Part One

Valve Guide Replacement

Installation

1. Valve Guide





1. Take out the new guide(s) from the freezer, one at a time, as you need them.

2. Apply a thin coat of new engine oil to the outside of the new valve guide.

3. Install the guide from the camshaft side of the head; use the valve guide driver to drive the guide into the specified installed height (A) of the guide (B). If you have all eight guides to do, you may have to reheat the head.












4. Coat both the valve guide reamer, 5.5 mm and the valve guide with cutting oil.

5. Rotate the valve guide reamer clockwise the full length of the valve guide bore.

6. Continue to rotate the reamer clockwise while drawing it from the bore.

7. Thoroughly wash the guide in detergent and water to remove any cutting residue.

2. Valve Inspection

1. Measure the valve in these areas.


















3. Valve Stem To Guide Clearance Inspection

1. Subtract the O.D. of the valve stem, measured with a micrometer, from the I.D. of the valve guide measured with an inside micrometer or a ball gauge. Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest stem measurement should not exceed the service limit.











4. Valve Seat - Inspection

1. Inspect the valve seating, if necessary, renew the valve seat using a valve seat cutter.

5. Valve Seal





1. Install the new valve seals (A) using the 5.5 mm side of the stem seal driver (B).

NOTE: The exhaust valve seal (C) has a black spring (D), and the intake valve seal (E) has a white spring (F), they are not interchangeable.

6. Valve Spring





1. Install the valve spring and the spring retainer. Place the end of the valve spring with the closely wound coils toward the cylinder head.

2. Install the valve spring compressor attachment and the valve spring compressor.

3. Compress the spring and install the valve cotters.

4. Remove the valve spring compressor and the valve spring compressor attachment.





5. Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and the valve cotters. Tap the valve stem only along its axis so you do not bend the stem.

NOTE: Be sure to raise the head off the work bench so the valve is not possibly damaged.

7. Camshaft





1. Install the camshaft (A).

2. Install the camshaft thrust cover (B) with a new O-ring (C).

8. Camshaft Sprocket





1. Install the camshaft sprocket.

2. Apply new engine oil to the threads of the camshaft sprocket mounting bolt.

3. Install the camshaft sprocket mounting bolt.

4. Hold the camshaft with a 27 mm open-end wrench.

5. Tighten the camshaft sprocket mounting bolt.








9. Rocker Arm Assembly





1. If the rocker arm assembly is disassembled, reassemble the rocker arm assembly.

2. Install the oil control orifice (A) with a new O-ring (B).

3. Install the rocker arm assembly (C).

4. Install the lost motion assembles (D) and the lost motion holder (E).

NOTE: Apply new engine oil to the lost motion assembly.





5. Tighten each bolts two turns at a time in sequence.








10. Set The Crankshaft To Top Dead Center





1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.

11. Cylinder Head Assembly





1. Clean the cylinder head and the engine block surface.

2. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.

3. Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder head gasket.

4. Install the cylinder head on the engine block.





5. Measure the diameter of each cylinder head bolt at point A and point B.

6. If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.





7. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.

8. Torque the cylinder head bolts in sequence to 40 Nm (4.1 kgfm, 30 lbfft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.





9. After torquing, tighten all cylinder head bolts in two steps (90 ° per step using the sequence shown in step 8). If you are using a new cylinder head bolt, tighten the bolt an extra 60 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 5 of the procedure. Do not loosen it back to the specified angle.

12. Set The No.1 Piston at Top Dead Center (Without Cam Chain Case/Oil Pump)





1. Set the camshaft to TDC. The "UP" mark (A) on the camshaft sprocket should be at the top, and the TDC grooves (B) on the camshaft sprocket should line up with the top edge of the head.

13. Cam Chain





1. Install the cam chain on the crankshaft sprocket with the colored piece (A) aligned with the mark (B) on the crankshaft sprocket.





2. Install the cam chain on the camshaft sprocket with the colored link plate (A) aligned with the mark (B) on the camshaft sprocket.





3. Install the cam chain guide (A) and the cam chain tensioner arm (B).

14. Cam Chain Auto-Tensioner





1. Compress the cam chain auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.0 mm (1/32 in) diameter pin back into the holes (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will be damaged.





2. Install the cam chain auto-tensioner.





3. Remove the pin from the cam chain auto-tensioner.

15. Engine Oil Pump Assembly





1. Check the oil pump oil seal for damage. If the oil seal is damaged, replace the oil seal.

2. Remove all of the old liquid gasket from the oil pump mating surfaces, the bolts, and the bolt holes.

3. Clean and dry the oil pump mating surfaces.

4. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A), (B), and (C).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





5. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the oil pan mating surface of the oil pump, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.









6. Set the edge of the oil pump (A) on the edge of the oil pan (B) with new O-rings (C).

7. Install the oil pump on the engine block (D).

8. Loosely install the dowel bolts (E), then tighten the 8mmbolts (F), the 6 mm bolts (G) and the dowel bolts.

9. Wipe off the excess liquid gasket on the oil pan and oil pump mating surface.

NOTE:
* When installing the oil pump, do not slide the bottom surface onto the oil pan mounting surface.
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine within 3 hours after installing the oil pump.

16. Mounting Bracket, Engine Side





1. Install the new side engine mount mounting bolts (A) and the side engine mount bracket (B) using a nut and a new bolt, then loosely install the new side engine mount bracket mounting bolts and nut (C).

2. Install the ground cable (D).

17. Engine Jack Support (State Of A Low Vehicle)

1. Remove the jack and the wood block.

18. Transmission Mount Bracket Mounting Bolt - Loosen

M/T





A/T





1. Loosen the transmission mount bracket mounting bolt and nuts (A).

19. Lower Torque Rod - Loosen





1. Loosen the lower torque rod mounting bolt (A).

20. Side Engine Mount - Tighten





1. Tighten the side engine mount bracket mounting bolt and nut.

21. Transmission Mount Bracket Mounting Bolt - Tighten

1. Tighten the transmission mount bracket mounting bolt and nuts.

M/T





A/T





22. Lower Torque Rod Mounting Bolt - Tighten





1. Tighten the lower torque rod mounting bolt.

23. Crankshaft Pulley





1. Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D).

2. Lubricate with new engine oil as shown.





3. Install the crankshaft pulley (A) onto the crankshaft (B) by aligning the flat sides (C) of the pulley with the flat sides (D) of the inner oil pump gear.









When a new crankshaft or a new pulley bolt is installed

4. Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), torque the bolt to 180 Nm (18.4 kgfm, 133 lbfft) with a torque wrench and a socket (C), then remove the bolt.

5. Torque the bolt to 50 Nm (5.1 kgfm, 37 lbfft) with a torque wrench and a socket.

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

6. Tighten the bolt an additional 82 °.









When the crankshaft or the pulley bolt is reused

7. Hold the pulley with the holder handle (A) and crankshaft pulley holder (B), then torque the bolt to 70 Nm (7.1 kgfm, 52 lbfft) with a torque wrench and a socket (C).

NOTE: Tighten the crankshaft pulley bolt. Do not use an impact wrench.

8. Tighten the bolt an additional 90 °.