DISASSEMBLY

Remove the 6 spark plugs.

Remove the oil filler cap gasket.

Remove the cylinder head cover gasket.

Remove the cylinder head cover gasket No.2.

Remove the O-ring from each camshaft timing oil control valve assembly.

Remove the 4 bolts, engine oil level sensor and gasket.

Remove the oil level gage sub-assembly from the oil level gage guide.

Remove the bolt and oil level gage guide.

Remove the O-ring from the oil level gage guide.

SST

09213-54015   (91651-60855)
09330-00021  

SST

09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05031)

NOTICE:

Before using SST, apply lubricating oil on the threads and tip of the SST center bolt.

Set No.1 cylinder to TDC/compression.

1. Temporarily install the crankshaft pulley bolt and washer to the crankshaft.
   

2. Turn the crankshaft clockwise, and align the timing marks of the crankshaft timing pulley with the oil pump body.
   

3. Check that timing marks of the camshaft timing pulleys and No.3 timing belt cover are aligned.
   

   HINT:

   If not, turn the crankshaft 1 revolution (360°).

4. Remove the crankshaft pulley bolt.
   

1. If the installation marks have disappeared, put new installation marks on the timing belt before removing.
   

1. Turn the crankshaft counterclockwise by approximately 60°.
   

   NOTICE:

   1. Be sure to set the timing pulley at the correct angle in order to prevent it from being damaged when the timing belt is removed.
      
   2. If the timing belt is removed when the crankshaft timing pulley is not installed at the correct angle, the piston head or valve head may come into contact with the pulley and damage it. Make sure that the timing pulley is installed at the correct angle.
      

Remove the timing belt tensioner.

NOTICE:

Do not reinstall the tensioner with its plunger extended.

NOTICE:

Do not turn the crankshaft or camshaft timing pulley with the timing belt removed. If turned, the piston head or valve head may come into contact with the crankshaft or timing pulley and damage them.

Using a socket hexagon wrench 10 mm, remove the pivot bolt, timing belt idler No.1 and distributor drive gear plate washer.

Remove the bolt and timing belt idler sub-assembly No.2.

Remove the bolt and crankshaft position sensor.

SST

09960-10010   (09962-01000, 09963-01000)

SST

09960-10010   (09962-01000, 09963-01000)

HINT:

Arrange the camshaft timing pulleys (RH and LH sides) so that they can be returned to the original locations when reassembling.

Remove the 6 collars and 6 bushings from the timing belt No.3 cover.

Remove the 2 bolts and timing belt idler bracket.

Remove the bolt and the timing belt plate.

Install the pulley bolt to the crankshaft.

SST

09950-50013   (09951-05010, 09952-05010, 09953-05020, 09954-05011)

NOTICE:

1. Do not scratch the sensor part of the crankshaft timing pulley.
   
2. Before using SST, apply lubricating oil to the threads and tip of the SST center bolt.
   

Torque:

5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

HINT:

When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

NOTICE:

1. Do not pry out the camshaft.
   
2. Do not damage the portion of the cylinder head which receives the shaft thrust.
   

NOTICE:

1. Do not pry out the camshaft.
   
2. Do not damage the portion of the cylinder head which receives the shaft thrust.
   

Remove the oil seal from the No.2 camshaft.

Torque:

5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

HINT:

When removing the camshaft, make certain that the torsional spring force of the sub-gear has been eliminated by installing the service bolt.

NOTICE:

1. Do not pry out the camshaft.
   
2. Do not damage the portion of the cylinder head which receives the shaft thrust.
   

NOTICE:

1. Do not pry out the camshaft.
   
2. Do not damage the portion of the cylinder head which receives the shaft thrust.
   

Remove the oil seal from the No.4 camshaft.

Check that the VVT-i does not turn.

Apply about 100 kPa (1 kgf/cm², 14 psi) of air pressure to the port on the advance angle side.

NOTICE:

Cover the ports with a shop rag or piece of cloth when applying pressure to keep oil from splashing.

HINT:

This operation releases the lock pin for the most retard angle lock.

Turn the VVT-i to the advance angle side (the white arrow marked direction in the illustration) by hand.

Standard:

The VVT-i turns.

HINT:

Depending on the air pressure, the VVT-i will turn to the advance angle side without applying force by hand. Also, if the pressure can be hardly applied because of the air leakage from the port, it might be difficult to get the lock-pin to release.

Check that the VVT-i moves freely within about 30° range. Do not move the VVT-i unit to the most retard angle position as the lock-pin will be engaged again.

Standard:

Smooth movable range is about 30°

Turn the VVT-i by hand and lock it at the most retard angle position.

NOTICE:

Do not damage the camshaft.

NOTICE:

1. Remove it with the lock-pin engaged and locked at the most retard angle position.
   
2. The lock nut has left-hand threads.
   
3. Never use any tool other than the socket wrench. Other tools will deform the cam angle rotor.
   

Remove the camshaft VVT-i.

NOTICE:

Never remove the 3 bolts on the gear.

NOTICE:

Do not damage the camshaft.

SST

09960-10010   (09962-01000, 09963-00500)

Remove the wave washer, camshaft sub-gear and camshaft gear bolt washer.

HINT:

Arrange the camshaft sub-gears and gear bolt washers (RH and LH sides) so that they can be returned to the original locations when re-assembling.

Remove the 2 bolts and engine hanger No.2 from the cylinder head.

NOTICE:

1. Do not drop the washers into the cylinder head.
   
2. Head warpage or cracking could result from removing bolts in an incorrect order.
   

Remove the cylinder head gasket from the cylinder block.

NOTICE:

1. Do not drop the washers into the cylinder head.
   
2. Head warpage or cracking could result from removing bolts in an incorrect order.
   

Remove the cylinder head gasket No.2 from the cylinder block.

SST

09228-07501  

Using a socket hexagon wrench 12 mm, remove the oil filter union.

Remove the oil pan drain plug and gasket.

SST

09032-00100  

NOTICE:

1. Do not damage the contact surfaces of oil pan and oil pan No.2.
   
2. Do not damage the flange portion of oil pan No.2 when removing.
   

NOTICE:

Do not damage the contact surfaces of the oil pan and cylinder block.

Remove the 6 bolts and the oil pan baffle plate from the oil pan.

Remove the 6 bolts.

Using a screwdriver, remove the oil pump by prying between the oil pump and the main bearing cap.

Remove the O-ring.

NOTICE:

Do not damage the baffle plate of the cylinder head cover.

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

NOTICE:

Do not damage the cylinder head cover.

1. Check for proper installation.
   
2. Check the timing cover gasket for damage and proper installation.
   

If the belt teeth are cracked or damaged, check if either camshaft is locked.

If there is noticeable wear or cracks on the belt face, check if there are nicks on the side of the idler pulley lock and water pump.

If there is wear or damage to only one side of the belt, check the belt guide and the alignment of each pulley.

If there is noticeable wear on the belt teeth:

1. Check the timing cover for damage.
   
2. Check that the gasket has been installed correctly.
   
3. Check for foreign object on the pulley teeth.
   

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 in.)
   

   If the runout is greater than the maximum, replace the camshaft.
   

1. Using a micrometer, measure the cam lobe height.
   

   Standard cam lobe height:

   Intake:

   43.132 to 43.232 mm (1.6981 to 1.7020 in.)
   

   Exhaust:

   43.010 to 43.110 mm (1.6933 to 1.6972 in.)
   

   Minimum cam lobe height:

   Intake:

   42.98 mm (1.6921 in.)
   

   Exhaust:

   42.86 mm (1.6874 in.)
   

   If the cam lobe height is less than the minimum, replace the camshaft.
   

1. Using a micrometer, measure the journal diameter.
   

   Journal diameter:

   26.959 to 26.975 mm (1.0614 to 1.0620 in.)
   

   If the journal diameter is not as specified, check the oil clearance.
   

Standard outside diameter:

8.95 to 9.05 mm (0.3524 to 0.3563 in.)

Minimum outside diameter:

8.75 mm (0.3445 in.)

Using a hexagon wrench 14 mm, remove the 2 straight screw plugs and 2 gaskets.

Using a hexagon wrench 14 mm, remove the 2 straight screw plugs and 2 gaskets.

SST

09202-70020   (09202-00010)

HINT:

Store the valves, valve springs and spring retainers in the correct order so that they can be returned to the original locations when reassembling.

SST

09202-70020   (09202-00010)

HINT:

Store the valves, valve springs and spring retainers in the correct order so that they can be returned to the original locations when reassembling.

Using needle-nose pliers, remove the oil seals.

Remove the valve spring seats from the cylinder head.

Remove the semicircular plug from the cylinder head.

Maximum warpage:

Cylinder block surface:

0.05 mm (0.0020 in.)

Intake manifold surface:

0.10 mm (0.0039 in.)

Exhaust manifold surface:

0.10 mm (0.0039 in.)

Standard overall length:

95.45 mm (3.7579 in.)

Minimum overall length:

94.95 mm (3.7382 in.)

Valve stem diameter:

5.470 to 5.485 mm (0.2154 to 0.2159 in.)

Standard margin thickness:

1.0 mm (0.039 in.)

Minimum margin thickness:

0.5 mm (0.020 in.)

Standard overall length:

95.40 mm (3.7559 in.)

Minimum overall length:

94.90 mm (3.7362 in.)

Valve stem diameter:

5.465 to 5.480 mm (0.2152 to 0.2157 in.)

Standard margin thickness:

1.0 mm (0.039 in.)

Minimum margin thickness:

0.5 mm (0.020 in.)

Free length:

45.50 mm (1.7913 in.)

Maximum deviation:

2.0 mm (0.079 in.)

Installed tension:

186 to 206 N (19.0 to 21.0 kgf, 41.9 to 46.3 lbf) at 33.8 mm (1.331 in.)

Bushing inside diameter:

5.510 to 5.530 mm (0.2169 to 0.2177 in.)

Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement.

Standard oil clearance:

Intake:

0.025 to 0.060 mm (0.0010 to 0.0024 in.)

Exhaust:

0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Maximum oil clearance:

Intake:

0.08 mm (0.0031 in.)

Exhaust:

0.10 mm (0.0039 in.)

SST

09201-10000   (09201-01055)
09950-70010   (09951-07100)

Diameter:

10.295 to 10.313 mm (0.4053 to 0.4060 in.)

HINT:

Using a caliper gauge, measure of the cylinder head.

Bush diameter:

	Bush diameter
STD	10.333 to 10.344 mm (0.4068 to 0.4072 in.)
O/S	10.383 to 10.394 mm (0.4088 to 0.4092 in.)

HINT:

Using vernier calipers, measure of the bush.

Bush length:

	Bush length
Intake	34.5 mm (1.358 in.)
Exhaust	40.5 mm (1.594 in.)

SST

09201-10000   (09201-01055)
09950-70010   (09951-07100)

Protrusion height:

Intake:

11.1 to 11.5 mm (0.437 to 0.453 in.)

Exhaust:

8.9 to 9.3 mm (0.350 to 0.366 in.)

Standard oil clearance:

Intake:

0.025 to 0.060 mm (0.0010 to 0.0024 in.)

Exhaust:

0.030 to 0.065 mm (0.0012 to 0.0026 in.)

Apply a light coat of prussian blue (or white lead) to the valve face.

Lightly press the valve against the seat.

NOTICE:

Do not rotate the valve.

1. If prussian blue appears around the entire face, the valve is concentric. If not, replace the valve.
   

2. If prussian blue appears around the entire valve seat, the guide and face are concentric. If not, resurface the seat.
   

3. Check that the seat contacts in the middle of the valve face with the width between 1.0 and 1.4 mm (0.039 and 0.055 in.).
   

Handrub the valve and valve seat with an abrasive compound.

Recheck the valve seating position.

Lifter diameter:

30.966 to 30.976 mm (1.2191 to 1.2195 in.)

Lifter bore diameter:

31.009 to 31.025 mm (1.2208 to 1.2215 in.)

Subtract the lifter diameter measurement from the lifter bore diameter measurement.

Standard oil clearance:

0.033 to 0.059 mm (0.0013 to 0.0023 in.)

Maximum oil clearance:

0.07 mm (0.0028 in.)

Install camshaft timing gear assembly.

Install the camshafts to the cylinder head.

NOTICE:

1. Install without valves and sub-gear.
   
2. Install with its timing mark matched.
   

Set the dial indicator to the teeth of the intake camshaft at a right angle (90°).

Standard backlash:

0.020 to 0.200 mm (0.0008 to 0.0079 in.)

Maximum backlash:

0.30 mm (0.0118 in.)

Install the camshafts.

Standard thrust clearance:

0.040 to 0.090 mm (0.0016 to 0.0035 in.)

Maximum thrust clearance:

0.12 mm (0.0047 in.)

Clean the bearing caps and camshaft journals.

Place the camshafts on the cylinder head.

Install the bearing caps.

Torque:

16 N*m{ 163 kgf*cm , 12 ft.*lbf }

NOTICE:

Do not turn the camshaft.

Remove the bearing caps.

Standard oil clearance:

Intake #4, #5 journals:

0.025 to 0.057 mm (0.0010 to 0.0022 in.)

Other journals:

0.025 to 0.062 mm (0.0010 to 0.0024 in.)

Maximum oil clearance:

0.10 mm (0.0039 in.)

NOTICE:

Completely remove the Plastigage.

Remove the water drain cock sub-assembly from the cylinder block.

Remove the 2 nuts and water seal plate from the cylinder block.

Using a socket hexagon wrench 10 mm, remove the straight screw No.1 plug and gasket.

Using a socket hexagon wrench 10 mm, remove the straight screw No.2 plug and gasket.

Using a socket hexagon wrench 10 mm, remove the straight screw No.3 plug and gasket.

Standard thrust clearance:

0.15 to 0.30 mm (0.0059 to 0.0118 in.)

Maximum thrust clearance:

0.35 mm (0.0138 in.)

Check that the matchmarks on the connecting rod and cap are aligned to ensure correct reassembly.

Remove the 2 connecting rod cap bolts.

Clean the crank pin, the bearing and the connecting rod.

Check the crank pin and bearing for pits and scratches.

Apply a light coat of engine oil to the threads of the connecting rod cap bolts.

Torque:

25 N*m{ 255 kgf*cm , 18 ft.*lbf }

NOTICE:

Do not turn the crankshaft.

Remove the 2 bolts, the connecting rod cap and the lower bearing.

Standard oil clearance:

0.038 to 0.066 mm (0.0015 to 0.0026 in.)

Maximum oil clearance:

0.08 mm (0.0031 in.)

NOTICE:

Completely remove the Plastigage.

HINT:

1. Standard bearing center wall thickness
   
2. There are 4 sizes of standard bearings, marked "1", "2", "3" and "4" accordingly.
   

Push out the piston and the connecting rod assembly from the top of the cylinder block.

HINT:

1. Keep the bearings, the connecting rod and the cap together.
   
2. Arrange the piston and the connecting rod assemblies in the correct order so they can be returned to the original locations when re-assembling.
   

Remove the connecting rod bearing from the connecting rod and connecting rod bearing cap.

Using a piston ring expander, remove the oil ring side rail.

Remove the oil ring expander by hand.

HINT:

1. The piston and pin are a matched set.
   
2. Store the pistons, the pins, the rings, the connecting rods and the bearings in the correct order so that they can be returned to the original locations when reassembling.
   

Standard thrust clearance:

0.04 to 0.24 mm (0.0016 to 0.0094 in.)

Maximum thrust clearance:

0.30 mm (0.0118 in.)

HINT:

Thrust washer thickness is 1.93 to 1.98 mm (0.0760 to 0.0780 in.)

NOTICE:

1. Carefully pry out the main bearing cap by alternating lifting a little at a time on each end of the cap.
   
2. Do not damage the joint surface of the cylinder block and the main bearing cap.
   

Remove the crankshaft thrust washer set.

Remove the crankshaft bearing from the cylinder block and crankshaft bearing cap.

Maximum warpage:

0.05 mm (0.0020 in.)

Standard diameter:

92.000 to 92.012 mm (3.6220 to 3.6225 in.)

Maximum diameter:

92.132 mm (3.6272 in.)

Piston diameter:

91.975 to 91.989 mm (3.6211 to 3.6216 in.)

Subtract the piston diameter measurement from the cylinder bore diameter measurement.

Standard oil clearance:

0.033 to 0.059mm (0.0013 to 0.0023 in.)

Maximum oil clearance:

0.13 mm (0.0051 in.)

Using a rod aligner and feeler gauge, check the connecting rod alignment.

1. Check for misalignment.
   

   Maximum misalignment:

   0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
   

   If misalignment is greater than the maximum, replace the connecting rod assembly.
   

2. Check for twist.
   

   Maximum twist:

   0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
   

   If twist is greater than the maximum, replace the connecting rod assembly.
   

Bushing inside diameter:

22.005 to 22.014 mm (0.8663 to 0.8667 in.)

Piston pin diameter:

21.997 to 22.006 mm (0.8660 to 0.8664 in.)

Subtract the piston pin diameter measurement from the bushing inside diameter measurement.

Standard oil clearance:

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Maximum oil clearance:

0.05 mm (0.0020 in.)

SST

09222-30010  

SST

09222-30010  

Standard oil clearance:

0.005 to 0.011 mm (0.0002 to 0.0004 in.)

Ring groove clearance:

Item	Specified Condition
No.1	0.03 to 0.08 mm (0.0012 to 0.0031 in.)
No.2	0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Oil (Side rail)	0.03 to 0.11 mm (0.0012 to 0.0043 in.)

Standard end gap:

Item	Specified Condition
No.1	0.30 to 0.40 mm (0.0118 to 0.0157 in.)
No.2	0.50 to 0.60 mm (0.0197 to 0.0236 in.)
Oil (Side rail)	0.15 to 0.40 mm (0.0059 to 0.0157 in.)

Maximum end gap:

Item	Specified Condition
No.1	0.95 mm (0.0374 in.)
No.2	1.05 mm (0.0413 in.)
Oil (Side rail)	1.00 mm (0.0394 in.)

Standard diameter:

7.2 to 7.3 mm (0.283 to 0.287 in.)

Minimum diameter:

7.0 mm (0.276 in.)

Standard diameter:

7.5 to 7.6 mm (0.295 to 0.299 in.)

Minimum diameter:

7.2 mm (0.283 in.)

Maximum circle runout:

0.06 mm (0.0024 in.)

Diameter:

60.988 to 61.000 mm (2.4011 to 2.4016 in.)

Check each main journal for taper and out-of-round as shown.

Maximum taper and out-of-round:

0.02 mm (0.0008 in.)

Diameter:

52.992 to 53.000 mm (2.0863 to 2.0866 in.)

Check each crank pin for taper and out-of-round as shown.

Maximum taper and out-of-round:

0.02 mm (0.0008 in.)

HINT:

Main bearings come in widths of 22.4 mm (0.882 in.) and 19.0 mm (0.748 in.). Install the 22.4 mm (0.882 in.) bearings in the No.1 and No.2 cylinder block journal positions with the main bearing cap. Install the 19.0 mm (0.748 in.) bearings in the No.3 and No.4 positions.

NOTICE:

Do not apply engine oil to the bearing and its contact surface.

NOTICE:

Do not apply engine oil to the bearing and its contact surface.

HINT:

A number is marked on each main bearing cap to indicate the installation position.

Place the crankshaft on the cylinder block.

Apply a light coat of engine oil to the threads of the bearing cap bolts.

Temporarily install the 8 main bearing cap bolts to the inside positions.

Apply a light coat of engine oil to the threads of the main bearing cap bolts.

Torque:

22 N*m{ 224 kgf*cm , 16 ft.*lbf }

Retighten the bearing cap bolts by 90° in the same sequence shown as step (l).

NOTICE:

Do not turn the crankshaft.

Torque:

27 N*m{ 275 kgf*cm , 20 ft.*lbf }

HINT:

Use the short bolt for the marked position (arrow).

Remove the main bearing caps.

Standard oil clearance:

No.1 and No.2 journals:

0.014 to 0.031 mm (0.0006 to 0.0012 in.)

No.3 and No.4 journals:

0.026 to 0.043 mm (0.0010 to 0.0017 in.)

Maximum clearance:

No.1 and No.2 journals:

0.05 mm (0.0020 in.)

No.3 and No.4 journals:

0.06 mm (0.0024 in.)

NOTICE:

Completely remove the Plastigage.