4236 to 0.4319 inch)
Minimum outside diameter: 10.40 mm (0.4094 inch)

HINT:
- If a visual check reveals no excessively thin areas, check the center of the bolt (see illustration) and find the area that has the lowest diameter.
- If the diameter is less than the minimum, replace the cylinder head bolt.





56. INSTALL CRANKSHAFT PULLEY SET CRANKSHAFT KEY
a. Install the 2 pulley keys to the crankshaft.





57. INSTALL CHAIN VIBRATION DAMPER NO.4
a. Install the vibration damper No.4 with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)




58. INSTALL NO.2 CHAIN SUB-ASSEMBLY
a. Install the timing sprocket No.2 as shown in the illustration.

NOTICE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side.

HINT: Install the sensor plate with the front mark facing forward.





b. As shown in the illustration, install the chain on the sprocket and gear with the painted marks aligned with the timing marks on the sprocket and gear.





c. Fit the other mark link of the crankshaft timing sprocket behind the large timing mark of the balance shaft drive gear.
d. Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole.





e. Align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear.
f. Install the bolt to the balance shaft drive gear and tighten it.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





g. Check that each timing mark is matched with the corresponding mark link.

NOTICE: Check that the No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side.





59. INSTALL CHAIN TENSIONER ASSEMBLY NO.2
a. Install the chain tensioner assembly No.2 with the nut.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)

NOTICE: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the vibration damper against the chain.





b. Move the stopper plate downward to release the lock, and push the plunger deep into the tensioner.
c. Move the stopper plate upward to set the lock, and insert a hexagon wrench into the stopper plate's hole.





60. INSTALL CHAIN VIBRATION DAMPER NO.3
a. Install the chain vibration damper No.3 with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)





61. INSTALL CHAIN VIBRATION DAMPER NO.2
a. Install the chain vibration damper No.2 with the bolt.
Torque: 27 Nm (270 kgf-cm, 20 ft. lbs.)
b. Remove a pin from the chain tensioner assembly No.2 and release the plunger.





62. INSTALL W/HEAD TAPER SCREW PLUG NO.1
a. Install the screw plug No.1 to the cylinder block.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





63. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
a. Using a hexagon wrench, install the oil filter bracket union.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





b. Install a new oil filter bracket gasket to the oil filter bracket.
c. Install a new O-ring to the oil filter bracket union.

NOTICE: Apply a light coat of engine oil to the new O-ring and oil filter bracket.

d. Install 2 new gaskets and the 2 screw plugs to the oil filter bracket.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)





e. Install the oil filter bracket with the 2 bolts and nut.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)





f. Using a 27 mm socket wrench, install the oil filter union.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)





64. INSTALL OIL FILTER SUB-ASSEMBLY
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 the oil filter.
SST 09228-07501
(1) When using a torque wrench: Using a torque wrench, tighten the oil filter.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
(2) When not using a torque wrench: Tighten it an additional 3/4 turn.