Part 3

PARTIAL ENGINE ASSY
OVERHAUL
51. INSTALL ENGINE REAR OIL SEAL
a. Apply multipurpose grease to a new oil seal lip.

NOTICE: Keep the lip free of foreign materials.

b. Using SST and a hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-56010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Wipe any extra grease off the crankshaft.

52. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Put the camshaft timing gear assembly and camshaft together with the straight pin off the groove.
b. Turn the camshaft timing gear assembly clockwise while pushing it lightly towards the camshaft. Push further at the position where the pin fits into the groove.

NOTICE: Be careful not to turn the camshaft timing gear to the retard angle side (to the right).

c. Check that there is no clearance between the gear fringe and camshaft.
d. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
e. Check that the camshaft timing gear assembly can move to the retard angle (to the right) and is locked in the most retarded position.
53. INSTALL CAMSHAFT
a. Apply a light coat of engine oil to the camshaft journals.
b. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.

54. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Clamp the camshaft in a vise.
b. Align the knock pin hole of the camshaft timing sprocket with the knock pin of the camshaft, and install the camshaft timing sprocket.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

NOTICE: Be careful not to damage the camshaft.

55. INSTALL NO.2 CAMSHAFT
a. Apply a light coat of engine oil to the camshaft journals.
b. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.

c. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9.4 ft. lbs.)

NOTICE: Tighten each bolt uniformly keeping the camshaft level.

d. Install the bearing cap No. 1.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
56. INSTALL CAMSHAFT POSITION SENSOR
a. Apply engine oil to the O-ring.

NOTICE: If the O-ring is damaged, replace the camshaft position sensor.

b. Install the camshaft position sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

57. INSTALL CHAIN SUB-ASSY
a. After setting the crankshaft at ATDC 40 to 140°, set cams of intake and exhaust timing sprockets at ATDC 20° and then reset the crankshaft at ATDC 20°.
b. Install the chain vibration damper with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
c. Align the matchmarks of the camshaft timing sprocket, camshaft timing gear and crankshaft timing sprocket with each mark plate (colored in yellow) of the timing chain.

HINT: To prevent the exhaust camshaft from springing back, turn it using a wrench and set it at the mark on the chain.

d. Install the chain tensioner slipper with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

e. Rotate the stopper plate of the chain tensioner upward as shown in the illustration, push in the plunger of the tensioner.
f. Rotate the stopper plate of the tensioner downward, insert a 2.5 mm (0.098 inch) diameter bar into the holes of the stopper plate and tensioner to hold the stopper plate.
g. Install the chain tensioner with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
h. Remove the bar from the chain tensioner.
i. Check the tension between the intake and exhaust camshaft timing sprockets.

58. INSTALL OIL PUMP SEAL
a. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09950-60010 (09951-00250, 09951-00380, 09952-06010), 09950-70010 (09951-07100)

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the lip free of foreign objects.

b. Apply multipurpose grease to the oil seal lip.

59. INSTALL OIL PUMP ASSY
a. Install 2 new O-rings onto the 2 locations as shown in the illustration.
b. Remove any old packing material from the contact surface.
c. Apply seal packing to the oil pump assembly, cylinder head and cylinder block as shown in the illustration.
Seal packing: Water pump part: part No. 08826-00100 or equivalent
Other part: part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pump within 3 minutes of applying the seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installation.
^ Do not start the engine for at least 2 hours after installation.

d. Align the keyway of the oil pump drive rotor with the rectangular portion of the crankshaft, and slide the oil pump into place.

e. Install the oil pump assembly with the 15 bolts and nut. Uniformly tighten the bolts and nut in several steps.
Torque:
Bolt A 24 Nm (245 kgf-cm, 18 ft. lbs.)
Bolt B 11 Nm (112 kgf-cm, 8.1 ft. lbs.)
Bolt C 11 Nm (112 kgf-cm, 8.1 ft. lbs.)
Nut D 24 Nm (245 kgf-cm, 18 ft. lbs.)
Bolt E 24 Nm (245 kgf-cm, 18 ft. lbs.)

NOTICE:
^ Pay attention not to disturb the seal packing.
^ After installing the oil pump assembly, the mounting bracket and water pump must be installed within 15 minutes.

HINT: Each bolt length is as follows.
A 30 mm (1.18 inch)
B 35 mm (1.38 inch)
C 20 mm (0.79 inch)
E 20 and 14 mm (0.79 and 0.55 inch) double ended bolt

60. INSTALL WATER PUMP ASSY
a. Install the water pump and a new gasket with the 3 bolts and 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8.1 ft. lbs.)

61. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket RH with the 4 bolts.
Torque: 55 Nm (561 kgf-cm, 41 ft. lbs.)

62. INSTALL WATER PUMP PULLEY
a. Using SST, install the pump pulley with the 3 bolts.
SST 09960-10010 (09962-01000, 09963-00600)
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)

63. INSTALL CRANKSHAFT DAMPER SUB-ASSY
a. Align the hole of the crankshaft damper with the pin position and install the crankshaft damper.
b. Using SST, install the pulley bolt.
SST 09330-00021, 09213-58012 (91111-50845)
Torque: 128 Nm (1,305 kgf-cm, 95 ft. lbs.)
64. INSPECT VALVE CLEARANCE

HINT: Inspect and adjust the valve clearance when the engine is cold.

a. Set the No. 1 cylinder to the TDC/compression.
1. Turn the crankshaft damper until its timing notch and the timing mark "O" of the chain cover are aligned.
2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward as shown in the illustration.

HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

b. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.
Valve clearance (Cold):
Intake 0.15 to 0.25 mm (0.006 to 0.010 inch)
Exhaust 0.25 to 0.35 mm (0.010 to 0.014 inch)
2. Record any out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
c. Turn the crankshaft 1 complete revolution until its timing notch and the timing mark "O" of the chain cover are aligned.

d. Check the valves indicated in the illustration.
1. Using a feeler gauge, measure the clearance between the valve lifter and the camshaft.
Valve clearance (Cold):
Intake 0.15 to 0.25 mm (0.006 to 0.010 inch)
Exhaust 0.25 to 0.35 mm (0.010 to 0.014 inch)
2. Record any out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.

65. ADJUST VALVE CLEARANCE

NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft damper counterclockwise 40° from the TDC and align its timing notch with timing mark of the chain cover to prevent the pistons from coming into contact with the valves.

a. Set the No. 1 cylinder to the TDC/compression.
1. Turn the crankshaft damper until its timing notch and the timing mark "0" of the chain cover are aligned.
2. Check that both timing marks on the camshaft timing sprocket and camshaft timing gear are facing upward as shown in the illustration.

HINT: If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

b. Put paint marks on the timing chain in place where the timing marks of the camshaft timing sprocket and camshaft timing gear are located.

c. Using an 8 mm hexagon wrench, remove the screw plug.

d. Insert a screwdriver into service hole of the chain tensioner to hold the stopper plate of the chain tensioner at upward position.
e. Using a wrench, rotate the camshaft No. 2 clockwise to push in the plunger of the chain tensioner.
f. Remove the screwdriver from the service hole, then align the hole of the stopper plate with the service hole and insert a 2 to 3 mm (0.08 to 0.12 inch) diameter bar into the holes to hold the stopper plate.

HINT:
^ Fix the stopper plate using the bar while rotating the cam shaft right and left slightly.
^ Hold the bar with tape so that the bar does not come off.

g. Hold the camshaft with a wrench on the hexagonal lobe, and remove the bolt.
SST 09023-38400

h. Using several steps, uniformly loosen and remove the 11 bearing cap bolts in the sequence shown in the illustration, then remove the 5 bearing caps.

NOTICE: Loosen each bolt uniformly keeping the camshaft level.

i. Remove the fringe bolt with the No. 2 camshaft lifted up, then detach the No. 2 camshaft and camshaft timing sprocket.

j. Using several steps, uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration, then remove the 4 bearing caps.

NOTICE: Loosen each bolt uniformly keeping the camshaft level.

k. Hold the timing chain by hand, and remove the camshaft and camshaft timing gear assembly.

l. Tie the timing chain with a string as shown in the illustration.

NOTICE: Be careful not to drop anything inside the timing chain cover.

m. Remove the valve lifters.
n. Using a micrometer, measure the thickness of the removed lifter.

o. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.
A Thickness of new lifter
B Thickness of used lifter
C Measured valve clearance
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.008 inch))
Exhaust A = B + (C - 0.30 mm (0.012 inch))

p. Select a new lifter with a thickness as close to the calculated value as possible.

HINT:
^ Lifters are available in 35 sizes in increments of 0.020 mm (0.0008 inch), from 5.060 mm (0.1992 inch) to 5.740 mm (0.2260 inch)
^ Refer to the New Lifter Thickness table on the next 2 pages.

Valve Lifter Selection Chart (Intake)

Valve Lifter Selection Chart (Exhaust)

q. Reinstall the valve lifters.
r. Apply a light coat of engine oil to the camshaft journals.

s. Install the timing chain onto the camshaft timing gear with the painted link and timing marks are aligned as shown in the illustration.

t. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9.4 ft. lbs.)

NOTICE: Tighten each bolt uniformly keeping the camshaft level.

u. Hold the timing chain, and align the timing mark on the camshaft timing sprocket with the painted link on the timing chain.

v. Align the alignment pin hole on the camshaft timing sprocket with the alignment pin of the camshaft, and install the sprocket to the camshaft.
w. Temporarily install the timing sprocket bolt.

x. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9.4 ft. lbs.)

NOTICE: Tighten each bolt uniformly keeping the camshaft level.

y. Install the bearing cap No. 1.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)

z. Hold the camshaft with a wrench on the hexagonal lobe, and install the bolt.
SST 09023-38400
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
aa. Remove the bar from the timing chain tensioner.

ab. Turn the crankshaft damper until its timing notch and the timing mark "0" of the chain cover are aligned.
ac. Check that all the pairs of the matchmarks are aligned.

ad. Apply the seal packing 2 or 3 threads to the screw plug end.
Seal packing: Part No. 08833-00070 or equivalent
ae. Using an 8 mm hexagon wrench, install the screw plug.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)

66. INSTALL FUEL INJECTOR ASSY
a. Install new insulators onto each fuel injector.
b. Apply a light coat of grease or gasoline to a new O-ring and install it onto each fuel injector.
c. Apply a light coat of grease or gasoline to the place where a delivery pipe comes into contact with the O-ring.

d. While turning the injector clockwise and counterclockwise, push it to the delivery pipe.

NOTICE:
^ Be careful not to twist the O-ring.
^ After installing the fuel injectors, check that they turn smoothly. If not, replace it with a new O-ring.

67. INSTALL FUEL DELIVERY PIPE SUB-ASSY
a. Install the 2 spacers onto the cylinder head.

b. Install the fuel delivery pipe and 4 fuel injectors together.
Torque:
Bolt A 19 Nm (194 kgf-cm, 14 ft. lbs.)
Bolt B 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE:
^ Be careful not to drop the fuel injectors when installing the fuel delivery pipe.
^ Check that the fuel injectors rotate smoothly after installing the fuel delivery pipe.

68. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
a. Apply a light coat of engine oil to a new O-ring, and install it onto the camshaft timing oil control valve.
b. Install the camshaft timing oil control valve with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

NOTICE: Be careful not to twist the O-ring.

69. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Install the gasket onto the cylinder head cover.

b. Apply the seal packing to the 2 locations as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head cover within 3 minutes of applying the seal packing.
^ Do not start the engine for at least 2 hours after installation.

c. Install the cylinder head cover with the 9 bolt, 2 seal washers and 2 nuts.
d. Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 10 Nm (102 kgf-cm, 7.4 ft. lbs.)

70. INSTALL VENTILATION VALVE SUB-ASSY
a. Install the ventilation valve onto the cylinder head cover.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
71. INSTALL OIL LEVEL GAGE GUIDE
a. Apply engine oil to a new O-ring.
b. Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
72. INSTALL CRANKSHAFT POSITION SENSOR
a. Apply a light coat of engine oil to the O-ring on the crankshaft position sensor.

NOTICE: If the O-ring is damaged, replace the crankshaft position sensor.

b. Install the crankshaft position sensor with the bolt.
Torque: 7.5 Nm (76 kgf-cm. 66 inch lbs.)

73. INSTALL THERMOSTAT
a. Install a new gasket onto the thermostat.
b. Install the thermostat with the jiggle valve facing upward.

HINT: The jiggle valve may be set within 10° at either side as shown in the illustration.

c. Install the water inlet with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
74. INSTALL SPARK PLUG
a. Using a spark plug wrench, install the spark plugs.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)