6-13

Cylinder Head
Cam Chain Removal
Special Tools Required
Handle, 07JAB-0010200
Pulley holder attachment, HEX 50 mm, 07JAB0010400
Socket wrench, 19 mm, 07JAA-0010200
NOTE: Keep the cam chain away from magnetic fields.
1.

1.
2.
3.

1. Turn the crankshaft pulley so its TDC mark (A)

lines up with the pointer (B).

4.
5.
2.
3.

4. Remove the drive belt (see page 4-25).

5. Remove the cylinder head cover (see page 624).
6. Hold the pulley with handle (A) and holder
attachment (B).

2. Remove the front tyres/wheels.

3. Remove the splash shield.

7. Remove the bolt with a 19 mm socket (C) and

breaker bar.
8. Remove the oil cooler hose joint pipe from the
water pump.


6-14

Cylinder Head
Cam Chain Removal (cont'd)
1.

2.
3.
4.

9. Disconnect the CKP sensor connector (A) and

VTC oil control solenoid valve connector (B).

10. Remove the VTC oil control solenoid valve (see

page 11-107).
11. Support the engine with a jack and wood block
under the oil pan.
12. Remove the ground cable (A) and remove the
upper bracket (B).

1.

13. Remove the side engine mount bracket.

2.

14. Remove the chain case.


6-15

Cylinder Head
Cam Chain Removal (cont'd)
1.
2.

3.

15. Loosely install the crankshaft pulley.

16. Turn the crankshaft counterclockwise to
compress the auto-tensioner.

17. Align the holes on the lock (A) and the autotensioner (B), then insert a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the
crankshaft clockwise to secure the pin.

1.

18. Remove the auto-tensioner.

2.

19. Remove the cam chain guide B.

6-16

Cam Chain Installation

Cylinder Head
Cam Chain Removal (cont'd)
1.

2.

20. Remove the cam chain guide A (A) and

tensioner arm (B).

Special Tools Required

Handle, 07JAB-0010200
Pulley holder attachment, HEX 50 mm, 07JAB0010400
Socket wrench, 19 mm, 07JAA-0010200
NOTE: Keep the cam chain away from magnetic fields.
1.

1. Set the crankshaft to TDC. Align the TDC mark

(A) on the crankshaft sprocket with the pointer
(B) on the cylinder block.

2.

2. Set the camshafts to TDC. The punch mark (A)

marked with an arrow on the Variable Valve
Timing Control (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 exhaust camshaft
sprocket.

21. Remove the cam chain.

Cylinder Head

6-17

Cam Chain Installation (cont'd)

1.

3. Install the cam chain on the crankshaft sprocket

with the coloured piece (A) aligned with the
punch mark (B) on the crankshaft sprocket.

2.

4. Install the cam chain on the VTC actuator and

exhaust camshaft sprocket with the punch
marks (A) aligned with the two coloured pieces
(B).

1.

5. Install the cam chain guide A (A) and tensioner

arm (B).

2.

6. Install the auto-tensioner.

Cylinder Head

6-18

Cam Chain Installation (cont'd)

1.

7. Install the cam chain guide B.

1.
2.
3.

2.

8. Remove the pin from the auto-tensioner.

4.
5.

3.

10. Remove old liquid gasket from the chain case

mating surfaces, bolts and bolt holes.
11. Clean and dry the chain case mating surfaces.
12. Apply liquid gasket, P/N 08C70-K0234M,
08C70-K0334M or 08C70-X0331S, evenly to
the cylinder block mating surface of the chain
case and to the inner threads of the holes.

9. Check the chain case oil seal for damage. If

the oil seal is damaged, replace the chain case
oil seal (see page 6-23).

13. Apply liquid gasket to the cylinder block upper

surface contact areas (A) on the chain case.
14. Apply liquid gasket, P/N 08C70-K0334M or
08C70-X0331S, evenly to the oil pan mating
surface of the chain case and to the inner
threads of the holes.
NOTE: Do not install the parts if 5 minutes or
more have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing
old residue.

Cylinder Head

6-19

Cam Chain Installation (cont'd)

1.

15. Install the new O-ring (A) on the chain case.

Set the edge of the chain case (B) to the edge
of the oil pan (C), then install the chain case on
the cylinder block (D).
NOTE: When installing the chain case, do not
slide the bottom surface on the oil pan
mounting surface.

1.

16. Install the side engine mount bracket.

2.

17. Install the upper bracket (A), then tighten the

bolt/nuts in the numbered sequence shown.

3.

18. Install the ground cable (B).

Cylinder Head

6-20

Cam Chain Installation (cont'd)

1.
2.

19. Install the VTC oil control solenoid valve (see

step 1 on page 11-107).
20. Connect the CKP sensor connector (A) and
VTC oil control solenoid valve connector (B).

1.

22. Clean the crankshaft pulley (A) and pulley bolt

(B), and apply lubricant to the pulley bolt and
washer (C).
O: Clean
: Lubricate

3.

2.

23. Install the crankshaft pulley and hold the pulley

with handle (A) and holder attachment (B).

3.

24. Tighten the bolt to 245 Nm (25.0 kgf/m, 181

lbf/ft) with a torque wrench and 19 mm socket
(C). Do not use an impact wrench.
25. Install the cylinder head cover (see page 6-44).
26. Install the drive belt.

21. Install the oil cooler hose joint (A), using a new
O-ring (B).

4.
5.

Cylinder Head

Cam Chain Installation (cont'd)

1.

27. Install the splash shield.

6-21
Auto-Tensioner Removal/Installation

Removal:
1.

1. Remove the chain case cover.

2.

2. Turn the crankshaft counterclockwise to

compress the auto-tensioner.

Cylinder Head

6-22

Auto-Tensioner Removal/Installation (cont'd)

1.

2.

3. Align the holes on the lock (A) and the autotensioner (B), then insert a 1.5 mm (0.06 in.)
diameter pin (C) into the holes. Turn the
crankshaft clockwise to secure the pin.

4. Remove the auto-tensioner.

Installation:
1.

1. Install the auto-tensioner.

2.

2. Remove the pin from the auto-tensioner.

Chain
6-23 Case Oil Seal Installation

Cylinder Head
Auto-Tensioner Removal/Installation (cont'd)
1.
2.
3.

3. Remove old liquid gasket from the chain case

cover mating surfaces, bolts and bolt holes.
4. Clean and dry the chain case cover mating
surfaces.
5. Apply liquid gasket, P/N 08C70-K0234M,
08C70-K0334M or 08C70-X0331S, evenly to
the chain case mating surface of the chain
case cover and to the inner threads of the
holes.
NOTE: Do not install the parts if 5 minutes or
more have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing old
residue.

Special Tools Required

Handle driver, 07749-0010000
Driver attachment, 52 x 55 mm, 077460010400
1.

2.
4.

6. Install the chain case cover.

1. Use the special tools to drive a new oil seal

squarely into the chain case to the specified
installed height.

2. Measure the distance between the chain case

surface and oil seal.
Oil Seal Installed Height:
33.0 - 33.7 mm (1.30 - 1.33 in.)

Cylinder Head

6-24

Cylinder Head Cover Removal

1.

1. Remove the intake manifold cover.

2.
3.

2. Remove the four ignition coils (see page 4-17).

3. Remove the dipstick (A) and breather hose (B).

1.

4. Remove the cylinder head cover.

Ignition System
Ignition Coil Removal/Installation
1.

1. Remove the ignition coil cover (A), then remove

the ignition coils (B).

2.

2. Install the ignition coils in the reverse order of

removal.

4-17

Charging System

Drive Belt Inspection

Check that the auto-tensioner indicator (A) is within the
standard range (B) as shown. If it is out of the standard
range, replace the drive belt (see page 4-25).

4-25
Drive Belt Replacement

1.

1. Move the auto-tensioner (A) to relieve tension

from the drive belt (B), and remove the drive
belt.

2.

2. Install the new belt in the reverse order of

removal.

Cylinder Head

Cylinder Head Installation (cont'd)

1.

13. Install the water bypass hose.

1.
2.

2.
3.
4.
5.
6.
7.

14.
15.
16.
17.
18.
19.

8.

20.

9.

21.

10.

22.

11.
12.

23.
24.

Install the intake manifold (see page 9-5).

Install the exhaust manifold (see page 9-7).
Install the cam chain (see page 6-16).
Adjust the valve clearance (see page 6-10).
Install the drive belt (see page 4-25).
Clean the battery posts and cable terminals
with sandpaper, then assemble them and apply
grease to prevent corrosion.
After installation, check that all tubes, hoses
and connectors are installed correctly.
Inspect for fuel leaks. Turn the ignition switch
ON (II) (do not operate the starter) so that the
fuel pump runs for about 2 seconds and
pressurises the fuel line. Repeat this operation
two or three times, then check for fuel leakage
at any point in the fuel line.
Refill the radiator with engine coolant, and
bleed air from the cooling system with the
heater valve open (see page 10-6).
Inspect the idle speed (see page 11-110).
Inspect the ignition timing (see page 4-16).

3.
4.

6-44
Cylinder Head Cover Installation

1. Thoroughly clean the head cover gasket and

the groove.
2. Install the head cover gasket (A) in the groove
of the cylinder head cover (B).

3. Check that the mating surfaces are clean and

dry.
4. Apply liquid gasket, P/N 08C70-K0234M,
08C70-K0334M or 08C70-X0331S on the chain
case and the No. 5 rocker shaft holder mating
areas.
NOTE: Do not install the parts if 5 minutes or
more have elapsed since applying liquid gasket.
Instead, reapply liquid gasket after removing
old residue.

Cylinder Head

6-45

Cylinder Head Cover Installation (cont'd)

1.

2.

5. Set the spark plug seals (A) on the spark plug

tubes. Once the cylinder head cover (B) is on
the cylinder head, slide the cover slightly back
and forth to seat the head cover gasket.

6. Inspect the cover washers (C). Replace any

washer that is damaged or deteriorated.

1.

7. Tighten the bolts in two or three steps. In the

final step, tighten all bolts, in sequence, to 12
Nm (1.2 kgf/m, 8.7 lbf/ft).

2.

8. Install the dipstick (A) and breather hose (B).

Cylinder Head
Cylinder Head Cover Installation (cont'd)
1.
2.
3.

4.

9. Install the four ignition coils (see page 4-17).

10. Check that all tubes, hoses, and connectors are
installed correctly.
11. Install the intake manifold cover.

12. After assembly, wait at least 30 minutes before

filling the engine with oil.

6-46

VTC System

11-107

VTC Oil Control Solenoid Valve Test

1.

1. Remove the VTC oil control solenoid valve (A).

NOTE: Install the part in the reverse order of removal
with a new O-ring (B), then check these items:

1.

4. Connect the battery positive terminal to the

VTC oil control solenoid valve 2P connector
terminal No. 2.

2.

5. Connect the battery negative terminal to the

VTC oil control solenoid valve 2P connector
terminal No. 1, then check the clearance
between the port (advance side) and the valve.
Clearance (A) should be above 1 mm (1/16 in.).

Clean and dry the VTC oil control solenoid

valve mating surface.
Coat the VTC oil control solenoid valve with
engine oil.
Do not install VTC oil control solenoid valve
while wearing fibrous gloves.
Be careful not to contaminate the cylinder
head hole.

2.

2. Check the port (A) of the VTC oil control

solenoid valve for dirt.

3.

3. Check the clearance between the port (retard

side) and the valve. Clearance (B) should be
above 1 mm (1/16 in.).