Overhaul

REMOVAL
1. Disconnect the negative terminal from battery.
2. Drain the engine coolant.
3. Remove the breather hose between the air cleaner and the rocker cover.
4. Remove the air cleaner.
5. Remove the timing belt cover.
6. Remove the rocker cover, crank angle sensor.





7. Loosen the camshaft, sprocket bolts and remove the camshaft sprockets.
8. Loosen the bearing cap bolts and remove the bearing caps, camshafts, rocker arms, lash adjusters.

INSPECTION
Rocker Arms
1. Check rotation of the roller. If it does not rotate smoothly or if looseness is evident, replace it.





2. Check the roller and replace if there are any dent, damage or signs of bearing seizure.
3. Check the valve contact surface for possible damage or seizure and replace as necessary.

Camshafts
1. Check the camshaft journals for wear. If the journals are badly worn, replace the camshaft.





2. Check the cam lobes for damage. If the lobe is damaged or worn excessively, replace the camshaft.
Cam height
[Standard]
Intake 35.493 mm (1.3974 inch)
Exhaust 35.317 mm (1.3904 inch)
[Limit]
Intake 34.993 mm (1.3777 inch)
Exhaust 34.817 mm (1.3707 inch)

INSTALLATION





1. Install the camshafts on the cylinder head.

NOTE:
1 Apply engine oil to journals and cams of the cam shafts.
2 The intake camshaft has a slit on its rear end for driving the crankshaft position sensor.

2. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol.
R - Intake camshaft
L - Exhaust camshaft





3. Check that the camshaft can be easily turned by hand. After checking, remove the bearing caps and the camshafts, and then install the rocker arms.





4. Make sure that the dowel pins on the camshaft sprocket end are located on the top.

Camshaft Cap Tightening Sequence:

5. Tighten the bearing caps to the specified torque in two or three steps as shown.

NOTE: Tighten the rocker arms uniformly.

Tightening torque Rocker arm bolts 19 - 21 Nm (190 - 210 kg.cm, 14 - 15 ft. lbs.)





6. Using special tools, Camshaft Oil Seal Installer and guide (09221-21000, 09221-21100), press fit the camshaft oil seal. Be sure to apply engine oil to the external surface of the oil seal. Insert the oil seal along the camshaft front end and install by driving the installer with a hammer until the oil seal is fully seated.





1 of 2





2 of 2

7. Install the camshaft sprockets to the specified torque.
Tightening torque Camshaft sprocket bolts 80 - 100 Nm (800 - 1000 kg.cm, 58 - 72 ft. lbs.)





8. Install the rocker cover. Apply sealant as shown.
Tightening torque
Rocker cover bolts 8 - 10 Nm (80 - 100 kg.cm, 6 - 7 ft. lbs.)
Center cover bolts 4 - 5 Nm (40 - 50 kg.cm, 3 - 3.6 ft. lbs.)
Sealant
A Portion Threebond No.1212D or equivalent
B Portion Threebond No.1212D or equivalent

Bolt length x Diameter
Center cover bolt: 16 mm x 6 mm
Rocker cover bolt: special bolt





9. Install the spark plugs, ignition coil, connect the connector and then install the center cover.





10. Locate the dowel pin on the sprocket side of the exhaust cam shaft.
11. Align the notch of the crankshaft sensor to the hole in camshaft (intake manifold side) and tighten the bolts.

NOTE: The crankshaft position sensor can be installed even when the punch mark is positioned opposite the notch; however, the position results in incorrect fuel injection and ignition timings.

12. Install the crankshaft position sensor on the cylinder head.