Part 2
OVERHAUL32. REMOVE OIL FILTER UNION
a. Using a 12 mm socket hexagon wrench,remove the oil filter union.
33. REMOVE ENGINE REAR OIL SEAL
a. Using a knife, cut off the oil seal lip.
b. Using a screwdriver with its tip taped, pry out the oil seal.
NOTICE: After the removal, check if the crankshaft is not damaged. If there is, mend it with a sandpaper (# 400).
34. REMOVE OIL PAN DRAIN PLUG AND GASKET
35. REMOVE OIL PAN SUB-ASSY
a. Remove the 12 bolts and 4 nuts.
b. Insert the blade of SST between the bearing cap sub-assembly and oil pan, and cut off applied sealer and remove the oil pan.
SST 09032-00100
NOTICE: Be careful not to damage the oil pan contact surface of the bearing cap sub-assembly and the oil pan flange.
36. REMOVE OIL STRAINER SUB-ASSY AND GASKET
37. REMOVE OIL PAN BAFFLE PLATE
38. INSPECT CHAIN TENSIONER ASSY NO.1
a. Check that the plunger moves smoothly when the ratchet pawl is raised with your finger.
b. Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger.
39. INSPECT CHAIN SUB-ASSY
a. Using a spring scale, pull the timing chain with 140 N (4.3 kgf, 315 lbs.) and measure the length of it.
Maximum chain elongation: 122.6 mm (4.827 inch)
b. It the elongation is greater than maximum, replace the chain.
HINT: Make the same measurements pulling at 3 or more places selected at random.
40. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing sprocket.
b. Using a vernier calipers, measure the timing sprocket diameter with the chain.
Minimum sprocket diameter (w/chain): 97.3 mm (3.831 inch)
NOTICE: Vernier calipers must contact the chain rollers for measuring.
41. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a. Wrap the chain around the timing sprocket.
b. Using a vernier calipers, measure the timing sprocket diameter with the chain.
NOTICE: Vernier calipers must contact the chain rollers for the measuring.
Minimum sprocket diameter (w/chain): 51.6 mm (2.031 inch)
If the diameter is less than minimum, replace the chain and sprockets.
42. INSPECT CHAIN TENSIONER SLIPPER
a. Measure the chain tensioner slipper wears.
Maximum wear: 1.0 mm (0.039 inch)
b. If the wear is greater than maximum, replace the slipper.
43. INSPECT CHAIN VIBRATION DAMPER NO.1
a. Measure the vibration damper wears.
Maximum wear: 1.0 mm (0.039 inch)
b. If the wear is greater than maximum, replace the damper.
44. INSPECT CYLINDER HEAD BOLT
a. Using vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length: 146.8 - 148.2 mm (5.780 - 5.835 inch)
Maximum bolt length: 148.5 mm (5.846 inch)
b. If the length surpasses the maximum, replace the bolt.
45. INSPECT VALVE ROCKER SHAFT SUB-ASSY NO.1
a. Using a micrometer, measure the rocker No. 1 shaft diameter.
Standard: 15.965 - 15.985 mm (0.6285 - 0.6293 inch)
46. INSPECT VALVE ROCKER SHAFT SUB-ASSY NO.2
a. Using a micrometer, measure the rocker No.2 shaft diameter.
Standard: 15.965 - 15.985 mm (0.6285 - 0.6293 inch)
47. INSPECT VALVE ROCKER ARM
a. Cover oil paths of the rocker arm shaft except 2 paths with vinyl type.
b. Align the oil path of the rocker arm shaft to the oil path of the rocker arm.
c. Check that the posfon inside of the rocker arm moves when air pressure 150 kPa (1.5 kgf/cm2) is put to the oil paths.
48. INSPECT CAMSHAFT
a. Inspect camshaft for runout.
1 Place the camshaft on V-blocks.
2 Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.03 mm (0.0012 inch)
If the circle runout is greater than maximum, replace the camshaft.
b. Inspect cam lobes.
1 Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
No.1: 40.607 - 40.707 mm (1.5987 - 1.6026 inch)
No.2: 38.769 - 38.869 mm (1.5236 - 1.5303 inch)
Minimum cam lobe height:
No.11: 40.45 mm (1.5925 inch)
No.2: 38.61 mm (1.5201 inch)
2 If the cam lobe height is less than minimum, replace the camshaft.
c. Inspect camshaft journals.
1 Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 34.449 - 34.465 mm (1.3563 - 1.3569 inch)
Others journal diameter: 27.949 - 27.965 mm (1.1004 - 1.1010 inch)
2 If the journal diameter is not as specified, check the oil clearance.
49. INSPECT NO.2 CAMSHAFT
a. Inspect cam lobes.
1 Using a micrometer, measure the cam lobe height.
Standard cam lobe height:
No.11: 40.019 - 40.119 mm (1.5756 - 1.5795 inch)
No.2: 38.863 - 38.963 mm (1.5300 - 1.5340 inch)
Minimum cam lobe height:
No.1: 39.86 mm (1.5693 inch)
No.2: 38.71 mm (1.5240 inch)
2 If the cam lobe height is less than minimum, replace the camshaft.
b. Inspect camshaft journals.
1 Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 34.449 - 34.465 mm (1.3563 - 1.3569 inch)
Others journal diameter: 27.949 - 27.965 mm (1.1004 - 1.1010 inch)
2 If the journal diameter is not as specified, check the oil clearance.
50. INSTALL OIL PAN BAFFLE PLATE
a. Install the oil pan baffle plate with the 2 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
51. INSTALL OIL STRAINER SUB-ASSY
a. Install a new gasket and the oil strainer with the 2 nuts and a bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
52. INSTALL OIL PAN SUB-ASSY
a. Remove any old packing material from the contact surface.
b. Apply seal packing in the shape of bead (Diameter 3.5 mm - 4.5 mm (0.1379 - 0.177 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not put into engine oil within 2 hours after installing.
c. Install the oil pan with the 12 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
53. INSTALL OIL PAN DRAIN PLUG
a. Place a new gasket on the drain plug and install the oil pan drain plug.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)
54. INSTALL ENGINE REAR OIL SEAL
a. Apply MP grease to a new oil seal lip.
NOTICE: Keep the lip off 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 09223-15030, 09950-70010 (09951-07100)
NOTICE: Wipe off extra grease on the crankshaft.
55. INSTALL OIL FILTER UNION
a. Using a 12 mm socket hexagon wrench, install the oil filter union.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
56. INSTALL OIL FILTER SUB-ASSY
a. Check and clean the oil filter installation surface.
b. Apply clean engine oil to the gasket of a new oil filter.
c. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat.
d. Using SST, tighten it an additional 3/4 turn.
SST 09228-06501
57. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE:
^ Pay attention to the installation direction.
^ Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
b. Apply seal packing to the cylinder head gasket as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
HINT: avoid applying an excessive amount to the surface.
^ Parts must be assembled with in 3 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
58. INSTALL CYLINDER HEAD SUB-ASSY
HINT: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts with plate washers, in several passes, in the sequence shown.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
c. Mark the front of the cylinder head bolt with paint.
d. Retighten the cylinder head bolts 180° in the numerical order shown.
e. Check that the point marked bolts are moved at 180° angle.
59. INSTALL VALVE ROCKER SHAFT SUB-ASSY NO.2
a. Put the valve rocker shaft through the cylinder head and the hole of the valve rocker arm, and check the direction of the groove.
b. Install a bolt to fix the rocker shaft No.2.
Torque: 9.0 Nm (92 kgf-cm 80 inch lbs.)