TIMING CHAIN REMOVAL


  1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT

    Click here

  2. SEPARATE BATTERY NEGATIVE TERMINAL

  3. REMOVE ENGINE UNDER COVER NO.1 (w/ Engine Under Cover No.1)

  4. REMOVE ENGINE UNDER COVER NO.2 (w/ Engine Under Cover No.2)

  5. REMOVE ENGINE SIDE UNDER COVER LH (w/ Engine Side Under Cover LH)

  6. REMOVE ENGINE SIDE UNDER COVER RH (w/ Engine Side Under Cover RH)

  7. DRAIN ENGINE COOLANT

    CAUTION:

    Do not remove the radiator reservoir cap sub-assembly while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

    Tech Tips

    Collect the engine coolant in a container and dispose of it according to local regulations.


    1. Loosen the radiator drain cock plug and drain the engine coolant.

      A003CRDE01
      Text in Illustration
      *1 Radiator Reservoir Cap Sub-assembly *2 Radiator Reservoir Assembly
      *3 Radiator Drain Cock Plug *4 Cylinder Block Water Drain Cock Plug
      *5 2-Way - -

    2. Remove the radiator reservoir cap sub-assembly.

    3. Loosen the cylinder block water drain cock plug and drain the engine coolant from the engine.

  8. DRAIN ENGINE OIL


    1. Remove the oil filler cap.

    2. Remove the oil drain plug and drain the engine oil from the oil pan.

      Note

      Collect the oil in a disposable oil container.

    3. Clean the oil pan drain plug and install it with a new gasket.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  9. REMOVE FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  10. REMOVE FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  11. REMOVE FRONT DOOR SCUFF PLATE RH

  12. REMOVE ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Roll up the carpet, and remove the 5 bolts and engine service hole sub cover.

  13. REMOVE FAN & GENERATOR V BELT


    1. A003GP7E01

      Use the hexagon-shaped part indicated by the arrow in the illustration to move the tensioner pulley downward and decrease the tension in the drive belt. Then remove the drive belt.

      Note

      When removing the drive belt, do not use the idle pulley's bolt.

      Tech Tips

      After removing the drive belt, move the tensioner upward to the maximum amount.

  14. DISCONNECT RADIATOR HOSE INLET


    1. Remove the clamp, and disconnect the radiator hose inlet from the engine.

  15. DISCONNECT RADIATOR HOSE OUTLET


    1. Remove the clamp, and disconnect the radiator hose outlet from the engine.

  16. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. A003F6O

      Disconnect the fuel vapor feed hose from the VSV.

  17. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. Disconnect the union to connector tube hose from the intake manifold.

  18. REMOVE INTAKE AIR CONNECTOR


    1. A003DHQE01

      Slide the clamp and disconnect the No. 2 ventilation hose and vacuum hose. (A)

    2. Loosen the 2 hose clamp bolts. (B)

    3. Remove the 2 bolts and intake air connector. (C)

  19. DISCONNECT FUEL HOSE


    1. A003B95E01

      Pull the fuel hose connector cover up to release the lock. Click here

    2. Disengage the fuel connector to disconnect the fuel hose. Click here

  20. DISCONNECT FUEL HOSE NO.2


    1. Remove the clamp, and disconnect the fuel hose No.2 from the delivery pipe.

  21. DISCONNECT VANE PUMP ASSEMBLY


    1. A003HW8E01

      Disconnect the PS fluid pressure switch connector.

    2. Remove the 2 bolts and disconnect the pump from the engine.

    3. Support the vane pump securely.

  22. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

  23. REMOVE OIL LEVEL GAUGE GUIDE


    1. A003EFGE01

      Remove the bolt and gauge guide.

  24. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)


    1. Disconnect the compressor connector.

    2. A003DDVE02

      Remove the 4 bolts and disconnect the compressor from the engine.

      Tech Tips

      Disconnect the compressor with the low pressure hose and high pressure hose stuck by suspended from the rope.

    3. Support the cooler compressor securely.

  25. DISCONNECT ENGINE WIRE

  26. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A003CU9E01

      Disconnect the throttle motor connector. (A)

    2. Slide the clamp and disconnect the water by-pass hose. (B)

    3. Slide the clamp and disconnect the No. 2 water by-pass hose. (C)

    4. for Type A:

      Remove the 2 bolts and 2 nuts, and then remove the throttle body assembly. (D)

    5. for Type B:

      Remove the 4 bolts and throttle body assembly. (D)

    6. A003FSM

      Remove the gasket from the intake manifold.

  27. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

    Note

    Be careful not to drop the injectors when removing the delivery pipe.


    1. A003DE7

      Disconnect the fuel hoses.

    2. Disconnect the 4 injector connectors.

    3. Remove the 2 bolts O-ring and fuel pulsation damper assembly.

    4. Remove the 2 bolts and delivery pipe together with the 4 injectors.

    5. Remove the delivery pipe spacers.

    6. A003FRX

      Using a screwdriver, pry out the 4 spacers from the cylinder head.

  28. REMOVE INJECTOR ASSEMBLY


    1. A003CZSE01

      Pull out the 4 injectors from the delivery pipe.

    2. Remove the O-rings from the injectors.

  29. REMOVE INTAKE MANIFOLD


    1. Disconnect the ventilation hose No.3.

    2. A003DMOE01

      Remove the 5 bolts, 2 nuts, intake manifold and gasket.

  30. REMOVE FAN PULLEY


    1. Remove the 4 nuts, fan pulley and fan spacer.

  31. REMOVE WATER BY-PASS PIPE NO.1


    1. Remove the bolt, 2 nuts, water by-pass pipe and gasket.

  32. REMOVE GENERATOR ASSEMBLY


    1. A003H3N

      Disconnect the generator connector.

    2. Remove the terminal cap.

    3. Remove the nut and disconnect the wire harness from terminal B.

    4. Remove the 3 bolts and generator assembly.

  33. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (w/ Air Conditioning System)


    1. A003EEI

      Remove the 5 bolts and compressor mounting bracket No.1.

  34. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1


    1. A003CXV

      Remove the bolt, pulley plate, collar, and idler pulley sub-assembly No.1.

  35. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A003HZ2

      Remove the 2 bolts and belt tensioner.

  36. REMOVE MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

    Click here

  37. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  38. REMOVE AIR PRESSURE SENSOR (w/ Manifold Absolute Pressure Sensor)


    1. A003F7L

      Disconnect the connector.

    2. Disconnect the vacuum hose and clamp.

    3. Detach the wire harness clamp

    4. Remove the 2 bolts and air pressure sensor together with the bracket.

    5. A003BTJ

      Remove the bolt and air pressure sensor.

  39. REMOVE IGNITION COIL ASSEMBLY


    1. Remove the bolts and ignition coil assembly.

  40. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Disconnect the ventilation hose No.1.

    2. A003FUV

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

    3. Remove the cylinder head cover gasket and cylinder head cover No.2 from the cylinder head cover.

  41. REMOVE CRANKSHAFT PULLEY

    A003BI4E05

    1. Set No.1 cylinder to TDC/compression.


      1. Turn the crankshaft pulley, and align its groove with timing mark 0 of the timing chain cover.

      2. Check that the timing marks of the camshaft timing gear and sprocket are aligned with the timing marks of bearing cap No.1, as shown in the illustration.

        Tech Tips

        If not, turn the crankshaft pulley 1 revolution (360°) and align the marks as shown above.

    2. A003ARDE01

      Using SST, loosen the pulley bolt.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

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

      Tech Tips

      Apply grease to the thread and tip of the SST (center bolt) prior to use.

      A003FH7E01
      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05010, 09954-05021 )

  42. REMOVE OIL PAN SUB-ASSEMBLY NO.2


    1. A003GO5

      Remove the 18 bolts and 2 nuts.

    2. A003IC9

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

      Note

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

  43. REMOVE OIL STRAINER SUB-ASSEMBLY


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

  44. REMOVE OIL PAN SUB-ASSEMBLY


    1. A003H85E01

      Remove the 16 bolts and 2 nuts.

    2. A003CPI

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

    3. Remove the O-ring.

  45. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

    Click here

  46. REMOVE TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL


    1. A003DN1E01

      Using a screwdriver with its tip taped, pry out the oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  47. REMOVE TIMING CHAIN GUIDE


    1. A003CZU

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

  48. REMOVE CHAIN TENSIONER ASSEMBLY NO.1


    1. A003CG1E03

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

      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.

    2. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper plate's hole.

    3. Remove the bolt, nut, chain tensioner and gasket.

  49. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the bolt and tensioner slipper.

  50. REMOVE CHAIN VIBRATION DAMPER NO.1


    1. Remove the bolt, nut, and vibration damper.

  51. REMOVE CHAIN SUB-ASSEMBLY

  52. REMOVE CRANKSHAFT TIMING GEAR OR SPROCKET


    1. A003ARW

      Remove the crankshaft timing gear from the crankshaft.

  53. REMOVE CHAIN VIBRATION DAMPER NO.2


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

    2. A003HNIE03

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

    3. A003DXJE02

      Remove the bolt and chain vibration damper No.2.

  54. REMOVE CHAIN VIBRATION DAMPER NO.3


    1. A003I36E02

      Remove the 2 bolts and chain vibration damper No.3.

  55. REMOVE CHAIN TENSIONER ASSEMBLY NO.2


    1. Remove the hexagon wrench from the chain tensioner.

    2. A003HKOE02

      Remove the nut and chain tensioner assembly No.2.

  56. REMOVE NO.2 CHAIN SUB-ASSEMBLY


    1. A003EZ2

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

    2. Remove the crankshaft timing sprocket No.2 and No.2 chain.