Part One

Connecting Rod Bearing Replacement

Installation

1. Connecting Rod Bearing Clearance - Inspection





1. Clean the connecting rod journal and the bearing half with a clean shop towel.

2. Place plastigage across the connecting rod journal.

3. Reinstall the bearing half and the connecting rod cap, then torque the bolts to 41 Nm (4.2 kgfm, 30 lbfft)+ 120 °.

NOTE:
* Apply new engine oil to the bolt threads and flanges.
* Do not rotate the crankshaft during inspection.

4. Remove the connecting rod cap and the bearing half, and measure the widest part of the plastigage.





5. If the plastigage measures too wide or too narrow, remove the cap, and the upper half of the bearing. Install a new, complete bearing with the appropriate color code(s), and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance.

6. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below the current one), and check the clearance again. If the proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over.

2. Connecting Rod Bearing - Selection





1. Each connecting rod has a tolerance range from 0 to 0.024 mm (0.00094 in), in 0.006 mm (0.00024 in) increments, depending on the size of its big end bore. It's then stamped with a number or bar (1, 2, 3, or 4/I, II, III, or IIII) indicating the range. You may find any combination of numbers and bars in any engine. (Half the number or bar is stamped on the rod cap, the other half is on the connecting rod.) If you cannot read the code because of an accumulation of oil and varnish, do not scrub it with a wire brush or scraper. Clean it only with solvent or detergent.









2. The connecting rod journal codes are stamped on the crankshaft in either location.





3. Use the big end bore codes and the rod journal codes to select appropriate replacement bearings from the following table.

NOTE:
* Color code is on the edge of the bearing.
* When using bearing halves of different colors, it does not matter which color is used in the top or bottom.

3. Connecting Rod Caps/Bearing Halves





1. Apply new engine oil to the threads of the connecting rod bolts.

2. Seat the rod journals into connecting rod No. 1 and connecting rod No. 4. Line up the mark (A) on the connecting rod and the bearing cap.

3. Install the bearing caps and the bolts finger-tight.

4. Rotate the crankshaft clockwise, and seat the journals into connecting rod No. 2 and connecting rod No. 3. Line up the mark on the connecting rod and the bearing cap.

5. Install the bearing caps and the bolts finger-tight.





6. Torque the bolts to 41 Nm (4.2 kgfm, 30 lbfft).

7. Tighten the connecting rod bolts an additional 120 °.

NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, inspect the connecting rod bolts. Do not loosen it back to the specified angle.

4. Engine Baffle Plate





1. Install the baffle plate.

5. Engine Oil Pump Assembly





1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.





2. Install the oil pump chain on the crankshaft sprocket with the colored link plate (A) aligned with the TDC mark (B) on the crankshaft sprocket.





3. Set the oil pump chain on the oil pump chain sprocket (A) with the punch mark (B) aligned with the center of the two colored link plates (C), then install the oil pump chain sprocket to the oil pump.

4. To hold the rear balancer shaft, insert a 6 mm long pin punch (D) into the maintenance hole in the balancer shaft holder and through the rear balancer shaft.

5. Apply new engine oil to the threads of the oil pump sprocket mounting bolt (E), then install the oil pump sprocket mounting bolt and the oil pump chain guide (F).

6. Remove the 6 mm long pin punch.





7. Turn the plate (A) counterclockwise, to release the lock, then push the oil pump chain auto-tensioner arm (B), and set the first cam (C) to the first edge of the rack (D). Insert a 3.0 mm (7/64 in) diameter pin (E) into the hole (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will become damaged.

6. Oil Pump Chain Tensioner





1. Install the oil pump chain tensioner.

7. Oil Pan Assembly





1. Remove all of the old liquid gasket from the oil pan mating surfaces, the bolts, and the bolt holes.

2. Clean and dry the oil pan mating surfaces.

3. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the oil pan and to the inner threads of the bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply liquid gasket about 2.5 mm (0.098 in) diameter bead along the broken line (A).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

4. Install the oil pan on the engine block.





5. Tighten the bolts in three steps. In the final step, torque all bolts, in sequence, to 12 Nm (1.2 kgfm, 9 lbfft). Wipe off the excess liquid gasket on the each side of crankshaft pulley and the flywheel/drive plate.

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 oil pan.

8. Cylinder Head Assembly





1. Install a new coolant separator (A) in the engine block whenever the engine block is replaced.





2. Clean the cylinder head and the engine block surface.

3. Install the new cylinder head gasket (A) and the dowel pins (B) on the engine block. Always use a new cylinder head gasket.

4. Install the cylinder head on the engine block.





5. Measure the diameter of each cylinder head bolt at point A and point B.

6. If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.

7. Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.





8. Torque the cylinder head bolts in sequence to 39 Nm (4.0 kgfm, 29 lbfft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.





9. After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 8. If you are using a new cylinder head bolt, tighten the bolt an extra 90 °.

NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 of the procedure. Do not loosen it back to the specified angle.

9. Set The Crankshaft To Top Dead Center





1. Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.

10. Cam Chain





1. To hold the intake camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate A and through the No. 5 rocker shaft holder (D).

2. To hold the exhaust camshaft, insert a camshaft lock pin set (C) into the maintenance hole in CMP pulse plate B and through the No. 5 rocker shaft holder (D).





3. Install the cam chain on the crankshaft sprocket with the colored link plate (A) aligned with the mark (B) on the crankshaft sprocket.





4. Install the cam chain on the VTC actuator and the exhaust camshaft sprocket with the punch marks (A) aligned with the center of the two colored link plates (B).

11. Cam Chain Tensioner Arm and Cam Chain Guide





1. Install cam chain guide A and the tensioner arm (B).





2. Install cam chain guide B.

12. Cam Chain Auto-Tensioner





1. Compress the auto-tensioner when replacing the cam chain. Remove the pin (A) from the auto-tensioner that was installed during removal. Turn the plate (B) counterclockwise, to release the lock, then press the rod (C), and set the first cam (D) to the first edge of the rack (E). Insert the 1.2 mm (3/64 in) diameter pin back into the holes (F).

NOTE: If the chain tensioner is not set up as described, the tensioner will be damaged.





2. Install the auto-tensioner.





3. Remove the pin from the auto-tensioner.





4. Remove the camshaft lock pin set.

13. Cam Chain Case





1. Check the chain case oil seal for damage. If the oil seal is damaged, replace the chain case oil seal.

2. Remove the old liquid gasket from the chain case mating surfaces, the bolts, and the bolt holes.

3. Clean and dry the chain case mating surfaces.

4. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the engine block mating surface of the chain case and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A) and (B).
* Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket along the broken line (C).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





5. Apply liquid gasket (P/N 08718-0004 or 08718-0009) to the oil pan mating surface of the chain case, and to the inside edge of the threaded bolt holes. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* Apply a 2.5 mm (0.098 in) diameter bead of liquid gasket along the broken line (A).
* Apply a 3.0 mm (0.118 in) diameter bead of liquid gasket along the broken line (B).
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.

6. Install the spacer (A), then install a new O-ring (B) on the chain case. Set the edge of the chain case (C) to the edge of the oil pan (D), then install the chain case on the engine block (E). Wipe off the excess liquid gasket on the oil pan and the chain case mating area.

NOTE:
* When installing the chain case, do not slide the bottom surface onto the oil pan mounting surface.
* Wait at least 30 minutes before filling the engine with oil.
* Do not run the engine for at least 3 hours after installing the chain case.










14. Side Engine Mount Bracket, Engine Side





1. Install the side engine mount bracket (A), then tighten the side engine mount bracket mounting bolts.

15. Crankshaft Pulley





1. Clean the crankshaft pulley (A), the crankshaft (B), the bolt (C), and the washer (D). Lubricate with new engine oil as shown.





2. Install the crankshaft pulley, and hold the pulley with the holder handle (A) and the crankshaft pulley holder (B).

3. Torque the bolt to 50 Nm (5.1 kgfm, 37 lbfft) with a torque wrench and a socket, 19mm(C). Do not use an impact wrench. If the pulley bolt or crankshaft are new, torque the bolt to 177 Nm (18.0 kgfm, 131 lbfft), then remove the bolt and torque it to 50 Nm (5.1 kgfm, 37 lbfft).

4. Tighten the pulley bolt an additional 90 °.

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.