Part 2

RH Bank:

LH Bank:

PARTIAL ENGINE ASSY
OVERHAUL
35. REMOVE CYLINDER HEAD COVER REAR
36. REMOVE OIL CONTROL VALVE FILTER





a) Remove the plug, gasket and valve filter.
37. REMOVE CYLINDER HEAD SUB-ASSY





a) Using an 8 mm socket hexagon wrench, remove the hexagon bolt.





b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

38. REMOVE CYLINDER HEAD GASKET
39. REMOVE CYLINDER HEAD LH





a) Using an 8 mm socket hexagon wrench, remove the hexagon bolt.





b) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

40. REMOVE CYLINDER HEAD GASKET NO.2
41. REMOVE WATER INLET HOUSING





a) Uniformly loosen and remove the 8 bolts and 2 nuts in the sequence shown in the illustration. Remove the water inlet housing.
42. REMOVE OIL FILTER SUB-ASSY





a) Using SST, remove the oil filter.
SST 09228-07501
b) Using a 12 mm socket hexagon wrench, remove the oil filter union.
43. REMOVE OIL PAN DRAIN PLUG
44. REMOVE OIL PAN SUB-ASSY NO.2





a) Remove the 10 bolts and 2 nuts.





b) Insert the blade of SST between oil pan No. 1 and oil pan No. 2. Cut through the sealer and remove the oil pan No. 2.
SST 09032-00100

NOTICE:
^ Do not damage the contact surface of oil pan No. 1 and oil pan No. 2.
^ Do not damage the flange portion of oil pan No. 2 during removal.

45. REMOVE OIL STRAINER SUB-ASSY
a) Remove the bolt and 2 nuts, then remove the oil strainer and gasket.
46. REMOVE OIL PAN SUB-ASSY





a) Uniformly loosen and remove the 15 bolts and 2 nuts in the sequence shown in the illustration.





b) Using a screwdriver, remove the oil pan by prying between the cylinder block and the oil pan.

NOTICE: Be careful not to damage the contact surfaces of the oil pan and cylinder block.

47. REMOVE OIL PAN BAFFLE PLATE
48. REMOVE ENGINE REAR OIL SEAL RETAINER





a) Uniformly loosen and remove the 6 bolts.
b) Using a screwdriver, remove the oil seal retainer by prying between the oil seal retainer and the main bearing cap.
49. REMOVE ENGINE REAR OIL SEAL





a) Using a screwdriver and a hammer, tap out the oil seal.
50. REMOVE OIL PUMP ASSY





a) Remove the 9 bolts.
b) Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.
c) Remove the O-ring.
51. REMOVE OIL PUMP SEAL





a) Using a screwdriver, pry out the oil seal.
52. REMOVE SPARK PLUG TUBE GASKET





a) Bend up the tab on the ventilation baffle plate which prevents the gasket from slipping out.

NOTICE: Be careful not to damage the baffle plate of the cylinder head cover.

b) Using a screwdriver and a hammer, tap out the gasket.





c) Using needle-nose pliers, pry out the gasket.

NOTICE: Be careful not to damage the cylinder head cover.

53. INSPECT TIMING BELT

NOTICE:
^ Do not bend, twist or turn the timing belt inside out.
^ Do not allow the timing belt to come into contact with oil, water or steam.
^ Do not utilize timing belt tension when installing or removing the mounting bolt of the camshaft timing pulley.

Check the belt for any defects, as shown in the illustrations.
Also, check these points.





a) If there is premature parting:
^ Check for proper installation.
^ Check the timing cover gasket for damage and proper installation.
b) If the belt teeth are cracked or damaged, check to see if either camshaft is locked.
c) If there is noticeable wear or cracks on the belt face, check to see if there are nicks on the side of the idler pulley lock and water pump.
d) If there is wear or damage on only one side of the belt, check the belt guide and the alignment of each pulley.
e) If there is noticeable wear on the belt teeth:
^ Check the timing cover for damage.
^ Check that the gasket has been installed correctly.
^ Check for foreign object on the pulley teeth.
If there is any doubt about the belt condition, replace the timing belt.
54. INSPECT CAMSHAFT





a) Inspect the camshaft for runout.
1) Place the camshaft on V-blocks.
2) Using a dial indicator, measure the runout at the center journal.
Maximum circle runout: 0.06 mm (0.0024 inch)
If the runout is greater than the maximum, replace the camshaft.





b) Inspect the cam lobes.
1) Using a micrometer, measure the cam lobe height.





Specified cam lobe height

If the cam lobe height is less than the minimum, replace the camshaft.
c) Inspect the camshaft journals.





1) Using a micrometer, measure the journal diameter.
Journal diameter: 26.959 to 26.975 mm (1.0614 to 1.0620 inch)
If the journal diameter is not as specified, check the oil clearance.
55. INSPECT CYLINDER HEAD SET BOLT





a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Specified outside diameter: 8.75 to 9.05 mm (0.3445 to 0.3563 inch)
If the diameter is less than the minimum, replace the bolt.
56. INSTALL SPARK PLUG TUBE GASKET





a) Using SST and a hammer, tap in a new gasket until its surface is flush with the upper edge of the cylinder head cover.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07100)
b) Return the ventilation plate tab to its original position.
c) Apply a light coat of MP grease to the gasket lip.
57. INSTALL ENGINE REAR OIL SEAL





a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal retainer edge.
SST 09223-15030, 09950-70010 (09951-07100)

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the gap between the rear oil seal retainer edge and the oil seal free of foreign matter.

b) Apply MP grease to the oil seal lip.
58. INSTALL ENGINE REAR OIL SEAL RETAINER
a) Remove any old packing material from the contact surface.





b) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the oil seal retainer within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

c) Install the oil seal retainer. Tighten the 6 bolts uniformly.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
59. INSTALL OIL PUMP SEAL





a) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump body edge.
SST 09223-00010

NOTICE:
^ Be careful not to tap the oil seal at an angle.
^ Keep the gap between the oil pump body edge and the oil seal free of foreign matter.

b) Apply MP grease to the oil seal lip.
60. INSTALL OIL PUMP ASSY





a) Remove any old packing material from the contact surface.
b) Apply a light coat of engine oil to a new O-ring and place it on the cylinder block.





c) Apply a continuous bead of seal packing (diameter 2 to 3 mm (0.08 to 0.12 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pump within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing the oil pump.





d) Align the key of the oil pump drive gear with the keyway located on the crankshaft, and slide the oil pump into place.





e) Install the oil pump with the 9 bolts. Tighten the bolts uniformly in several steps.
Torque:
8.0 Nm (82 kgf-cm, 71 inch lbs.) for bolt A
20 Nm (204 kgf-cm, 15 ft. lbs.) for bolt B
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt C
61. INSTALL CRANKSHAFT POSITION SENSOR
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
62. INSTALL OIL PAN BAFFLE PLATE
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
63. INSTALL OIL PAN SUB-ASSY





a) Remove any old seal packing from the contact surface.
b) Apply a continuous bead of seal packing (diameter 3 to 4 mm (0.12 to 0.16 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the outer side of the bolt holes in region "X".
^ Apply seal packing to the inner side of the bolt holes in region "Y".
^ Install the oil pan within 3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

c) Install the oil pan No. 1 with the 15 bolts and 2 nuts. Tighten the bolts uniformly in several steps.
Torque:
8.0 Nm (82 kgf-cm, 71 inch lbs.) for 10 mm head
20 Nm (199 kgf-cm. 14 ft. lbs.) for 12 mm head
64. INSTALL OIL STRAINER SUB-ASSY
a) Install a new gasket and the oil strainer with the bolt and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
65. INSTALL OIL PAN SUB-ASSY NO.2





a) Remove any old seal packing from the contact surface.
b) Apply a continuous bead of seal packing (diameter 4 to 5 mm (0.16 to 0.20 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Apply seal packing to the inner side of the bolt holes.
^ Install the oil pan within3 minutes after applying seal packing.
^ Do not expose the seal to engine oil for at least 2 hours after installing.

c) Install the oil pan No. 2 with the 10 bolts and 2 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
66. INSTALL OIL PAN DRAIN PLUG
a) Install the drain plug with a new gasket.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.)
67. INSTALL WATER INLET HOUSING





a) Remove any old packing material from the contact surface.
b) Apply a continuous bead of seal packing (diameter 3 to 5 mm (0.12 to 0.20 inch)) as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent

NOTICE:
^ Remove any oil from the contact surface.
^ Install the water inlet housing within 3 minutes after applying seal packing.
^ Do not expose the seal to coolant for at least 2 hours after installing.





c) Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
68. INSTALL CYLINDER HEAD GASKET





a) Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Make sure the cylinder head gasket is facing in the correct direction.

69. INSTALL CYLINDER HEAD SUB-ASSY

NOTICE:
^ To prevent damage to the block, place the the gasket carefully.
^ The cylinder head bolts are tightened in 2 successive steps.





a) Apply a light coat of engine oil on the threads of the cylinder head bolts.
b) Install the plate washers to the cylinder head bolts.
c) Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e) Retighten the cylinder head bolts by 90° in the same sequence as step (c).
f) Check that each painted mark is now at a 90° angle to the front.





g) Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)