Overhaul

REMOVAL





1. Remove the engine cover and intake manifold
2. Disconnect the breather hose and the engine harness.
3. Remove the coolant pump pulley, crankshaft pulley, idler pulley and tensioner pulley.
4. Remove the timing belt cover.
5. Loosen the timing belt tensioner pulley, and temporarily secure it.
6. Remove the timing belt from the camshaft sprocket.
7. Remove the spark plug cables.





8. Loosen the cylinder head cover bolts and then remove it.
9. Remove the camshaft sprocket.
10. Remove the camshaft bearing caps.





11. Remove the camshaft.

INSPECTION
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 43.95 - 44.15 mm (1.7303 - 1.7382 inch)
Exhaust 43.95 - 44.15 mm (1.7303 - 1.7382 inch)
[Limit]
Intake 43.45 mm (1.7106 inch)
Exhaust 43.45 mm (1.7106 inch)
3. Check the cam surface for abnormal wear or damage, and replace if necessary.
4. Check each bearing for damage. If the bearing surface is excessively damaged, replace the cylinder head assembly or camshaft bearing cap, as necessary.
Camshaft end play 0.1 - 0.15 mm (0.0039 - 0.0059 inch)

Oil Seal (camshaft front)
1. Check the lips for wear. If lip threads are worn, replace.
2. Check the oil seal lip contacting surface or camshaft. If it is worn in stages, replace the camshaft.

HLA (Hydraulic Lash Adjuster)





With the HLA filled with engine oil, hold A and Press B by hand. If B moves, replace the HLA.





Diagnosis table

Chain guide





1. Check the chain guide for bend, cracks or damage. Replace if necessary.
2. Check the rubber part of chain guide for abnormal wear. Replace if necessary.

Timing chain





Check the bushing and plate of timing chain for wear. Replace if there is severe wear.

INSTALLATION
1. Install the HLA.





2. Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.





3. Install the camshaft after lubricating the journal of camshaft with engine oil.





4. Install the bearing caps. Check the markings on the caps for intake/exhaust identification symbol.
I: Intake camshaft
E: Exhaust camshaft





5. Tighten the bearing caps to the specified torque in two or three steps as shown.
Tightening torque
Bearing cap bolt 14 - 15 Nm (140 - 150 kg-cm, 10 - 11 ft. lbs.)





6. Using the special tool, camshaft oil seal installer (09221-21000), 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 pulley is seated.





7. Install the camshaft sprocket to the specified torque.
Tightening torque
Camshaft sprocket bolt 90 - 11 Nm (900 - 1100 kg-cm, 65 - 80 ft. lbs.)

Cylinder Head Cover Tightening Sequence:

8. Install the cylinder head cover.
Tightening torque
Cylinder head cover bolts 5 - 6 Nm (50 - 60 kg-cm, 3.6 - 4.4 ft. lbs.)

1) Tighten all bolts with temporary torque. (half of the standard torque) in orders of 1.2.3.4.5.6.7.8.
2) Tighten all bolts with standard torque.
9. Install the spark plug cables, center cover.
10. Install the timing belt and then tighten the timing belt tensioner pulley.
11. Install the timing belt cover.





12. Install the coolant pump pulley and crankshaft pulley, and tensioner pulley.





13. Install the intake manifold and engine cover.
14. Install the oil filler cap.
15. Connect the breather hose and engine harness.