Part 2
With A/T:
With M/T:
With A/T:
With M/T:
Except PZEV:
PARTIAL ENGINE ASSY
OVERHAUL
34. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
35. REMOVE OIL CONTROL VALVE FILTER
a) Using a 6 mm socket hexagon wrench, remove the plug and filter.
36. REMOVE W/HEAD TAPER SCREW PLUG NO.1
37. INSPECT BALANCE SHAFT THRUST CLEARANCE
a) Using a dial indicator, measure the thrust clearance while moving the balance shaft back and forth.
Specified thrust clearance: 0.050 to 0.090 mm (0.0020 to 0.0035 inch)
If the thrust clearance is greater than the maximum, replace the balance shaft housing and bearings. If necessary, replace the balance shaft.
38. INSPECT BALANCE SHAFT OIL CLEARANCE
a) Uniformly loosen and remove the 8 bolts in the sequence shown in the illustration.
NOTICE: Be careful not to damage the contact surfaces of the balance shaft housing and crankcase.
HINT: Keep the lower bearing and balance shaft housing together.
b) Lift out the No. 1 and No. 2 balance shafts.
HINT: Keep the upper bearing with the crankcase.
c) Clean each bearing and journal.
d) Check each bearing and journal for pitting and scratches. If a bearing or journal is damaged, replace the bearings. If necessary, replace the balance shaft.
e) Place the No. 1 and No. 2 balance shafts on the crankcase.
f) Lay a strip of Plastigage across each journal, and install the balance shaft housing.
g) Apply a light coat of engine oil on the threads and under the heads of the balance shaft housing bolts.
h) Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)
HINT: The balance shaft housing bolts are tightened in 2 progressive steps.
i) Mark the front side of each balance shaft housing bolt head with paint.
j) Retighten the bolts by 90° as shown in the illustration.
k) Check that the paint marks are now at a 90° angle to the front.
l) Remove the balance shaft housing, and measure the Plastigage at its widest point.
Specified oil clearance: 0.004 to 0.031 mm (0.0002 to 0.0012 inch)
If the clearance is greater than the maximum, replace the bearing. If necessary, replace the balance shaft.
m) Completely remove the plastigage after the inspection.
HINT: If replacing a bearing, replace it with one that has the same number as the stiffening crankcase. There are 3 sizes of standard bearings: 1, 2 and 3.
Balance shaft housing journal bore diameter
Balance shaft journal diameter: 22.985 to 23.000 mm (0.9049 to 0.9055 inch)
Standard bearing center wall thickness
n) Completely remove the Plastigage after the inspection.
39. REMOVE BALANCE SHAFT
40. REMOVE BALANCE SHAFT BEARING NO. 1
41. 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 the crankshaft for damage. If it is damaged, smooth the surface with 400-grit sandpaper.
42. REMOVE STIFFENING CRANKCASE ASSY
a) Uniformly loosen and remove the 11 bolts in the sequence shown in the illustration.
b) Using a screwdriver, remove the crankcase by prying between the crankcase and cylinder block.
NOTICE: Be careful not to damage the contact surfaces of the crank case and cylinder block.
c) Remove the O-ring from the cylinder block.
43. INSPECT OIL PUMP DRIVE SPROCKET
a) Wrap the chain around the drive sprocket.
b) Using a vernier caliper, measure the drive sprocket diameter with the chain.
NOTICE: The vernier caliper must contact the chain rollers for the measurement.
Minimum sprocket diameter (w/ chain): 48.2 mm (1.898 inch)
If the diameter is less than the minimum, replace the chain and sprocket.
44. INSPECT OIL PUMP DRIVEN SPROCKET
a) Wrap the chain around the driven sprocket.
b) Using a vernier caliper, measure the driven sprocket diameter with the chain.
NOTICE: The vernier caliper must contact the chain rollers for the measurement.
Minimum sprocket diameter (w/ chain): 48.2 mm (1.898 inch)
If the diameter is less than the minimum, replace the chain and drive shaft gear.
45. INSPECT CRANKSHAFT TIMING GEAR OR SPROCKET
a) Wrap the chain around the timing sprocket.
b) Using a vernier caliper, measure the timing sprocket diameter with the chain.
NOTICE: The vernier caliper must contact the chain rollers for the measurement.
Minimum sprocket diameter (w/ chain): 51.6 mm (2.031 inch)
If the diameter is less than the minimum, replace the chain and timing gear.
46. INSPECT CHAIN TENSIONER SLIPPER
a) Measure the tensioner slipper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the tensioner slipper.
47. INSPECT CHAIN VIBRATION DAMPER NO.1
a) Measure the vibration damper wear.
Maximum wear: 1.0 mm (0.039 inch)
If the wear is greater than the maximum, replace the vibration damper.
48. INSPECT CYLINDER HEAD SET BOLT
a) Using a vernier caliper, measure the length of the head bolts from the seat to the end.
Specified bolt length: 161.3 to 164.2 mm (6.350 to 6.465 inch)
If the length is greater than the maximum, replace the bolt.
49. INSPECT CHAIN TENSIONER ASSY NO.1
a) Check that the plunger moves smoothly when the ratchet pawl is raised.
b) Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed.
50. INSPECT CHAIN SUB-ASSY
a) Using a vernier caliper, measure the length of 15 links with the chain fully stretched.
Maximum chain elongation: 115.4 mm (4.543 inch)
If the elongation is greater than the maximum, replace the chain.
NOTICE: Make the same measurements pulling at 3 or more places selected at random. Average the measurements.
51. INSPECT CAMSHAFT TIMING GEAR OR SPROCKET
a) Wrap the chain around the timing sprocket.
b) Using a vernier caliper, measure the timing sprocket diameter with the chain.
Minimum sprocket diameter (w/chain): 97.3 mm (3.831 inch)
If the diameter is less than the minimum, replace the chain and timing gear.
NOTICE: The vernier caliper must contact the chain rollers for the measurement.
52. INSPECT CAMSHAFT
a) Check the 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 the maximum, replace the camshaft.
b) Using a micrometer, measure the cam lobe height.
Specified cam lobe height: 46.599 to 46.809 mm (1.8346 to 1.8429 inch)
If the cam lobe height is less than the minimum, replace the camshaft.
c) Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 inch)
Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 inch)
If the journal diameter is not as specified, check the oil clearance.
53. INSPECT NO.2 CAMSHAFT
a) Check the 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 the maximum, replace the camshaft.
b) Using a micrometer, measure the cam lobe height.
Specified cam lobe height: 45.599 to 46.809 mm (1.8346 to 1.8429 inch)
If the cam lobe height is less than the minimum, replace the camshaft.
c) Using a micrometer, measure the journal diameter.
No. 1 journal diameter: 35.971 to 35.985 mm (1.4162 to 1.4167 inch)
Other journal diameter: 22.959 to 22.975 mm (0.9039 to 0.9045 inch)
If the journal diameter is not as specified, check the oil clearance.
54. INSTALL BALANCE SHAFT BEARING NO. 1
a) Install the bearings in the crankcase and balance shaft housing.
b) Apply a light coat of engine oil on the bearings.
55. INSTALL BALANCE SHAFT NO. 1 AND NO. 2
a) Rotate the driven gear No. 1 of balance shaft No. 1 in the rotating direction until it hits the stopper.
b) Confirm that the matchmarks on driven gear No. 1 and No. 2 are matched.
c) Align the timing marks of the No. 1 and No. 2 balance shafts as shown in the illustration.
d) Place the No. 1 and No. 2 balance shafts on the crankcase.
e) Apply a light coat of engine oil under the heads of the balance shaft housing bolts.
f) Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 22 Nm (220 kgf-cm, 16 ft. lbs.)
HINT: The balance shaft housing bolts are tightened in 2 progressive steps.
g) Mark the front side of each balance shaft housing bolt head with paint.
h) Retighten the bolts by 90° as shown in the illustration.
i) Check that the painted marks are now at a 90° angle to the front.
56. INSTALL STIFFENING CRANKCASE ASSY
a) Apply seal packing in a continuous bead (diameter: 2.5 to 3 mm (0.098 to 0.118 inch)) to the places shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.
b) Place a new O-ring on the cylinder block, as shown in the illustration.
c) With the No. 1 crank pin of the crankshaft placed at 6 o'clock, install the No.1 and No.2 balance shafts and the adjusting hole as shown in the illustration.
d) Uniformly tighten the 11 bolts in the sequence shown in the illustration.
Torque: 33 Nm (332 kgf-cm, 24 ft. lbs.)
e) Confirm that the timing marks of the balance shafts are matched when the key groove is placed at 6 o'clock, as shown in the illustration.
57. INSTALL ENGINE REAR OIL SEAL
a) Apply MP grease to a new oil seal lip.
NOTICE: Keep the lip free from foreign materials.
b) Using SST and a hammer, evenly tap 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.
58. INSTALL W/HEAD TAPER SCREW PLUG NO.1
a) Apply adhesive to the threads of the plug and install it.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
59. INSTALL OIL CONTROL VALVE FILTER
a) Check that no foreign matter is on the mesh part of the filter.
b) Using a 6 mm socket hexagon wrench, install a new gasket and the oil control valve filter with the screw plug.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
60. INSTALL CYLINDER BLOCK WATER DRAIN COCK SUB-ASSY
a) Install the water drain cock within the range shown in the illustration.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
61. INSTALL CYLINDER HEAD GASKET
a) Place a new gasket on the cylinder block surface with the "Lot No." stamp facing upward.
NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installation direction.
^ To avoid damage to the gasket, place the cylinder head on the gasket carefully.
62. 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) Install the 10 bolts and plate washers to the cylinder head.
NOTICE: Do not drop the washers into the cylinder head.
c) Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)
d) Mark the front side of each cylinder head bolt with paint.
e) Retighten the cylinder head bolts by 90° in the sequence shown in the illustration.
f) Check that the painted marks are now at a 90° angle to the front.
63. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
64. INSTALL CAMSHAFT BEARING NO.2
65. INSTALL CAMSHAFT TIMING GEAR ASSY
a) Put the camshaft timing gear against the camshaft.
b) Turn the camshaft timing gear (in the direction shown in the illustration) while pushing it lightly against the camshaft. Push further at the position where the pin enters the groove.
NOTICE: Be sure not to turn the camshaft timing gear to the retarded angle side (to the right direction).
c) Check that there is no clearance between the gear's fringe and the camshaft.
d) Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
e) Check that the camshaft timing gear can move to the retarded angle side (the right direction) and is locked at the extreme retarded angle position.
66. INSTALL CAMSHAFT TIMING SPROCKET
a) Fix the camshaft with a vise, and install the sprocket with the bolt.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)