Part 3

OVERHAUL
90. INSTALL TIMING BELT NO.3 COVER [11322C / 98-9]
a. Visually check the crack and break in the gasket of the timing belt cover.

NOTICE: If It Is judged that water is entering at the visual check, repair It with seal packing when the crack length is within 2 - 3 cm (0.79 - 1.18 inch). Change the gasket when the crack length is 3 - 4 cm (1.18 - 1.57 inch) and more.





b. In case of repairing the timing belt cover gasket, follow the procedure.
1. Repair the crack and break portion applying the seal packing.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: In case of applying the seal packing, apply it as wide and high as the gasket.

c. In case of replacing the timing belt cover gasket, follow the procedure.
1. Using a screwdriver and gasket scraper, remove the remained gasket.

NOTICE: Be careful not to damage the timing belt cover.





2. Remove the backing paper from a new gasket, and affix the gasket along the groove of the timing belt cover as shown in the illustration.

NOTICE:
- Affix the gasket in the center of the groove.
- At the corner, affix it without making the thickness of the gasket less.





HINT:

3. In case of having clearance at the joining portion of the gasket, apply the seal packing.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE: In case of applying the seal packing, apply it as wide and high as the gasket.

d. Install the timing belt cover with the 6 bolts.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)
91. INSTALL CAMSHAFT TIMING PULLEY [13523P / 98-14]





a. Pay attention to the direction of the belt guide, install the camshaft timing pulley and tighten the bolt temporally.

HINT:
- Face the belt guide of the RH timing pulley toward the engine front.
- Face the belt guide of the LH timing pulley toward the engine rear.





b. Using SST, tighten the RH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)





c. Using SST, tighten the LH pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 125 Nm (1,275 kgf-cm, 92 ft. lbs.)
92. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 [13502 / 98-14]
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
93. INSTALL TIMING BELT IDLER SUB-ASSY NO.1 [13505 / 98-14]
a. Using a 10 mm socket hexagon wrench, install the plate washer and idler pulley.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
94. INSTALL TIMING BELT [13568 / 98-14]
a. Remove any oil or water on the pulleys, and keep them clean.

NOTICE:
- If adherence of water and/or oil to the timing belt Is found, restore the leakage and install a new timing belt.
- Wipe only the pulleys; do not use any cleansing agent.

b. Inspect the idler pulleys.
1. Check that the idler pulley turns smoothly.
2. Visually check the seal portion of the idler pulley for grease leakage.
c. Inspect the water pump.
1. Turn the pulley, and check that water pump bearing moves smoothly and quietly.
2. Visually check the drain hole for coolant leakage.
d. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.





e. Turn the crankshaft, and align the timing marks of the crankshaft timing pulley and oil pump body.





f. Using SST, turn the camshaft pulley, align the timing marks of the timing pulley and No. 3 timing belt cover.
SST 09960-10010 (09962-01000, 09963-01000)





g. Face the front mark on the timing belt forward.
h. Align the installation mark on the timing belt with the timing mark of the crankshaft timing pulley.
i. Align the installation marks on the timing belt with the timing marks of the camshaft timing pulleys.

HINT: The installation marks are placed when the timing belt is re- moved, or printed originally are used as matchmarks.








j. Install the timing belt in this order.
95. INSTALL CHAIN TENSIONER ASSY NO.1 [13540 / 98-14]
a. Set the timing belt tensioner upright on the press.





b. Slowly press in the push rod.

NOTICE: Do not apply pressure more than 9.8 kN (1,000 kgf, 2,205 lbs) to the rod.

c. Align the holes of the push rod and housing, pass a 1.5 mm hexagon wrench through the holes to keep the setting position of the push rod.
d. Release the press.
e. Temporarily install the tensioner with the 2 bolts. Alternately tighten the 2 bolts.
Torque: 27 Nm (280 kgf-cm, 20 ft. lbs.)

NOTICE: Be sure to tighten the bolts equally. Installing the tensioner slantingly may cause failure of its proper operation.

f. Remove the 1.5 mm hexagon wrench from the tensioner.





g. Slowly turn the crankshaft 2 revolutions, and align the timing marks of the crankshaft timing pulley with oil pump body.

NOTICE: Always turn the crankshaft clockwise.





h. Check the timing marks of the RH and LH timing pulleys with the timing marks of the No. 3 timing belt cover as shown in the illustration.
If the marks do not align, remove the timing belt and reinstall it.
i. Remove the crankshaft pulley bolt.





96. INSTALL TIMING BELT GUIDE NO.2 [13567 / 98-13]
a. Install the timing belt guide, facing the cup side toward the engine front.
97. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET [12315A / 98-10]
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
98. INSTALL TIMING BELT NO.2 COVER [11322B / 98-9]
a. Visually check the crack and break in the gasket of the timing belt cover.

HINT: If it is judged that water is entering at the visual check, replace the timing belt cover.

b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)
99. INSTALL TIMING BELT NO.1 COVER [11322A / 98-9]
a. Visually check the crack and break in the gasket of the timing belt cover.

HINT: If it is judged that water is entering at the visual check, replace the timing belt cover.

b. Install the timing belt cover.
Torque: 8.5 Nm (87 kgf-cm, 76 inch lbs.)





100. INSTALL CRANKSHAFT PULLEY [13471/ 98-13]
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213-54015 (91651-60855), 09330-00021
Torque: 215 Nm (2,192 kgf-cm, 159 ft. lbs.)
101. INSTALL CRANK POSITION SENSOR NO.1 [11101W / 98-5]
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
102. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY [11101J / 98-5]
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
103. INSTALL ENGINE HANGER NO.2 [12282D / 98-5]
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
104. INSPECT VALVE CLEARANCE





a. Turn the crankshaft pulley, and align its groove with the timing mark "0" of the No. 1 timing belt cover.
b. Check that the valve lifters on the No. 1 (IN and EX) are loose.
If not, turn the crankshaft 1 revolution (360°) and align the mark.





c. Check only those 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 - 0.25 mm (0.006 - 0.010 inch)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





d. Turn the crankshaft 2/3 of a revolution (240°), and check only 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 - 0.25 mm (0.006 - 0.010 inch)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





e. Turn the crankshaft 2/3 of a revolution (240°), and check only 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 - 0.25 mm (0.006 - 0.010 inch)
Exhaust 0.25 - 0.35 mm (0.010 - 0.014 inch)
2. Record out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.
105. ADJUST VALVE CLEARANCE





a. Turn the camshaft so that the cam lobe for the valve to be adjusted faces up.
b. Turn the valve lifter with a screwdriver so that the notches are perpendicular to the camshaft.





c. Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter. Remove SST (A).
SST 09248-55040 (09248-05410, 09248-05420)





HINT:
- Apply SST (B) at a slight angle on the side marked with "9", or "7", at the position shown in the illustration.
- When SST (B) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it gently from the intake side, at a slight angle.





d. Using a small screwdriver and magnetic finger, remove the adjusting shim.





e. Using a micrometer, measure the thickness of the removed shim.





f. Calculate the thickness of a new shim so the valve clearance comes within the specified value.
Specified value (Cold):
Intake A = B + (C - 0.20 mm (0.008 inch))
Exhaust A = B + (C - 0.30 mm (0.012 inch))
g. Select a new shim with a thickness as close as possible to the calculated values.

HINT: Shims are available in 17 sizes in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch).





h. Place a new adjusting shim on the valve lifter, with imprinted numbers facing down.
i. Press down the valve lifter with SST (A), and remove SST
SST 09248-55040 (09248-05410, 09248-05420)
j. Recheck the valve clearance.
106. INSTALL CYLINDER HEAD COVER SUB-ASSY [11201 / 98-5]
a. Install the gasket to the cylinder head cover.





b. Apply seal packing to the cylinder head 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 after applying seal packing.
- Do not start the engine within 2 hours after installing.

c. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts, in several passes.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
107. INSTALL CYLINDER HEAD COVER SUB-ASSY LH [11202 / 98-5]
a. Install the gasket to the cylinder head cover.





b. Apply seal packing to the cylinder head 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 after applying seal packing.
- Do not start the engine within 2 hours after installing.

c. Install the cylinder head cover with the 9 bolts. Uniformly tighten the bolts, in several passes.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
108. INSTALL SPARK PLUG [19100P / 98-34]
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)