No. 1 Piston at Top Dead Center - Set (Crank Side)
Turn the crankshaft so its white mark (A) lines up with the pointer (B).
9.
No. 1 Piston at Top Dead Center - Set (Cam Side)
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.
10.
Chain Case Cover - Remove
Remove the chain case cover.
11.
Cam Chain Auto-Tensioner - Lock
1.
Rotate the crankshaft counterclockwise to align the holes on the lock (A) and the cam chain auto-tensioner (B), then insert a 1.2 mm (3/64 in) diameter pin (C) into the holes.
NOTE: If the holes in the lock and the cam chain auto-tensioner do not align, continue to rotating the crankshaft counterclockwise until the holes align, then install the pin.
2.
Turn the crankshaft clockwise to secure the pin and the TDC on the No. 1 cylinder.
12.
Camshaft Holder - Remove
1.
Loosen the rocker arm and the adjusting screws (A).
2.
Remove the camshaft holder bolts. To prevent damaging the camshafts, loosen the bolts, in sequence, two turns at a time.
3.
Remove cam chain guide B and the camshaft holders (A).
13.
Camshaft - Remove
1.
Carefully tip up the intake camshaft on the transmission side of the engine until there is enough slack in the chain to lift the chain off of the VTC actuator's teeth.
2.
Remove the intake camshaft (A), then remove the exhaust camshaft (B) while keeping some tension on the cam chain.
3.
Secure the cam chain (C) to the A/C compressor suction hose with a wire tie to prevent the chain from falling down into the chain case.
Clean and dry the No. 5 rocker shaft holder mating surface.
2.
Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the cylinder head mating surface of the No. 5 rocker shaft holder 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).
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
3.
Install the lost motion assembly in the cylinder head.
NOTE: Apply new engine oil to the lost motion assembly.
4.
Install the rocker arm assembly (A) on the cylinder head.
3.
Camshaft - Install
1.
Remove the wire tie while keeping light tension on the cam chain.
2.
Slide the exhaust camshaft (A) and the intake camshaft (B) in at an angle to allow the cam chain to slip over the teeth.
3.
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.
4.
Apply new engine oil to the camshaft journals and lobes on both cams.
4.
Camshaft Holder - Install
1.
Apply new engine oil to the threads of the camshaft holder bolts.
2.
Set the camshaft holders (A) and cam chain guide B in place.
3.
Tighten the bolts to the specified torque.
Specified Torque:
13 N·m (1.3 kgf·m, 10 lbf·ft)
5.
Rocker Shaft Bolt - Tighten
If the rocker arm assembly is disassembled, tighten the rocker shaft bolts.
6.
Cam Chain Auto-Tensioner - Unlock
Remove the pin from the cam chain auto-tensioner.
7.
Chain Case Cover - Install
1.
Remove all of the old liquid gasket from the chain case cover mating surfaces, the bolts, and the bolt holes.
2.
Clean and dry the chain case cover mating surfaces.
3.
Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the chain case mating surface of the chain case cover 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).
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 chain case cover.
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 chain case cover.
Remove all of the old liquid gasket from the high pressure fuel pump base mating surfaces, the bolts, and the bolt holes.
2.
Clean and dry the high pressure fuel pump base mating surfaces.
3.
Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the cylinder head mating surface of the high pressure fuel pump base 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).
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 high pressure fuel pump base.
10.
Camshaft Holder Cover - Install
1.
Remove all of the old liquid gasket from the camshaft holder cover mating surfaces, the bolts, and the bolt holes.
2.
Clean and dry the camshaft holder cover mating surfaces.
3.
Apply liquid gasket (P/N 08717-0004, 08718-0003, or 08718-0009) to the cylinder head mating surface of the camshaft holder cover and to the inside edge of the threaded bolt holes. Install the component within 4 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).
If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.
Turn the ignition switch to ON (II), or press the engine start/stop button to select the ON mode, but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel rail will be pressurized. Repeat this two or three times, then check for fuel leakage.
