Part 2

OVERHAUL (CONTINUED)

37. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Fix the intake camshaft in 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 that the camshaft timing gear assembly is locked.





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

HINT: One of the 2 grooves on the cam journal is for the retard side path (upper) and the other is for the advance side path (lower). Each groove has 2 oil paths. Plug one of the oil paths for each groove with a piece of rubber before wrapping the cam journal with tape.

(2) Puncture the tape covering the advance oil path and retard oil path on the opposite side of the groove as shown in the illustration.





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

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





(4) Confirm that the camshaft timing gear assembly rotates in the timing advance direction when reducing the air pressure on the timing 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 on the timing retard side path, and release that of the timing advance side path.

NOTICE: Camshaft timing assembly gear occasionally shifts to the retard side abruptly if the air compression on the advanced side path is released first. This often causes the breakage of the lock pin.
e. Check the smooth revolution.

(1) Rotate the camshaft timing gear several times within the movable range except for the most retarded position and check it rotates smoothly.
Standard: Move smoothly in the range about 31°

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

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





g. Remove the set bolt, then remove the camshaft timing gear assembly.

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





38. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the outer diameter of the bolt thread.
Standard outer diameter: 10.85 to 11.00 mm (0.4272 to 0.4331 inch)
Minimum outer diameter: 10.7 mm (0.421 inch)
If the cylinder head set bolt is less than the minimum, replace the bolt.





39. INSPECT CHAIN SUB-ASSEMBLY
a. Using a spring scale, apply 147 Nm (15.0 kgf, 33.1 ft. lbs.) to the chain and measure the length.
Maximum chain length: 146.8 mm (5.780 inch)

NOTICE: Measure the length at least 3 places and calculate the average length.

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




40. INSPECT NO.2 CHAIN SUB-ASSEMBLY
a. Using a spring scale, apply 147 N (15.0 kgf, 33.1 ft. lbs.) to the chain and measure the length.
Maximum chain length: 146.8 mm (5.780 inch)

NOTICE: Measure the length at least 3 places and calculate the average length.

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





41. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Wrap the No.1 chain around the larger gear of timing gear assembly.
b. Using vernier caliper, measure the timing gear with the chain wrapped.
Minimum gear diameter (w/ chain): 115.5 mm (4.547 inch)

NOTICE: Vernier caliper must be in contact with the chain rollers when measuring.

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





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

NOTICE: The vernier calipers must be in contact the chain rollers when measuring.

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





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

NOTICE: The vernier calipers must be in contact the chain rollers when measuring.

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





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

NOTICE: The vernier calipers must be in contact with the chain rollers when measuring.

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





44. INSPECT IDLE SPROCKET ASSEMBLY
a. Wrap the No.1 chain around the idle sprocket.
b. Using vernier caliper, measure the idle sprocket with the chain wrapped.
Minimum gear diameter (w/ chain): 61.0 mm (2.402 inch)

NOTICE: The vernier caliper must be in contact with the chain rollers when measuring.

If the gear diameter is less than the minimum, replace the No.1 chain and idle sprocket.




45. INSPECT IDLE GEAR SHAFT NO.1
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 internal diameter of the idle gear.
Idle gear internal 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 internal 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)





46. INSPECT CHAIN TENSIONER ASSEMBLY NO.1
a. Check that the plunger moves smoothly when the ratchet pawl is raised with finger.
b. Release the ratchet pawl, then check that the plunger is locked in place by the ratchet pawl and does not move when pushing it with finger.





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





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





49. INSPECT CHAIN TENSIONER SLIPPER
a. Measure the wear of the tensioner slipper.
Maximum wear: 1.0 mm (0.039 inch)
If the thickness is greater than the maximum, replace the tensioner slipper.





50. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Measure the wear of the vibration damper No.1.
Maximum wear: 1.0 mm (0.039 inch)
If the thickness is greater than the maximum, replace the vibration damper No.1.





51. INSPECT CHAIN VIBRATION DAMPER NO.2
a. Measure the wear of the vibration damper No.2.
Maximum wear: 1.0 mm (0.039 inch)
If the thickness is greater than the maximum, replace the vibration damper No.2.





52. INSTALL ENGINE REAR OIL SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-78010





b. Apply MP grease to the oil seal lip.
53. INSTALL ENGINE REAR OIL SEAL RETAINER
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the oil seal retainer and cylinder block.
b. Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) to the oil seal retainer as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Parts must be assembled within 3 minutes of application. Otherwise, the seal packing must be removed and reap plied.

c. Install the oil seal retainer with the 5 bolts and 2 nuts.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for nuts
10 Nm (102 kgf-cm, 7.4 ft. lbs.) for bolts





54. INSTALL KNOCK CONTROL SENSOR
a. Install the 2 knock sensors with the 2 bolts as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
b. Connect the knock sensor connectors.
c. Connect the knock sensor wire.





55. INSTALL WATER OUTLET PIPE NO.1
a. Install the water outlet pipe with the 3 bolts.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.)
56. INSTALL CYLINDER HEAD GASKET
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.





b. Apply a continuous bead of seal packing (diameter 2.5 to 3 mm (0.098 to 0.118 inch)) to a new cylinder head gasket as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the cylinder head within 3 minutes of applying the seal packing. After installation, cylinder head bolts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.





c. Place the cylinder head gasket on the cylinder block surface with the Lot No.stamp upward.

NOTICE:
- Be careful of the installation direction.
- Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

57. INSTALL CYLINDER HEAD SUB-ASSEMBLY
a. Place the RH cylinder head on the cylinder head gasket.
b. Install the 8 cylinder head bolts.

HINT:
- The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)).
- If any cylinder head bolts are broken or deformed, replace them.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





(2) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
If any cylinder head bolts do not meet the torque specification, replace them.

NOTICE: Do not drop the washers into the cylinder head.





(3) Mark the front of the cylinder head bolt with paint.
(4) Retighten the cylinder head bolts by 180° as shown.
(5) Check that the painted marks are now at 180° from the engine front.
58. INSTALL CYLINDER HEAD GASKET NO.2
a. Remove any old packing material and be careful not to drop any oil on the contact surfaces of the cylinder head and cylinder block.





b. Apply a continuous bead of seal packing (Diameter 2.5 to 3 mm (0.098 to 0.118 inch)) to a new cylinder head gasket as shown in the illustration.
Seal packing: Part No.08826-00080 or equivalent

NOTICE: Install the cylinder head within 3 minutes of applying the seal packing. After installation, cylinder head bolts must be tightened within 15 minutes. Otherwise, the seal packing must be removed and reapplied.





c. Place the cylinder head gasket on the cylinder block surface with the Lot No.stamp upward.

NOTICE:
- Be careful of the installation direction.
- Place the cylinder head carefully in order not to damage the gasket with the bottom part of the head.

59. INSTALL CYLINDER HEAD LH
a. Place the LH cylinder head on the cylinder head gasket.
b. Install the 8 cylinder head bolts.

HINT:
- The cylinder head bolts are tightened in 2 successive steps (steps (3) and (5)).
- If any cylinder head bolts are broken or deformed, replace them.

(1) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.





(2) Using several steps, uniformly install and tighten the 8 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
If any cylinder head bolts do not meet the torque specification, replace them.

NOTICE: Do not drop the washers into the cylinder head.





(3) Mark the front of the cylinder head bolt with paint.
(4) Retighten the cylinder head bolts by 180° as shown.
(5) Check that the painted marks are now at 180° from the engine front.





c. Install the 2 cylinder head bolts.
(1) Apply a light coat of engine oil to the threads of the cylinder head bolts.
(2) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





60. INSTALL CAMSHAFT BEARING NO.1
a. Align the bearing claw with the claw groove of the bearing cap, and push in the camshaft bearing.

NOTICE:
- Install the bearing while aligning it with the oil hole in the bearing cap.
- Clean the back side of the bearing and the surface of the bearing cap and keep them free of oils and fats.





61. INSTALL CAMSHAFT BEARING NO.2
a. Install camshaft bearing No.2 onto the cylinder head.

NOTICE: Clean the back side of the bearing and the bearing surface of the cylinder head and keep them free of oils and fats.

62. INSTALL CAMSHAFTS

NOTICE: Keep the camshaft level while it is being removed. The camshaft thrust clearance is very small and failing to keep it level could crack or damage the cylinder head journal surface, which receives the thrust. This could subsequently lead the camshaft to seize or break. Perform the following steps to avoid such problems.





a. Set the crankshaft position.
(1) Using the crankshaft pulley set bolt, turn the crankshaft, and set the crankshaft set key in the left horizontal position as indicated.

NOTICE: Setting the crankshaft at the wrong angle could cause the piston head and valve head to come into contact with each other when the camshaft is installed. This could cause damage, so always set the camshaft at the correct angle.

b. Apply new engine oil to the thrust portion and journal of the camshafts.





c. Install the camshaft. lbs. the RH bank.
(1) Place the 2 camshafts on the RH cylinder head with the No.1 cam lobes facing as shown the illustration.





(2) Install the 8 bearing caps in their correct locations.
(3) Apply a light coat of engine oil to the threads of the bearing cap bolts.





(4) Using several steps, uniformly tighten the 16 bearing cap bolts in the sequence shown in the illustration.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.)for 10 mm (0.39 inch) head
24 Nm (245 kgf-cm, 18 ft. lbs.) for 12 mm (0.47 inch) head





(5) Using a wrench, turn the camshafts clockwise until each camshaft knock pin comes to a position 90° to the cylinder head.





d. Install the camshafts of the LH bank.
(1) Place the 2 camshafts on the LH cylinder head with the No.1 cam lobes facing as shown the illustration.





(2) Install the 8 bearing caps in the correct locations as shown.
(3) Apply a light coat of engine oil to the threads and under the heads of the bearing cap bolts.





(4) Using several steps, uniformly tighten the 16 bearing cap bolts in the sequence shown in the illustration.
Torque:
9.0 Nm (92 kgf-cm, 80 inch lbs.) for 10 mm (0.39 inch) head
24 Nm (245 kgf-cm, 18 ft. lbs.) for 12 mm (0.47 inch) head





63. INSTALL CHAIN TENSIONER ASSEMBLY NO.2
a. While pushing in the tensioner, insert a pin of 1.0 mm (0.039 inch) into the hole to fix it.





b. Install the chain tensioner No.2 with the bolt.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)