Page 16 of 1139

nqtne
ItemMeasurementOualificationStandard or NewService LimirBlock
Piston
I Warpage of deck0.07 mm (0.003 in.) max.foro.. (ulur^^-"1tsore diameterAori
Borll
(3.3858 3.3862 in.)
85.980 85.990 mm (3.3850 3.3854 in.)
l-il?0 €s.980 r"i33846
86.010 86.020 mm
(3.3862 3.3866 in.)
86.000 86.010 mm
86.070 mm (3.3886 in.)
86.070 mm (3.3886 in.)
0.05 mm (0.002 In.J
85.920 mm (3.3827 in.)
0.25 mm (0 0l in.)
85.930 mm (3.383'l in.)
Reboring lrmit
Skirt O.D. at 11 mm (0.4 in.) from
bottom of skirtF" btt"' "' A
Letter B
0.020 0.040 mm (0 0008 0.0016 in.)0.05 mm {0.002 in.)Top1.220 1.230 mm (0.0481 0.0484 in.)1.25 mm 10.049 rn )Second1.220 1.230 mm (0.0481 0 0a84In.)1.25 mm 10.049 in.)
Piston ring
lFis,.€-"'"
",";"*
L-Ring end gap
o.D.
i 2.005 2.025 mm (0.0789 0.0797 in.)
fo.o:s o.oto.rn lo.oora o.ooza i.'.f
EO3t 0 056 rn. {OJ01r OOO2 i")
?.09rrl9.091lt )
0.13 mm (0.005 in )
0.13 mm (0.005 in.)Second (FEDEHAL
I\4OGUL)
Top
0.025 0.060 mm (0.0010 0.0024 in.)0.13 mm (0.005 in )
0.20 0.35 mm (0.008 0.014 in.)0.60 mm (0.024 in.)Second0.40 0.55 mm {0.016 0.022 in.)0.70 mm (0.028 in.)OiI (REKEN)
21.961 21.965 mm {0.8646 0.8648 in.)
0.25 0.65 mm (0.010 0.026 in.)
0 20 0.70 mm i0.008 0.028 in.)
0.75 mm (0.030 in.)OiI(FEDERAL
I\4OG U L)0.80 mm 10.031 in.)
Piston pin21.953 mm l0 8643 inPin'to-piston clearance0.005-*0.002 mm ( 0.00020 +
0.00008 in.)
0.005 mm (0.0002 in.)
Connecting rodPin to-rod clearance0.005 0.015 mm (0.0002 0.0006 in.)0.02 mm lO 0OO8 in ISmall end bore diameler21.970 21.976 mm (0.8650 0.8652 in.)Large-end bore diameter (Normal)48.0 mm (1.89 in.)End play inslalled on crankshaft0.15 0.30 mm (0.006 0.012 in.)0.40 mm (0.016 in.)CrankshaftMain journal diameter
Rod journal diameter
No. l journal
No. 2 journal
No. 4 journal
No. 5 journal
No. 3 journal
s4.e84 s5.008 mm (2.1648=16illl
54.976 55.000 mm (2.1644 2-1654in)
44.976 45.000 mm (1.1707 1.1717 in.lRod/main0.005 mm 10.0002 in.) max.0.010 mm (0.0004 in.)Rod/main iournal out of,round0.005 mm (0.0002 in.) max.0.010 mm (0.0004 in.)End play0.10 0.35 mm (0.004 0.0'14 in.)0.45 mm 10.018 in.)Runout..-'.: --'+0.03 mm (0.0012 in.) max.0.04 mm {0.0016 in.)
Deaflngs
Marn oear,n9-toJournat ott ctearanceNo. l journal
No. 2 journal
No. 4 journal
No.5
No. 3 journa/
0.017 0.041 mm (0.0007 0.0016 in.)
q0rr034, -rn {O'o010 0-o01r|"tl
0.050 mm (0.0020 in.)
0.055 mm (0.0022 in.)Bod bearing clearance0.021 0.049 mm (0.0008 0.0019 in.)0.060 mm (0.0024 in.)
Standards and Service Limits
Enqine Block
_f
c_a
2-4
-
Page 96 of 1139

\
Engine Mechanical
Cylinder Head
Special Tools
Comoonent Location Index
Engine Compression Inspection
VTEC Rocker Arm Test ........... ............ 6-7
VTC Actuator Inspection .................... 6-8
Valve Clearance Adjustment ............. 6-9
Crankshaft Pulley Removal and Installation .............. 6-11
Cam Chain Removal ........................... 6-12
Cam Chain Installation ....................... 6-15
Auto-Tensioner Removal/1nsta11ation ......................... 6-19
Chain Case Oil Seal Installation ........ 6-21
Cyf inder Head Cover Removal .......... 6-22
Cylinder Head Removal ..................... 6-23
WC Actuator. Exhaust Camshaft Sorocket
Repf acement .........6-24
Cylinder Head Inspection for Warpage ...................... 6-25
Rocker Arm Assembly Removal ................................. 6-26
Rocker Arms and Shafts
Disassembly/Reassembly .............. 6-27
Rocker Arms and Shafts Inspection ............................ 6-28
Camshaft Inspection .......................... 6-29
Valves, Springs, and Valve Seals Removal ................ 6-31
Valve Insoection ...................... ........... 6-32
Valve Stem-to-Guide Clearance Insoection ............... 6-32
Valve Guide Reolacement ................. 6-33
Valve Seat Reconditioning ................ 6-35
Valves, Springs, and Valve Seals Installation ............ 6-37
Rocker Arm Assemblv Installation .... 6-38
Cvlinder Head Installation ........................................... 6-39
Cylinder Head Cover Installation ...... 6-41
6-2
6-3
b-t'
Page 98 of 1139
Component Location lndex
TENSIONERARM
AUTO.TENSIONERReplacement, page 6-'l I
IGNITION COILCOVER
CYLINDER HEADCOVERRemoval, page 6-22lnstallation, page 6-41
CAM CHAINBemoval, page 6-'12Installation, page 6-15
frn
|]tJ ,"p
CAM CHAIN GUIDE B
CAM CHAIN GUIDE A
VARIABLE VALVETIMING CONTROLtwc) olL soLENotDVALVE
CRANKSHAFT PULLEYReplacement, page 6 11
O-RING
(cont'd)
6-3
Page 103 of 1139

Cylinder Head
WEC Rocker Arms Test (cont'dl
'10. Loosen the valve on the regulator, and apply thespecified air pressure.
Specified air pressure:
290 kPa 13.0 kgt/cm', 42 psi)
NOTE: lf the synchronizing piston does not moveafter applying air pressure; move the primary orsecondary rocker arm up and down manually byrotating the crankshaft clockwise.
11. With the specified air pressure applied, move theintake primary rocker arm (A)forthe No, 1 cylinder.The primary rocker arm and secondary rocker arm(B) should move together.
lf the intake secondary rocker arm does not move,
remove the primary and secondary rocker arms asan assembly, and check that the pistons in theprimary and secondary rocker arms move
smoothly. lf any rocker arm needs replacing,
replace the primary and secondary rocker arms asan assembly, and test.
Remove the special tools.
Tighten the camshaft holder mounting bolts lo22N m 12.2 kgf.m, 16 lbf.ft).
Tighten the sealing boltto 20 N.m (2.0 kgf.m,
14 tbf.ft).
Installthe cylinder head cover (see page 6-41).
12.
13.
14.
t5.
6-8
VTG Actuator Inspection
'11. Remove the cylinder head cover (see page 6-22lr.
2. Remove the auto-tensioner (see page 6-19).
3. Loosen the rocker arm adjusting screws lsee step 2on page 6-26).
4. Remove the camshaft holder (see step 3 on page 6-
26t.
5. Remove the intake camshaft.
6, Check that the variable valve timing control (VTC)
actuator is locked by turning the VTC actuator
clockwise and counterclockwise. lf the VTC actuatoris not locked, replace the VTC actuator.
7. Seal the advance holes (A)and retard holes (B) in
the No. 1 camshaft journal with tape.
Punch a hole through the tape over one of theadvance holes.
Page 105 of 1139
Gylinder Head
IValve Clearance Adjustment (cont'd)
3. Select the correct thickness feeler gauge for the
valves you're going to check.
Intake: 0.21 0.25 mm (0.008-0.010 in.)
Exhaust; 0.28 0.32 mm (0.011 0.013 in.)
Adiusting screw locations:
No. 1
EXHAUST
No. 2 No.3 No. 4
No. 1No.4
4.Insert the feeler gauge {A) between the adjusting
screw (B) and the end ofthe valve stem, and slide it
back and forth; you should feel a slight amount of
d rag.
6-10
\.
5. lf you feel toomuchortoolittledrag, loosenthe
locknut (A), and turn the adjusting screw {B) until
the drag on the feeler gauge is correct. .
Tighten the locknut, and recheck the clearance.
Repeat the adjustment if necessary
Rotate the crankshaft 180" clockwise (camshaft
pulley turns 90').
7.
t.\-
8. Check and, if necessary, adjust the valve clearance
on No. 3 cylinder.
Page 106 of 1139
10.
9. Rotate the crankshaft 180" clockwise (camshaft
pullev turns 90').
Check and, if necessary, adjust the valve clearance
on No.4 cylinder.
Rotate the crankshaft 180" clockwise (camshaft
pulley turns 90").
Check and, if necessary, adjust the valve clearance
on No. 2 cylinder.
Install the cylinder head cover (see page 6-41).
11.
12.
Crankshaft Pulley Removal and
Installation
Special Tools Required. Holder handle 07JAB-001020A. Holder attachment, 50 mm 07NAB-001040A. Socket, 19 mm 07JAA-001020,4 or a commercially
available 19 mm socket
Removal
1. Remove front tires/wheels.
2. Remove the splash shield (see step 23 on page 5-5).
3. Hold the pulley with holder handle (A) andholder
attachment (B).
B07NAB-001040A
el
/ Srroo.oo,oroo/ (or commercially
f available)
/
Remove the bolt with a 19 mm socket (C) and
breaker bar.
(cont'd)
6-11
Page 107 of 1139

Cylinder Head
Crankshaft Pulley Removal and
Installation (cont'dl
Installation
1. Clean the crankshaft pulley (A), crankshaft (B), bolt(C). and washer (D). Lubricate as shown below.
. .: Clean
O; Lubricate
Installthe crankshaft pulley, and hold the pulley
with holder handle (A) and holder attachment {B).
B07NAB-0010iroA
A07JAB-001020A
Tighten the bolt to 245 N.m (25.0 kgf.m, 181 tbf.ft)with a torque wrench and 19 mm socket (C). Do notuse an impact wrench.
Install the splash shield (see step 20 on page 5-12).
Insta ll front tires/wh eels.
ll
ll
t[] rL-'....-----=a
(-, ,
5U-1JItt-
5.
6-12
\-
Cam Chain Removal
NOTE: Keep the cam chain away from magnetic fields.
1. Turn the crankshaft pulley so ils top dead center(TDC) mark (A) lines up with the poinrer (B).
Remove the front tires/wheels.
Remove the splash shield.
a
2.
3.
-,,--.=.-----__--_
4. Remove the drive belt (see page 4-26).
5. Remove the cylinder head cover (see page 6-22).
6. Remove the crankshaft pulley (see page 6-11).
\
Page 108 of 1139
7. Disconnectthe crankshaft position (CKP) sensor
connector {A) and variable valve timing control
{VTC) oil control solenoid valve connector (B).
Remove the VTC oil control solenoid valve (see
step 1 on page 11-127).
Support the engine with a iack and wood block
under the oil pan.
Remove the ground cable (A). and remove the
upper bracket (B).
9.
10.
11. Remove the side engine mount bracket.
12. Remove the chain case.
(cont'd)
6-13