ENGINE UNIT DISASSEMBLY


  1. REMOVE SPARK PLUG


    1. A01DRNM

      Using a 16 mm spark plug wrench, remove the 4 spark plugs.

  2. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Disconnect the oil pressure switch connector.

    2. A01DU67

      Using a 24 mm deep socket wrench, remove the oil pressure switch.

  3. REMOVE KNOCK SENSOR

    A01DTH0E01

    1. Disconnect the knock sensor connector.

    2. Remove the bolt and knock sensor.

  4. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. Disconnect the engine coolant temperature sensor connector.

    2. A01DND5

      Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.

  5. REMOVE OIL FILLER CAP SUB-ASSEMBLY


    1. A01DNFAE01

      Remove the oil filler cap.

    2. Remove the gasket from the oil filler cap.

  6. REMOVE PCV VALVE SUB-ASSEMBLY


    1. A01DS3G

      Disconnect the PCV hose from the PCV valve.

    2. Using a 22 mm ball joint lock nut wrench, remove the PCV valve.

  7. REMOVE CAMSHAFT POSITION SENSOR

    A01DU16E01

    1. Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor.

  8. REMOVE CRANKSHAFT POSITION SENSOR


    1. A01DR5A

      Disconnect the crankshaft position sensor connector and detach the wire harness clamp.

    2. A01DM14E02

      Remove the bolt and crankshaft position sensor.

  9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01DNZV

      Detach the 2 clamps and disconnect the 2 connectors.

    2. Remove the bolt and wiring harness clamp bracket.

    3. A01DPBG

      Disconnect the camshaft timing oil control valve connector.

    4. Remove the bolt and camshaft timing oil control valve.

    5. Remove the O-ring from the camshaft timing oil control valve.

  10. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01DR40

      Remove the 19 bolts, 2 nuts, head cover and 2 gaskets.

  11. REMOVE WATER INLET


    1. A01DU4X

      Remove the bolt, 2 nuts, water inlet and gasket.

  12. REMOVE THERMOSTAT


    1. A01DQ7Z

      Remove the thermostat from the timing chain cover.

  13. REMOVE CRANKSHAFT PULLEY


    1. A01DN29E02
      Text in Illustration
      *a Loosen
      *b Hold

      Using SST, hold the crankshaft pulley and loosen the pulley bolt until 2 or 3 threads are screwed into the crankshaft.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
    2. A01DQFHE02
      Text in Illustration
      *a Loosen
      *b Hold

      Using SST and the pulley bolt, remove the crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

      Tech Tips

      Apply lubricant to the threads and end of SST.

  14. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A01DOGD

      Remove the drain plug and gasket.

    2. Remove the 18 bolts and 2 nuts.

    3. A01DRQE

      Insert the blade of an oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the oil pan.

      Note

      Be careful not to damage the contact surfaces of the oil pans.

  15. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A01DRPR

      Remove the bolt, 2 nuts, oil strainer and gasket.

  16. REMOVE OIL PAN SUB-ASSEMBLY


    1. A01DSSSE01

      Remove the 16 bolts and 2 nuts.

    2. A01DUNVE02
      Text in Illustration
      *1 Protective Tape

      Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

    3. A01DQNME01

      Remove the O-ring.

  17. REMOVE OIL PAN STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.

  18. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01DUO4E03

      Remove the 3 bolts and belt tensioner.

  19. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A01DMAJE01

      Remove the 19 bolts and 2 nuts shown in the illustration.

    2. A01DP4PE02
      Text in Illustration
      *1 Protective Tape

      Remove the timing chain cover by prying between the timing chain cover and cylinder head or cylinder block with a screwdriver.

      Tech Tips

      Tape the screwdriver tip before use.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.

    3. A01DO2LE02

      Remove the 3 O-rings.

  20. REMOVE STRAIGHT SCREW PLUG


    1. A01DNWV

      Using a 10 mm socket hexagon wrench, remove the straight screw plug.

  21. REMOVE WATER PUMP ASSEMBLY


    1. A01DR88

      Remove the 8 bolts, water pump and gasket.

  22. REMOVE TIMING CHAIN COVER OIL SEAL


    1. A01DNUBE02
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Block

      Place the timing chain cover on wooden blocks.

    2. Using a screwdriver pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  23. REMOVE OIL PUMP RELIEF VALVE


    1. A01DUMFE04

      Using a 27 mm socket wrench, remove the relief valve plug and gasket.

    2. Remove the valve spring and oil pump relief valve.

  24. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01DUVKE01
      Text in Illustration
      *1 Timing Mark
      *2 Key

      Temporarily install the crankshaft pulley bolt.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley bolt.

  25. REMOVE TIMING CHAIN GUIDE


    1. A01DUWO

      Remove the 2 bolts, chain guide and O-ring.

  26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note


    • When the chain tensioner is removed, do not rotate the crankshaft.

    • When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90° to the right.

    A01DS7UE07

    1. Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock and insert a 3.0 mm (0.118 in.) diameter bar into the stopper plate hole.

    3. A01DQEP
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Remove the bolt, nut, chain tensioner and gasket.

  27. REMOVE CHAIN TENSIONER SLIPPER


    1. A01DQ96E01

      Remove the bolt and tensioner slipper.

  28. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01DT7AE01

      Remove the 2 bolts and vibration damper.

  29. REMOVE CHAIN SUB-ASSEMBLY

  30. REMOVE CRANKSHAFT TIMING GEAR


    1. A01DS5F

      Remove the crankshaft timing gear from the crankshaft.

  31. REMOVE CAMSHAFT BEARING CAP


    1. A01DM7RE01

      Uniformly loosen and remove the 21 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    2. A01DUHJ

      Remove the oil delivery pipe and O-ring from the bearing caps.

    3. A01DSMO

      Remove the 9 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  32. REMOVE CAMSHAFT

    A01DS0Z

  33. REMOVE NO. 2 CAMSHAFT

    A01DT68

  34. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. A01DSZE

      Remove the 16 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  35. REMOVE CAMSHAFT TIMING SPROCKET


    1. A01DN25

      Mount the camshaft in a vise and remove the sprocket bolt and camshaft timing sprocket.

      Note

      Do not damage the camshaft.

  36. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01DO1CE14
      Text in Illustration
      *1 Retard Side Path
      *2 Advance Side Path
      *a Open
      *b Close
      A01DPL5 Rubber Piece
      A01DOXP Vinyl Tape

      Check the lock of the camshaft timing gear.


      1. Mount the camshaft in a vise and confirm that the camshaft timing gear is locked.

        Note

        Do not damage the camshaft.

    2. Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a rubber piece.

      2. Break through the tape over the advance side path, and then break through the tape over the retard side path on the opposite side of the hole over the advance side path as shown in the illustration.

      3. A01DQBXE14
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path

        Apply compressed air at approximately 200 kPa (2.0 kgf/cm2, 28 psi) to the two paths accessible through the holes in the tape.

        CAUTION:

        Some oil splashing will occur. Cover the paths with a piece of cloth.

      4. A01DQMBE12
        Text in Illustration
        *1 Retard Side Path
        *2 Advance Side Path
        *a Decompress
        *b Hold Pressure

        Check that the camshaft timing gear revolves in the advance direction when reducing the air pressure applied to the retard side path.

        OK
        Gear rotates in the advance direction.

        Tech Tips

        This operation releases the lock pin which holds the timing gear in the most retarded position.

      5. When the camshaft timing gear reaches the most advanced position, release the air pressure from the retard side path and advance side path in that order.

        Note

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    3. Check for smooth rotation.


      1. Rotate the camshaft timing gear within its movable range several times, but do not turn it to the most retarded position. Check that the gear rotates smoothly.

        CAUTION:

        Do not use air pressure to perform the smooth operation check.

    4. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear becomes locked at the most retarded position.

  37. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01DS1WE03
      Text in Illustration
      *a Do Not Remove

      Remove the flange bolt and camshaft timing gear.

      Note


      • Be sure not to remove the other 3 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  38. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01DOINE03

      Uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      Note


      • Be careful not to drop the washers into the cylinder head.

      • Head warpage or cracking could result from removing the bolts in the wrong order.

  39. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block.

  40. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01DMRVE04
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate downward to release the lock and push the plunger deep into the tensioner.

    2. Move the stopper plate upward to set the lock and insert a hexagon wrench into the stopper plate hole.

    3. A01DMJIE01

      Remove the bolt and chain vibration damper.

  41. REMOVE NO. 3 CHAIN VIBRATION DAMPER


    1. A01DM2VE01

      Remove the 2 bolts and chain vibration damper.

  42. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01DMTME01

      Remove the hexagon wrench from the tensioner assembly.

    2. Remove the nut and chain tensioner assembly.

  43. REMOVE NO. 2 CHAIN SUB-ASSEMBLY


    1. A01DNRN

      Remove the bolt, balance shaft drive gear shaft and balance shaft drive gear.

    2. Remove the crankshaft timing sprocket and chain.

  44. REMOVE NO. 4 CHAIN VIBRATION DAMPER


    1. A01DM65E01

      Remove the 2 bolts and vibration damper.

  45. REMOVE CRANKSHAFT PULLEY SET KEY


    1. A01DSD4

      Remove the 2 pulley set keys from the crankshaft.

  46. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DSJHE01

      Using SST, remove the oil filter.

      SST
      09228-07501

  47. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY


    1. A01DP1LE02

      Remove the 2 bolts and nut from the oil filter bracket.

    2. Remove the 2 screw plugs and 2 gaskets from the oil filter bracket.

    3. A01DTM4E02
      Text in Illustration
      *1 O-Ring
      *2 Oil Filter Bracket Gasket

      Remove the oil filter bracket gasket and O-ring.

    4. A01DSJDE01

      Using a hexagon wrench, remove the oil filter bracket union.

  48. REMOVE NO. 1 TAPER SCREW PLUG


    1. A01DPJ9E01

      Remove the taper screw plug from the cylinder block.

  49. REMOVE ENGINE REAR OIL SEAL RETAINER


    1. A01DQRRE02
      Text in Illustration
      *1 Protective Tape

      Remove the 6 bolts.

    2. Using a screwdriver, pry out the oil seal retainer.

      Tech Tips

      Tape the screwdriver tip before use.

  50. REMOVE ENGINE REAR OIL SEAL


    1. A01DNHHE02
      Text in Illustration
      *1 Protective Tape
      *2 Wooden Blocks

      Place the oil seal retainer on wooden blocks.

    2. Using a screwdriver and hammer, tap out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  51. REMOVE VALVE STEM CAP


    1. A01DQFI

      Remove the valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  52. REMOVE VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the lash adjuster free from dirt and foreign objects.

    • Only use clean engine oil.


    1. A01DQB4E03
      Text in Illustration
      *1 Taper Part
      *2 Plunger
      *3 Low Pressure Chamber
      *4 Check Ball
      *5 High Pressure Chamber
      *a CORRECT
      *b INCORRECT

      Place the lash adjuster into a container full of new engine oil.

    2. Insert the tip of SST into the lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010

    3. Squeeze SST and the lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed air.

      OK
      Plunger moves up and down.

      Note

      When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding the air, remove SST. Then try to quickly and firmly press the plunger with your fingers.

      OK
      Plunger can be pressed 3 times.

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster with a new one.

  53. REMOVE OIL CONTROL VALVE FILTER


    1. A01DO1U

      Using an 8 mm hexagon wrench, remove the screw plug.

    2. Remove the oil control valve filter and gasket.