Part 3

OVERHAUL





60. INSTALL VALVE ROCKER SHAFT SUB-ASSY NO.1
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.1.
Torque: 9.0 Nm (92 kgf-cm 80 inch lbs.)
61. INSTALL OIL CONTROL VALVE FILTER





a. Confirm that the filter is clear.
b. Place a new gasket on the bolt and install the filter. (Front side)
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)





c. Install the oil control valve filter from the cylinder head. (Rear side)
62. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 Nm (92 kgf-cm 80 inch lbs.)
63. INSTALL CAM TIMING CONTROL VALVE HOUSING
a. Install the cam timing control valve housing with a new gasket.
Torque: 9.0 Nm (92 kgf-cm 80 inch lbs.)





64. INSTALL CAMSHAFT TIMING GEAR ASSY
a. Put the camshaft timing gear assembly and the camshaft together with the straight pin off the key groove.
b. Turn the camshaft timing gear assembly to the left direction (as shown in the illustration) with pushing it lightly against the camshaft. Push further at the position where the pin gets into the groove.

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

c. Check that there is no clearance between the gear's fringe and the camshaft.
d. Tighten the fringe bolt with the camshafting gear fixed.
Torque: 54 Nm (551 kgf-cm 40 ft. lbs.)
e. Check that the camshaft timing gear assembly can move to the retard angle side (the right angle), and is locked at the most retarded position.





65. INSTALL CAMSHAFT TIMING GEAR OR SPROCKET
a. Grip the camshaft with a vice, and install the camshaft timing gear.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

NOTICE: Be careful not to damage the camshaft.

66. INSTALL CAMSHAFT
a. Apply light coat of engine oil on the camshaft journals.





b. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.





c. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





67. INSTALL OIL PUMP ASSY
a. Place a new gasket on the cylinder block.
b. Engage the spline teeth of the oil pump drive rotor with the large teeth of the crankshaft, and side the oil pump.
c. Install the oil pump with the 5 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
68. INSTALL CHAIN SUB-ASSY
a. Set No. 1 cylinder to TDC/compression.





1 Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.





2 Turn the crankshaft and set the set key on the crankshaft upward.





b. Install the timing chain on the crankshaft timing sprocket with the mark link (yellow color link) aligned with the timing mark on the crankshaft timing sprocket.

HINT: A yellow color link and 2 orange color links are on the chain.





c. Using a SST, install the sprocket.
SST 09223-22010





d. Install the timing chain on the camshaft timing sprockets with the mark link (orange color links) aligned with the timing marks on the camshaft timing sprockets.
69. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the 2 bolts and the chain vibration damper No.l.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
70. INSTALL CHAIN TENSIONER SLIPPER
a. Install the bolt and the chain tensioner slipper.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)





71. INSTALL CRANKSHAFT POSITION SENSOR PLATE
a. Install the plate with the "F" mark facing forward.
72. INSTALL TIMING GEAR COVER OIL SEAL
a. Apply MP grease to the oil seal lip.





b. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010

NOTICE: Keep the lip off foreign materials.

73. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY





a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the timing chain cover, cylinder head and cylinder block.
^ Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces,
b. Apply seal packing to the timing chain cover as shown in the illustration.
Seal packing:
Part No. 08826-00100 or equivalent
Install a nozzle that has been cut to a 1.5 mm opening.

HINT: Avoid applying an excessive amount to the surface.

^ Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and rein stall cap.
c. Install the 2 gaskets to the timing chain cover an shown in the illustration.





d. Apply seal packing to 4 locations an shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
^ Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 inch) opening.

HINT: Avoid applying an excessive amount to the surface.

^ Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and rein stall cap.

NOTICE: Do not put into engine oil within 2 hours after installing.





e. Install the timing chain cover, with the 13 bolts.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) (M8)
11 Nm (112 kgf-cm, 8 ft. lbs.) (M6)
f. Install the stud bolt.
74. INSTALL CHAIN TENSIONER ASSY NO.1





a. Check the O-ring is clean, and set the hook as shown in the illustration.





b. Apply engine oil to the chain tensioner and install it.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

NOTICE: When installing the tensioner, set the hook again if the hook releases the plunger.

75. INSTALL CRANKSHAFT PULLEY
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 09213-70011 (09213-70020), 09330-00021
Torque: 118 Nm (1,203 kgf-cm, 87 ft. lbs.)





c. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin from the hook.





d. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.





76. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
77. INSTALL WATER PUMP ASSY
a. Place a new O-ring on the timing chain cover.





b. Install the water pump with the 6 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





HINT: Each bolt length is indicated in the illustration.

78. INSTALL WATER PUMP PULLEY





a. Using SST the water pump pulley.
SST 09960-10010 (09962-01000, 09963-00600)
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
79. INSPECT VALVE CLEARANCE





a. Set No. 1 cylinder to TDC/compression.
1 Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
2 Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.

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





b. Check only the valves indicated.
1 Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
2 Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





Valve clearance (Cold)

c. Turn the crankshaft 1 revolution (360°) and set No. 4 cylinder to TDC/compression.





d. Check only the valves indicated.
1 Using a feeler gauge, measure the clearance between the valve rocker arm and camshaft.
2 Record the out-of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim.





Valve clearance (Cold)

80. ADJUST VALVE CLEARANCE





a. Set the SST.

NOTICE: Remove the spark plug and take off the compression.





1 Insert SST into the plug tube.
SST 09248-77010 (09248-07010)

NOTICE:
^ SST cannot be inserted unless the set screw is loosened.
^ Make sure that the camshaft is in the same condition as step (1).





2 Operate the lever so that SST's seat surface comes to contact with the valve retainer and lock them with the set screw.

NOTICE:
^ Clearance between the valve retainer and SST's seat surface is not allowed.
^ Care should be taken not to make clearance when inserting SST, since a presence of clearance may unlock the keeper.

3 lock the set screw on the plug tube side of SST.





4 Rotate the crankshaft so that the camshaft is positioned as shown in the illustration.

NOTICE:
^ Pay attention to the direction of the rotation to prevent the nose of the camshaft from interfering with the SST's shaft.
^ Do not rotate the crankshaft excessively.

b. Remove the adjusting shim.





1 Lift the rocker arm to make a room and remove the adjusting shim using SST
SST 09248-77010 (09248-07010)

NOTICE: Do not remove SST in the condition that adjusting shim is removed.

HINT:
^ Setting SST from the right makes the removal easy.
^ If there is not enough room, reset SST.

2 Determine the size of the replaced shim according to there Formula or Charts:





^ Using a dial indicator, measure the thickness of the removed shim.





^ Calculate the thickness of a new shim so that the valve clearance comes within the specified value.
Intake: A = B + (C - 0.13 mm (0.005 inch)) x 1.5
Exhaust: A = B + (C - 0.27 mm (0.011 inch)) x 1.5

HINT: Shim are available in 41 sizes in increments of 0.020 mm (0.0008 inch), from 2.000 mm (0.0787 inch) to 2.800 mm (0.1102 inch).





c. Lift the rocker arm to make a room and use SST, install the adjusting shim.

HINT:
^ Setting SST from the right makes the removal easy.
^ To remove SST from the adjusting shim, it is advisable to push down the rocker arm.





d. Turn the crankshaft so that the related rocker arm, where the valve clearance is adjusted, is fully pushed down.

NOTICE:
^ Pay attention to the direction of the rotation to prevent the nose of the camshaft from interfering with the SST's shaft.
^ Do not rotate the crankshaft excessively.

e. After loosening the 2 set screws of SST, remove SST itself.
SST 09248-77010 (09248-07010)
81. INSTALL CYLINDER HEAD COVER SUB-ASSY
a. Remove any old packing (FIPG) material.
b. Install the new cylinder head cover gasket to the cylinder head cover.





c. Install the new spark plug tube gasket and a new O-ring to the cylinder head cover.





d. Apply seal packing to 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 after applying seal packing.
^ Do not put into engine oil 2 hours after installing.





e. Install the cylinder head cover and cable bracket with the 9 bolts.
Uniformly tighten the bolts, in the several passes,in the sequence shown.
Torque: 10 Nm (102 kgf-cm, 89 inch lbs.)
82. INSTALL SPARK PLUG
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
83. INSTALL VENTILATION VALVE SUB-ASSY
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)