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Part Two




Connecting Rod and Crankshaft End Play Inspection

16. VTC Oil Control Solenoid Valve





1. Install the VTC oil control solenoid valve (A) with a new O-ring (B).

NOTE:
* Coat a new O-ring with engine oil.
* Clean and dry the mating surface of the valve.

2. Install the ground cable (C).

17. Cam Chain Case Peripheral Assembly





1. Install the harness clamp.

18. Valve Clearance - Adjustment





1. Set the No. 1 piston at top dead center (TDC). The punch mark (A) on the VTC actuator and the punch mark (B) on the exhaust camshaft sprocket should be at the top. Align the TDC marks (C) on the VTC actuator and the exhaust camshaft sprocket.

2. Select the correct feeler gauge for the valve clearance you are going to check.
















3. Insert the feeler gauge (A) between the adjusting screw (B) and the end of the valve stem on the No.1 cylinder, and slide it back and forth; you should feel a slight amount of drag.





4. If you feel too much or too little drag, loosen the locknut with the locknut wrench and the adjuster, and turn the adjusting screw until the drag on the feeler gauge is correct.

5. Tighten the locknut to the specified torque, and recheck the clearance. Repeat the adjustment if necessary.












6. Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

7. Check and, if necessary, adjust the valve clearance on the No. 3 cylinder.





8. Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

9. Check and, if necessary, adjust the valve clearance on the No. 4 cylinder.





10. Rotate the crankshaft 180 ° clockwise (camshaft pulley turns 90 °).

11. Check and, if necessary, adjust the valve clearance on the No. 2 cylinder.

19. Cylinder Head Cover





1. Check the spark plug seals for damage. If any seals are damaged, replace them.

2. Thoroughly clean the head cover gasket and the groove.

NOTE: Check and, if necessary, replace the head cover gasket.

3. Install the head cover gasket (A) in the groove of the cylinder head cover (B). Make sure the head cover gasket is seated securely.





4. Remove all of the old liquid gasket from the chain case and the No.5 rocker shaft holder.

5. Clean the head cover contacting surfaces with a shop towel.

6. Apply liquid gasket, (P/N 08718-0004 or 08718-0009) on the chain case and the No. 5 rocker shaft holder mating areas (A). Install the component within 5 minutes of applying the liquid gasket.

NOTE: If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





7. Set the spark plug seals (A) on the spark plug tubes. Place the cylinder head cover (B) on the cylinder head, then slide the cover slightly back and forth to seat the head cover gasket.

8. Inspect the spark plug seals for damage.

9. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated.





10. Tighten the bolts in two steps. In the final step torque bolts, in sequence, to 12 Nm (1.2 kgfm, 9 lbfft).

NOTE:
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine for at least 3 hours after installing the head cover.

20. Ignition Coil





1. Install the ignition coils.

21. Ignition Coil Cover





1. Install the ignition coil cover.

22. Starter





1. Install the starter.

23. Water Passage Assembly





1. Install the water passage with new O-ring.

24. Alternator





1. Install the alternator.

25. WU-TWC





1. Install the WU-TWC with new gasket.

2. Install the exhaust chamber cover.

26. A/F Sensor





1. Install the A/F sensor.

27. Injector Base Assembly





1. Install the injector base (A) with a new gasket (B).

28. Intake Manifold and Throttle Body Assembly





1. Install the intake manifold (A) with new gaskets (B), and tighten the bolts and nuts in a crisscross pattern in three steps, beginning with the inner bolt.

29. Fuel Injector and Rail Assembly





1. Install the rail with the fuel injector.

30. Flywheel





1. Install the flywheel (A) on the crankshaft, and install the mounting bolts (B) finger-tight.

2. Install the ring gear holder.





3. Tighten the flywheel mounting bolts (A) in a crisscross pattern in several steps.

31. Clutch Disc





1. Temporarily install the clutch disc onto the splines of the transmission mainshaft. Make sure the clutch disc slides freely on the mainshaft.

2. Apply super high temp urea grease (P/N 08798-9002) to the splines (A) of the clutch disc (B).

NOTE: Wipe off any excess grease.

3. Install the clutch disc using the clutch alignment shaft and the remover handle.

32. Pressure Plate





1. Install the pressure plate (A) and the mounting bolts (B) finger-tight.





2. Torque the pressure plate mounting bolts (A) in a crisscross pattern.

NOTE:
* Tighten the bolts in several steps to prevent warping the diaphragm spring.
* Make sure that there is no clearance between the pressure plate and the flywheel.







3. Remove the ring gear holder.

4. Remove the clutch alignment shaft and the remover handle.

5. Make sure the diaphragm spring fingers are all the same height.

33. Manual Transmission Assembly





1. Install the transmission.

34. Clutch Cover





1. Install the clutch case cover and the transmission mounting bolts.

35. Intermediate Shaft Assembly





1. Install the intermediate shaft into the differential correctly.

NOTE: Insert the intermediate shaft carefully to prevent damaging the oil seal.

36. Engine Wire Harness





1. Install the engine wire harness.
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